PPS MDE BDE CAQ CNC DNC - GEWATEC GmbH & CO.KGfile.gewatec.com/www/100_Kataloge/Englisch/101_Complete... · 2009. 1. 15. · CNC KALK DNC PPS IPC MDE BDE General. TJob time calculationime-Tec

PPSMDEBDECAQCNCDNC

Complete solution for

turning workpiece manufacturers

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Anyone who wants to survive today in increasingly competitive markets must make the right decisions. Anyone who wants to make the right decision, however, needs the right information about his own company and especially about his own production.

Can the delivery be made on time? How much longer will the machine be occupied? To what extent is the machine utilised? Why did the machine drop out tonight? How high is the actual job time? How much material was consumed? How high is the actual rate of return?

The modern "GPPS" ERP/PPS-system in combination with the “Pro-Vis" production monitoring supplies this information at the touch of a button, up-to-date and in real-time, as the events occur. The data can be prepared and filtered as desired. In its basic version alone, a multitude of reports are prepared that can be modified and expanded at any time.

Integrated system solution for the medium-sized manufacturing industry

Time-TecComplete solution for turning workpiece finishers

The GEWATEC system solution, with its six columns KALK, MDE, BDE, PPS, CAQ and CNC, offers a functionality that perfectly covers all the needs of a components supplier and chipper. The module can also be used separately as required. The perfect interaction of these columns on a uniform data basis opens up new horizons. The classical separation between office and workshop areas is a thing of the past.For example, test intervals from the MDE control station are converted directly into signals that request that the worker to conduct a test via a signal lamp on the machine or via the personnel search system. Setting-up times are reduced significantly due to workshop orders being sent directly to the machine from the PPS. The worker can decide for himself in what sequence the machine is setup within a certain time window.

The demand for information increases both within and outside of the company. The markets are becoming more and more global. The acquisition of information and current information offerings are important factors for success. The magic word is Internet. The possibilities are unlimited for

the inclusion of subsidiary plants or the support of sales operations via the Internet. Modern concepts must therefore be integrated into an intranet that works with the same mechanisms as the Internet.

Industrial computers and terminals specially developed for this purpose serve as an interface between man and machine on the basis of modern industrial standards. Beyond this, they serve to record machine conditions and unit volumes as well as to transmit CNC programs and tool data and much more.

The object-oriented program architecture of the GEWATEC solution allows for very brief development times and guarantees the highest measure of software quality. Costs are reduced in this way. The result is a solution attuned to the respective companies that offers maximum functional variety.

We boost your productivity

Job time calculation

Bid calculation

Production planning and control

Document management

Capacity planning

Production facility management

Recording of machine data and operational data

Quality management

CNC programming

CNC Program transmission

Industrial computer

CAQ

KALKCNC

DNC

PPS

IPC MDE

BDE

General

Time-TecJob time calculation

The GEWATEC job time calculation Time-Tec determines the exact runtime, also for complete processing, C-axis processing or multi-carriage processing.The parts geometry is recorded in a matter of seconds. During this, the geometry can be scanned in directly from the diagram via a scanner.The tools are defined by and the operating sequences are applied directly on the geometry. Time-Tec can simulate all processing cycles and also work with constant cutting speed.

The results are then summarised and presented as an overview in the job time table.

Geometry determinationAt the beginning, the parts geometry of the turning workpiece is recorded. Existing geometries in the DXF format can be imported during this. If no CAD data are available, the geometry is taken over directly from the scanned diagram. Any contour lines can also be constructed with the integrated geometry processor.Tools are defined and operating sequences such as scrubbing and finishing are carried out directly on the geometry. The immediate simulation of the operating sequence allows for a visual verification of the operation.

- Turning- Milling

From the scanned-in diagram to the job time!

Time-Tec

v-constant

Multi-carriage processing

Complete processing

Machine-independent

Simulation

Synchronisation

Autom. section distribution

Pocket cycles

programmingCNC

Job timeThe results are summarised and presented as an overview in the job time table. To determine the job time, you also get the entire CNC program free of charge. (Qualification: only in connection with the CNC programming module. In case of scanned diagrams, the CNC program is only an approximation).

