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A presentation by Werardt Systemss P Ltd
An Online Machine Monitoring System
2
ERP
MESField
Controls
The MES Overview
3
Online Factory Production
Data
Hardware
Independent
Open End Connectivity To Various Interfaces
Third Party Interface
Customization
Plug-n-Play Connectivity
FTM-MES
The MES Overview
4
If you are looking at an Online System to monitor Shop floor data of a
designated Machine or Section or Line, then FTM-MES is the system you
should consider. FTM-MES along with our FTM Maintenance software can
form a very effective tool in TPM implementation
The System would interface with the Machine/Line output and, with the
help of earlier entered Production plan, compute the efficiency or Yield of
the line. These figures would be made available on a shift/day basis
along with cumulative figures for that shift/day.
Similarly machine stoppage signal would be made available to display
the working status of the machines in the line.
The data would be stored in a Database on your Server and the MES
System will be available to users for viewing live information and MIS
based on user access control as set by an Administrator for this system.
The MES Solution in Brief
5
A. Production Data, This could be made available from every or last
machine in the process line to indicate the number of jobs or pieces
produced in the shop. This will then be compared with the planning
figures entered separately in the MES software to compute the Yield
B. Machine Stoppage Data, from every Machine on the shop-floor so as
to indicate a machine Stoppage along with the reason if possible. In
case of a CNC machine this could be made available from the
machine itself
C. The FTM-MES software, on a Server will provide various graphical
outputs on the screen as well as in MS-Excel and this will be controlled
through user access rights controlled by an Administrator
D. Display on the Shop-floor, Optionally, a Large LCD screen or Rolling
LED display could be interfaced with the system on which various
information screens could be flashed on a periodic basis, on the shop
floor, if required
The FTM-MES Solution
6
For Production Data Capture
Option-1 This can be a purely file based solution, where we will have access to a file
being generated by the Machine/Line indicating the number of pieces produced in
that shift or on that date. You will have to provide all necessary details of the file for
us to interface.
Option-2 This can be through an electronic interface, from the Digital Counter output
indicating the number of pieces produced by the machine/line. The signal should be
made available for us to interface
Option-3 This could be a totally manual entry at the end of every shift, which would
contain production data, rejection data, stoppages, and defects detected
For Machine Stoppage Data Capture
Option-1 This can be through an online file interface indicating the Stoppage start
date/Time and then the End Date/Time. This could also give us the Stoppage code
Option-2 This can be through an HMI (Human Machine Interface) device connected on
every machine where the operator will manually indicate a machine stoppage along
with the stoppage code entry into the device
Option-3 This can be using a set of Push buttons mounted on a Panel, using which the
operator will operate to indicate machine stoppage and then machine start
The various Data capture schemes
7
` `
MES System
Machine StoppageData Options
Data File Counter
Data File HMI P.B. Panel
Production Data Options
PLC in case of H/W Interfaces
OR OR OR
System Architecture
8
• Latest .NET Technology is used and the system can be hosted on
Organizational Intranet Site, thus easily accessible with restricted
access based on the Security profile
• Production Data, You can define the Production Order No. against
which Production losses are taking place
• Reporting, The system will generate pre-defined reports to display
Production efficiencies and Stoppage statistics. These reports have
been developed in MS-Excel
• User friendly Graphical Online Viewer is provided to view the
Machine wise Production Uptime and Lost Time over a time line
in a Graphical format
• Real time Statistics of Overall Equipment Efficiency (Runtime or
Cutting time or OEE) is provided to get to know the exact Stoppage
time along with an online indication of this OEE
Product Features
9
The Online or History Viewer
The Online Viewer indicates the Running and Stoppage of the Machines on which a
HMI device is connected in Real Time and the History Indicator in the same format
indicates the machine status of any previously selected date.
The Real Time or Shift Time Indicator
You can either view the proceedings in Real time or Shift time with a zooming
facility to zoom 8 hrs of working at a time.
Scrolling Indicator
As you move the cursor on any Stoppage block the system displays the details of
the stoppage in a dynamically placed scroll block
Color Indicators
Green indicated that the machine is running i.e. Cutting time is going on,
Blue indicated all Productive Stoppages,
Red indicates all Non-Productive Stoppages, and
Yellow indicates the loss of Communication with the device
Online Viewer
10
Real Time / History ViewerDisplays real time data and the historical archive of the machine’s status as running or stopped.
Machine RunningProductive StoppagesNon-Productive StoppagesCommunication Failure
Scrolling IndicatorDisplays the stoppage details as the cursor is moved dynamically over the scroll block.
Online Viewer Real Time/Shift TimeSet the time option to view the data of the specified period.
11
The Online or History Register
Similar to the Viewer, the register gives a detailed listing of the Stoppages along
with Downtime in a chronological order, with a total of the downtime as of now or
the selected date range.
Online OEE Indicator
In case of viewing the register in Real time, the system computes the current OEE
for the selected range at the bottom of the screen.
Filtering
You can filter the indicated data for a Particular Machine or Stoppage to get the
desired results instantly on the screen.
Online Register
12
Online OEEThis is the Machine Utilization % made available online based on Real time data.
