Lower costs, enhanced quality and efficiency

The key to lower costs and enhanced quality and efficiency in the production process is the question of information. Highly integrated information processing, requirement-based editing of production data, as well as intelligent process control are the main features of our solutions in this field. This ranges from simple data capture and visualization through to Manufacturing Execution Systems (MES) for an entire company.

Our approach in this field is based on component-based software development. The basic concept here is to create an application from easily changeable software components and thus to create – in contrast to standard software – the best, requirements-based solution for the needs of the customer. Our solutions are based on the smartPRODUCTION standardized module system and can thus be designed and implemented quickly. This means cost, quality and time-to-market benefits in comparison with a purely individual development.

The smartPRODUCTION module includes standard software components, which cover the necessary functionality of the commissioning and configuration, administration and operating processes right through to statistical analysis of quality-relevant in-process information and secure service access. The entire system can thus be designed quickly, implemented according to requirements, quickly configured for each individual production line and operated efficiently.

smartPRODUCTION function overview

  • Order and line control
  • Process control and analysis
  • Material flow control
  • Control station
  • Production basic data
  • Process documentation
  • Quality assurance
  • Order tracking
  • Production management
  • Breakdown analysis
  • Production simulation
  • Mobile MES components
  • SPC, OEE, …

The smartPRODUCTION module offers the option of quickly and cost-effectively implementing distributed and adaptive production. Using standard software components reduces the operating and maintenance costs for the software. Holding permissions for the specification and source code enables the release cycles to be determined in-house. There are no other licence costs since smartPRODUCTION is based on Open Source modules. The open architecture offers the necessary framework for further modifications, extensions or additional modules.
smartPRODUCTION from Software Factory provides a universal software module for production. Through its modular structure, it enables the requirements-based creation of automation and MES solutions in global and networked production.

smartPRODUCTION is based on component-based software development and is built from software components. Frequently required functionality of configuration and commissioning, administration, operating processes through to statistical analysis of quality-relevant information in operation and secure service access is available in the form of changeable and configurable standard software components.

The production line is implemented with the help of a configuration component. In doing so, the production process is configured by processing steps. These can be sequential, parallel or alternate. The products and product variants are also defined at this point. The configuration is the basis for operational order management, line control and material flow.

A simulation component is provided for easy and quick commissioning. This simulates the feedback from the production line based on individual processing steps and other checkpoints, e.g. RFID stations, by passing the virtual products through the virtual plant. In doing so, fluctuations in the cycle time are generated and factored into the simulation.

The component for administration also allows a system to operate independent of central information systems. This is especially necessary for high availability. Along with user and permissions management, the calendar and views can also be defined here. Complete documentation for system audits is guaranteed by recording the changes in the configuration.

The component for process monitoring lies at the heart of operations. The statuses of the entire line, orders, parts and specific parameters are visualized in this component and presented according to day or shift. In doing so, warning and control limits can be set to any figure, in order that they can be used according to the process run-in.

The documentation component allows complete recording of all produced parts with production, environment and assembly order data. To facilitate analysis, all production lines send the defined information to a central documentation server. If this server is not available, the data for each production line is saved and automatically transferred when the server is available again.

The statistical component offers availability monitoring of all components, the calculation of the overall equipment effectiveness (OEE) and various statistical analyses (quantities, faults, SPC, CPK). Reports on assembly faults, quantities, availability and various SPC charts allow the production process to be designed transparently and to be controlled.

The interfaces component offers a framework by which numerous external systems can be linked in. Thus PLM, MPM or ERP systems can be operated via Web services, linked to API access by direct linking or loosely linked via file exchange via the file system. Controllers are linked via a telegram-orientated connection. This enables event-based applications and the controller can trigger actions by the higher level controller.

The service component offers functionality for secure access from outside, even via the internet. In doing so, a connection to the service is established, and the connections are monitored. A reporting function is also provided as the basis for costing or controlling.

MES

Assembly Line with Micro PLC Control System and Java Framework

For the project Linie 2000 of the company TRW Airbag Systems a new generation of software to control assembly lines has been developed as a 100% Pure Java application with Java 1.3. Due to the heterogeneous structure of the company network at TRW Airbag Systems the platform independence of Java has become a great advantage.

FAILURE ANALYSIS

Optimization of Processes by Detecting Critical Process Components

Reducing costs and delivering quality in parallel is a problematic goal for manufacturing companies. The market demands “zero defective products” at minimal costs from their suppliers. To be successful, you have to improve your products and internal processes permanently.

 

PRODUCT DOCUMENTATION AND BACKTRACKING

Control of an Assembly Line for Airbag Gas Generators with Java

Gas generators for airbag- and retention systems are mass products with many variants. As a result an assembly line with a high degree of flexibility is required. On the other hand a highly automated assembly system consisting of a large number of mechanical and electronic components is required to meet today’s productivity goals. In the end, the extreme consumer safety requirements for gas generators demand a complete and consequent documentation of all process parameters for every single item produced.

REMOTE MAINTENANCE

mGRemoteService – For mGuard of Innominate

To ensure a safe remote access for machinery and equipment via the internet, a dedicated infrastructure for connecting single peripheral appliances of individual clients and centralized gateways for machinery tool manufacturers is offered by the company Innominate. The device series mGuard of Innominate provides with three options (mGuard Industrial RS, mGuard PCI, mGuard smart) a safe and in parallel fast VPN-Connection for the commercial usage in the industry.

 

RISK-ORIENTED INSPECTION AND MAINTENANCE

Optimization of Repair and Maintenance Intervals

Globalised and deregulated markets result in an increased competition and cost pressure for business enterprises and do force them to search for new possibilities to reduce operation- and maintenance costs of technical facilities. The focus of companies is on the preservation of safety and reliability for the production plants.

S7 CMX – JAVA AND .NET DRIVERS

Drivers for communication with Simatic S7 over TCP/IP

Simatic S7™ controllers make Ethernet connections possible. The S7 CMX software makes it possible to connect to an S7 controller from within a Java application via an RFC1006-compatible protocol. For this to be possible, the S7 must possess a communication module with an Ethernet connection (e.g. CP 343 or CP 443).

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