ProcessingThe working operations are carried out graphically and interactively on the geometry. The automatic section division and cutting radius compensation allow for the movement paths to be determined exactly and the accompanying main and non-productive times to be calculated exactly. The respective rotational speed is determined incrementally for each diameter.

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Bid calculation

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control

Capacity planning

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Recording of machine data

and operational data

Quality management

CNC Program

transmission

Industrial computer

Document management

SynchronisationIn the synchronisation module, the operating sequences are synchronised to the different systems distributed over the time axis. The synchronisation markers of the CNC-program are set automatically in the background.Initially, all operating sequences are recorded as if one were finishing on a spindle. The operating sequences collectedin this way are moved by drag & drop to channels or systems that depend on the kinematics of the machine. The job time results from the time of the system that requires the longest time.

Technology databaseThe GEWATEC technology database (TLG) is a SQL-based database that manages the technology data such as working materials, cutting materials depending on the processing (turning, milling, drilling, scrubbing, finishing etc.).The technology database is self-learning. Technology values such as feed and cutting speed are proposed to the respective operating sequence. If there are no technology data in the database, the manually entered data are stored automatically and are available for the next operating sequence.


Calculation / quotation managementKalk-Tec

Material costs ·Calculation of the finished weight on a graphic interface by

selecting volume symbols as desired·Calculation of the weight of the material used via graphical

symbols ·Display of the material needed in kg per quantity unit, kg

per lot size, number of rods and meters.

Production costs· Automatic calculation of the internal and external

production costs taking into account setting up costs and tool costs.

· Full and margin costs · Outsourcing from cost tables (for hardening shop,

electroplating, etc.)· Different units price/unit, /kg, per hour, etc.· Complete generation of a work plan

Hourly machine rateWith the hourly machine rate program part, production costs or cost rates can be calculated quickly and in great detail.· Hourly rate calculation for a multi-shift operation· Calculation of the annual plan runtime · Consideration of different labour costs for setting up andproduction.

· Detailed calculation of all cost types such as amortisations, occupancy costs, interest, maintenance, energy costs, tool costs, labour costs per year

· Determination of the total costs per year · Splitting of the costs into variable and fixed shares · Determination of cost rates in EUR/unit and EUR/kg · Extensive protocol printout · Other printout possibilities via list generator.

GEWATEC-WINKALK is a new object-oriented calculation system on the most modern client-server architecture and SQL database. The hard competition and high costs force the manufacturing shops into rational and transparent calculation on a full cost as well as margin cost basis. The overhead calculation is based ona detailed hourly machine rate calculation. It takes into account the concerns of an industrial production in an ideal way, since the costs are recorded where they are incurred. All machine-dependent costs are excluded from the production overhead and calculated separately in hourly machine rates.<0}GEWATEC offers effective instruments to realise several calculation models, so that you are a decisive step ahead of the competition.

Volume and weight calculationThe integrated volume and weight calculation allows for an exact and quick determination of volume and finished weight for any cubic and rotational-symmetrical parts. The volume model of a part is assembled by simply clicking basic geometric bodies. After the selection of the material, the weight is determined automatically.

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Quotation managementAll calculations remain stored and can be edited at any time and printed as often as desired. Extensive search functions ensure that quotations can be found quickly. An integrated list generator (optional) allows for freely controllable quotation printouts, such as quotation lists and analyses of their calculation.

Quotation rejectionsWith this module, quotation rejections can be printed. This also allows for inquiries that do not need to be additionally processed to be answered quickly and rationally.

Post-calculationIt is important for a cost-optimised production that the finished production orders can be post-calculated with little time and effort. This is possible with minimum time and effort in connection with the GEWATEC MDE/BDE system. All relevant data are recorded in the production. They include detailed specifications regarding the actual job times, setting up times, finished unit volumes, waste material values, material consumption and degrees of utilisation. A printout is generated automatically after the order is reported as being finished. Differences between target and actual values are shown in a clear overview.

Performance characteristics · Extensive search functions such as by customer, article, diagram, number, description, contact,

inquiry no., Date, etc.· Transfer of job time from the TIME-TEC job time calculation for turning and milling.· Job time calculation via specially prepared macros· Complete calculations of outsourcing from cost tables (for hardening shop, electroplating, etc.)· Taking into account different units such as price per unit, per kg, per hour, etc.· Individual quotation printout via form generator.