Online Register
13
View from anywhere in the Plant
As mentioned earlier, the system is a Web application hosted on an Intranet Server,
hence you can also view the Online Viewer and Register directly from
any PC in the plant using your Internet Browser.
URL for Online Viewer
The address or URL of the Online Viewer is
http://<server>/FtmProductionModule/MachineDownTimeStatus.aspx
URL for Online Register
The address or URL of the Online Viewer is
http://<server>/FtmProductionModule/OnlineMachineStopageRegister.aspx
Web enabled Viewing
14
• Reports are available in graphical form in MS-Excel for
the specified date range and set of filters
• The Reports that are available are …
– Daily Production Chart
– Daily Machine Utilization Chart
– Stoppage Code Pie Chart
– Stoppage wise Pareto Analysis
– Machine wise Pareto Analysis
– Monthly Machine Utilization Chart
– Machine wise Utilization Chart
… and various such outputs would be made available online
Information Outputs
15
Section-4 Production data - Jan 2003Production average : 31.45 k/d Eff iciency : 68.45 %
34.2133.2631.8831.0233.5933.5737.4
3133.1
42.9
34.137.134.9
11.2
29.529.725.5
34.731.932.731.832.5
19.124.2
28.532.432.8
27.932.932.2
27.3
39.23332.3
38.439.2
05
101520253035404550
Jul'0
2 av
e
Sep'
02 a
ve
Nov
'02
ave 31 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
0102030405060708090100
Production Eff iciency
Daily Production Report
16
Daily Machine Utilization Chart
90.9695.66 95.46 92.9993.46
96.83 96.46 94.8198.26
94.51
79.59
96.4898.2695.90
85.80
96.93
0.00
20.00
40.00
60.00
80.00
100.00
120.00
01
/08
/20
07
02
/08
/20
07
03
/08
/20
07
04
/08
/20
07
06
/08
/20
07
07
/08
/20
07
08
/08
/20
07
Avr
ag
e
Over All PercentagePercentage Without Productive DelaysTarget
Daily Machine Utilization Report
17
Stoppage Code Pie Chart
26%
18%
15%
10%
8%
7%
4%
3%
3%2% 2%
2%
0% MACHINE BREAKDWN
SETUP
WTNG-CRANE
LEGAL LEAVE
WTNG-TOOLS
M & P DELAY
REWORK (COPQ)
PREVENTIVE MAINT
ABSENTISM
PLANNING DELAY
HOUSEKP CLEANING
FAB. DELAY
Stoppage Code Pie Chart
18
Stoppage Reason Wise Pareto Analysis
17.40
12.53
10.18
7.15
5.42 5.15
3.022.23 2.13
1.30 1.14 1.070.07
25.01
43.24
57.82
68.08
76.15
83.5887.87
91.2594.39 96.51 98.25 99.83 100.00
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
MA
CH
INE
BR
EA
KD
WN
SE
TU
P
WT
NG
-CR
AN
E
LE
GA
L L
EA
VE
WT
NG
-TO
OLS
M &
P D
ELA
Y
RE
WO
RK
(CO
PQ
)
PR
EV
EN
TIV
E
MA
INT
AB
SE
NT
ISM
PLA
NN
ING
DE
LA
Y
HO
US
EK
P
CLE
AN
ING
FA
B.
DE
LA
Y
Stoppage Reason
Do
wn
tim
e
0.00
20.00
40.00
60.00
80.00
100.00
120.00
Down Time(In Hours)
Cumulative
Stoppage Reason wise Pareto Analysis
19
Machine Wise Pareto Analysis
23.45
13.30
11.55 11.0010.29
33.62
52.72
69.59
85.16
100.00
0.00
5.00
10.00
15.00
20.00
25.00C
MH
A-1
1-
SC
HIE
S
CM
HC
-11
-IN
OC
N
CM
HA
-12
-FA
RE
L
CM
HC
-12
-SK
OD
A
CM
HC
-51
-
WA
LD
R
Machine Names
Do
wn
tim
e(I
n H
ou
rs)
0.00
20.00
40.00
60.00
80.00
100.00
120.00
Down Time(In Hours)
Cumulative
Machine wise Pareto Analysis
20
Monthly Machine Utilization Chart
100.0 100.0 100.0 100.0 100.0 100.0 100.0
82.7
38.0
91.2
0.0 0.0 0.0 0.0 0.0 0.0 0.0
6.1
13.9
2.2
0.00.00.0
0.00.0 0.0 0.0
11.2
48.1
6.6
0%
20%
40%
60%
80%
100%
Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Cumulative
UpTime Productive Hours Non Productive Hours
Monthly Machine Utilization Chart
21
Machine wise Utilization Chart
94.54 94.27 93.79 92.9787.63
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
CM
HC
-51
-
WA
LD
R
CM
HC
-12
-
SK
OD
A
CM
HA
-12
-
FA
RE
L
CM
HC
-11
-
INO
CN
CM
HA
-11
-
SC
HIE
S
Machine Names
Perc
en
tag
e
Percentage
Target
Machine wise Utilization Chart
22
Contact Information
Werardt Systemss Pvt LtdPune, India
Phone : 91-20-25285256, 25285257
Website : http://www.werardt.com
email: [email protected]