Price determination· Individual consideration of packaging costs per article · Calculation of transport costs via stored cargo table.· Output of a calculated quotation prices at full and margin

costs; in addition, an arbitrary quotation price can be used.


GEWATEC PPS is a fourth generation production information system. It is based on a modern SQL database, works according to the client-server principle and was developed in an object-oriented way in accordance with the latest standards. The system is designed with an open structure. This makes it possible to have data so that every user can activate only the programs per registration name and password that are allocated to him. Together with the GEWATEC products for CALCULATION, MDE/BDE, CAQ and CNC/DNC, all needs of a production operation are completely covered. For the generation of one’s own analyses and for the individual alteration of forms, a list and form generator is available by default.

ProductionPlanningContorl

Production planning and control

PPS

GPPS

Customer/supplier baseFreely selectable 30-digit customer number and match code; expanded search across almost all fields of the basic template of customers / prospective client marking, correspondence address, as well as an arbitrary number of supplier and invoice addresses customer groups/discount groups, basic discount, price increase surcharge, bank connections; nationality marking;Telephone, fax, e-mail, homepage, parameters such as: agrees payment and delivery conditions; shipping type, packaging regulations; credit check, contract check, credit limit, blocking marker, responsible representative with commission rate, freely editable customer history, printout of customer lists, address labels, etc. Export function via list generator of cumulative order values and revenues over the last 5 years.

Article baseFreely definable 30-digit search criteria; article code, match code, diagram, ID no., group. The following part types can be managed:Article (finished parts, bought-in parts, component groups,...)Material (bar stock, ring material, profiles, sheet metal, etc .)Raw parts (cast blanks, etc.) Tools(simple or assembled tools) exact article description (long text field and match code as short text), corresponding material definition via code; date of creation, employee responsible, revision history, free comments, additional texts, order texts, cost unit, type of acquisition, release marking, serial number managementDisplay of article graphic via DXF CAD interface or bitmap graphics (scanner, digital picture) Gliding price scale management for customers and suppliers, machine no., machine descriptions, article dimensions, utilisation and finished weight, storage and dispatch inventories, work plan with arbitrary number of operating sequences, CNC program for direct DNC operation; job time, setting up time, non-productive times,Transfer of standard operating sequences from operating sequence catalogue; additional Comments about material and finished part, list/label printouts via Reports, order value and sales over 5 years, integrated parts lists module with several finishing stages.

Work plans/parts lists

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and operational dataOrdering

The Ordering module serves for the rational execution of the entire dispatching, in particular of bought-in parts, raw material and tools.- Supplier management- Invoice generation- Order monitoring

Recording of ordersIndividual or collective orders, framework/call ordersOrder-specific recording of all relevant data through a combination of master data with interactive inputs.

Delivery plan in accordance with VDA with arbitrary length for call orders with cumulative, calendar-related calculation of - Target delivery quantities;- Under-/over-deliveries, arrears, open order volumes; volumes already delivered.

Shipping/delivery receiptIndividual or collective delivery receipts; the generation of delivery receipts is a downstream component of the updating of the delivery plan, quantitative discrepancies between different files are excluded as a basic principle. Verification of commercial invoice status.

Invoices/credit notesIndividual or collective invoices; the invoicing takes place by calling up delivery receipts that usually include all required data, though additional inputs are also possible and provided in the operating sequence.Automatic generation of individual or collective invoices. Invoice data are stored for subsequent analyses or processing. Invoices can still be corrected after being printed out.Credit note generation, pro forma invoices/customs invoices.

Statistics/analyses/listsIn GPPS, extensive analyses and lists are available, such as: Customer-specific, article specific, period-related, according to statistical group, according to production index, histogram (graphic)Production orders, arrears lists, invoice book, journal of outgoing goods, representative commission accounts, management of payment receipts.

Inventory managementThe supplementary module for inventory control allows a cost-optimal management of your stock inventories. The storage management program offers the possibility to carry out incoming additions to the inventory, re-bookings and booking of outgoing inventory. Any number of storage locations can be set up. Printout of stock inventory lists, inventory lists and inventory assessment lists.

Report generatorA report generator allows the user to generate as many analyses as desired from the PPS database, including complex analyses. Exchanging data with other Windows applications is also possible.

Additional information about EDI/Edifakt

in the GPPS catalogue!


Financial accounting interfaces* IBM financial accounting of HS* KHK financial accounting* Schimaniak* Datev

Document managementDOKU

During a normal working day it is estimated that around 50 to 60% of working time is spent searching for documents. In modern business management, documents are therefore regarded as information objects and a fourth production factor. There is a good reason behind this idea: By keeping documents in digital form, you can save time and effort and also lay the foundation for more efficient working in general.

.Dokumentenverwaltung (document management) is a powerful tool that operates across modules and allows you to capture external documents relating to individual customer or item master records, as well as processes such as complaints or costing, and manage them within your

solution. It makes no difference whether the documents are image files, Office files (Word, Excel) or PDFs.

.Dokumentenverwaltung supports a large number of file formats. What’s more, you also have the option of connecting any scanner in order to digitise documents for direct integration into

.Dokumentenverwaltung.

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Gewatec

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With this solution, time-consuming searches through folders and filing cabinets looking for individual documents such as complaints or specific operating procedures will be a thing of the past.

Documents that you wish to link to an inspection plan or costing, for example, will be transferred automatically to the relevant master records linked to the process. In this way documents assigned to, for example, a costing calculation would automatically be transferred to the corresponding customer and item.

Paper documents

Digital documents (e.g. PDFs)

Transfer to GPPS, Win.Kalk, CAQ

Scanner for digitising paper documents

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Scenarios

Attach drawings or other documents directly to an article So that production orders are supplied and printed together with linked drawings or notes, provided that the corresponding documents are labelled "active". This allows inconsistencies and misunderstandings to be avoided from the outset.

Store your customers’ original complaint correspondence in

As with production orders in when planning inspections in , documents containing technical drawings, images or test instructions can be assigned to individual inspection plans.In conjunction with

.Dokumentenverwaltung include storing calibration certificates and invoices in the inspection equipment management module or assigning specific drawings and external inspection results to an initial sample inspection report. Naturally these documents can also be viewed at any time through the corresponding master data records.

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.KALKAdd drawings, quote requests, material quotes and correspondence, for example, to a costing. All documents are forwarded to the master records linked to the costing, Meaning that you will have any explicit notes regarding the costing that relate to a specific item or customer immediately to hand with the master data.

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.REK™ in order to meet any subsequent obligation to provide supporting documents at any time. It also makes sense to archive photographs documenting defects. Attaching correspondence between you and your customers (8D reports, statements), as well as external Inspection reports, can make life easier. Here again documents are transferred to a shared database – the master data – and are available in the individual master records.

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.FMEA™ handbooks or process instructions can be stored. Other scenarios where it makes sense to manage documents using

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GRIPS

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GEWATEC


KapPlan is a convenient production activity control system for the planning of production resources – machinery as well as labour. With KapPlan, the allocation and utilised capacity of all machines, employees and department is presented in a clear and comprehensible form. All operating sequences of the production orders are shown properly in the time axis while taking the calendar into account.

Capacity planningKapPlan

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Capacity graph, resource utilisationOn the left edge of the screen, the free capacity of the individual production resources are shown in the currentlydisplayed period in the form of a capacity graph. In case of capacity being exceeded, the colour of the capacity bar turns red.The upper capacity bar shows the average free capacity of the entire machine group.

Capacity bottlenecksWhen exceeding delivery deadlines operating sequences are shown in red.Overlapping operating sequences aremarked with a red frame.

With KapPlan you have a clear grasp of your production capacities. The graphic planning table allows for the effortless shifting of operating sequences using “drag & drop”. Comparable to an early warning system, capacity bottlenecks are shown right away. Free capacities can be optimally utilised. Zoom functions make it possible to set time windows as desired. Operating sequences can be shifted across different employees and departments.

Resource demands and resource supply for

the setting up and operating of machines.

Forward schedulingBackward schedulingCapacity displayBDE couplingPPS coupling

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PPS interfacesin practice, KapPlan receives its order data from a PPS system.

CalendarThe calendar is the basis for the calculation of start and end dates of the operating sequences. Freely definable shift models are allocated to the individual machines.The respective shift models are entered in the calendar.

Production orderThe program is based on a production in stages. For each production order, the corresponding operating sequences are presented in a chronological sequence one under the other. The respective next operating sequence can only start once the predecessor has been concluded or the indicated correlation has been reached. The individual operating sequences can be shifted by drag and drop on the time axis. The subsequent operating sequences of the production order can be shifted backwards automatically in case of any overlaps.

Order informationKapPlan supplies exact information about the order and the corresponding operating sequences at any time. The information window shows the article and the order data that belong to the respective operating sequence.

KapPlan analyses KapPlan allows for extensive analyses employees and production resources. The capacity graph compares machine allocations to each other and shows free capacities.

Additional features- Graphic presentation of the personnel situation (Personnel requirements and personnel available)- Production proposals- automatic planning of operating sequences or of complete production orders to free capacities - Planning the production processes in table form - Dynamic grouping- Shifting of several operating sequences in the block - Target/actual comparison of the production


Functional safety and reliability of complex systems and production resources and thus their availability can be maintained with a consistent preventive maintenance concept on a regular high productivity level.Reduced costs, higher efficiency and the increased availability of machines and spare parts are the requirements for a modern production facility management system. Systematic analysis of weak points and prevention are of central significance. The required maintenance measures are harmoniously integrated in the production process with PMS by GEWATEC.

Preventive maintenance

Production facility managementPMS

Production facility overviewThe production facilities can be sorted as desired according to column headings.The respective status of the production facilities is marked in colour.

Production facility master dataThe specific data are set up in the master data for the production facilities.

Number, description, type, maintenance plans, etc.

Intelligent parts list logicAllocation of components and maintenance plans via the parts list.

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Executing maintenance plansProduction facilities that are scheduled according to the specifications of the stored maintenance plans are inspected. The worker is led through the individual maintenance regulations.After successful maintenance, the status of the production facility is automatically set to the status “fully operational”.

After an unsuccessful execution of the maintenance plan, the user has the possibility to assign a corresponding status.

Carrying out unplanned maintenance actionsUnplanned maintenance actions are documented and can be reconstructed at any time via the PMS history.The specification of damage symptoms provides information about the current state of the production facilities.At the same time, the duration and costs of the unplanned maintenance actions are recorded.

Recording costs and consumption data The recording of different cost positions allows for an evaluation of the production facilities according to economic perspectives.

Environment-specific data are recorded for every individual production facility.

Monitoring of deadlinesThe automatic monitoring of deadlines provides an overview of all future maintenance tasks.

Maintenance and inspection historyMaintenance actions are documented and can be reconstructed at any time via the PMS history. Beyond this, maintenance tasks are registered in the ProVis event writer and shown in the run-time diagram of the respective machine.


MDE-BDE control station computer On this PC in the network, the MDE data are collected via the GEWATEC bus system and shown on the screen of the ONLINE condition of all machines in real-time.All machines are sorted by product group and presented graphically on screen. When the machine is not producing, this is shown at the control station via the status traffic light. Aside from the machine symbol, the article number, the current job time, the current reason for malfunction and the remaining quantity can be read out. The order progress display shows the current production status under the machine image. By clicking the machine with the mouse, additional information about the production progress is shown. All information is recorded and displayed "online" and in "real-time".

Post-calculation, forced printoutsAt the end of the last operating sequence, a forced printout that presents the overall post-calculation with a target/actual comparison of all operating sequences and all outgoing materials is started automatically.

Run-time diagramIn the run-time diagram, the reasons for malfunction are shown on the time axis. This presentation shows when which machine had what malfunction.

The hard competition and high costs force the manufacturing shops into a transparent, completely monitored, lean production (lean production). This can only be realised without problems with an easily operated EDP solution.

ProVis is a modern MDE/BDE system that meets these requirements in an object-oriented system architecture with graphical user interface and highly modern client-server technology. ProVis is one of the most important components in the GEWATEC MES solution

ProVis monitor mode All information about the ProVis control station including the run-time diagram can be called up and presented on any PC in the network.

Stamp client The stamp client can run on any PC or the GEWATEC industrial PC. Orders logged on and off with the stamp client. Any number of reasons for malfunction and status notifications can be recorded and managed. Beyond this, small orders and outsourcing jobs can be recorded and managed on the stamp client.Auxiliary programs such as DNC, CAQ etc. can also be called up from the interface of the stamp client.

for the medium-sized manufacturing industry. This results in the following advantages for the user:

With ProVis, GEWATEC offers an effective instrument to realise several these objectives, so that you are a decisive step ahead of the competition.

* Reduction of the processing times and delivery times

* Optimisation of the capacity and resource utilisation

* Increase in productivity * Transparent production control * Automatic post-calculation

ProVis Recording of machine data and operational data

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Order overviewAt any time open, partially finished and finished orders with their corresponding operating sequences and operating sequence status can be listed.

Order informationProVis supplies exact information about the order and the corresponding operating sequences at any time. The information window shows the article, information about the material consumption and much more. A calculation accompanying an operating sequence provides information about profit and loss as early as during the processing stage.

Pro-Vis capacity planningProVis shows not only analyses from the past, but also contains a powerful tool for capacity planning. The ProVis run-time diagram also shows stored future orders. Via graphic interactions with the individual operating sequences, these can be shifted and reallocated.Capacity bottlenecks can be detected at a glance.

1) Only in connection with KapPlan.

1)

Analysis ProVis allows the following analyses by default:

Machine:• Detailed machine, machine group and cost unit-utilised capacities over freely

selectable periods or shifts • Machine run-time diagram online or subsequently for all machines (screen and

printer) Shift protocol, with shift performance, order progress, downtime and residual run-times (machine run-time diagram)

• Recording ghost shift with automatic end (night shift)• Interruption and continuation as desired of orders

Separate analysis of bar/feed machines; • Analysis via production islands with manual workplaces or final processing

Material: • Material consumption per day, per shift, per order. • Preview of material requirements for the next day or for the remaining order • Analysis by different materials

Order: • Order analysis• Material/tool consumption and costs • Weak point analysis of all downtimes and causes • Return on investment analyses, value-creation per machine, group, period • Automatic post-calculation per article/production order • TARGET/ACTUAL comparison of production and setting up • Calculation of gross cycle time • Transfer to PPS system for post-calculation • Post-calculation over a production order with TARGET/ACTUAL comparison • Transfer to PPS system for post-calculation • Post-calculation over a production order with TARGET/ACTUAL comparison

ProVis and CAQIn connection with the GEWATEC CAQ solution , the control station also monitors the measuring intervals via dynamic control of testing accuracy. The control station prompts the worker to take measurements when the inspection interval is exceeded by activating a signal lamp.

GRIPS


"GRIPS" is a modern quality management system for graphical interactive testing and quality assurance. GRIPS places part geometry at the heart of testing. The geometry forms the basis of all activities. All actions performed by the machine

GRIPS

PPV: Inspection plan managementUsing GRIPS inspection plan management, inspection plans are drawn up with the respective work processes and associated attributes. Via context menus the user is guided quickly and efficiently through the creation of inspection plans to generating current inspection orders. Creating a control plan is embedded into standard inspection planning and thereby facilitates additional work significantly, because QS9000-specific data can be input in parallel to the standard inspection plan. By marking an inspection plan as a family inspection plan, its attributes can be transferred to other inspection plans as often as required. Linked attributes in inspection plans are readily apparent. Changes to a family attribute are transferred to all linked attributes in other inspection plans. Naturally these associations can also be removed.

GIP: Graphical interactive inspection planningGRIPS enables the graphical interactive generation of inspection plans using a mouse. Measuring points on the part drawing are set By simply moving the mouse to the position for measurement and clicking on the measuring point. The associated measuring flag is placed in a suitable position. A measurement operation is pre-assigned to each measuring point. The measuring operators available naturally depend on the measuring equipment. Measuring points are assigned to the individual attributes in the next step when creating measurement macros. By clicking on them, the measurement values for individual measuring points are averaged and then assigned to the attributes. In the background a complete measurement macro is created without entering a single line via the computer keyboard.

PMV: Inspection equipment managementQuality assurance requires that the inspection equipment being used is subject to continual monitoring and calibration. Using GRIPS inspection equipment management, all inspection equipment is recorded conforming to standards and managed efficiently. Grips.PMV™ features a scheduler to monitor test dates; location monitoring is also included in the GRIPS inspection equipment management by default.

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operator are based on simple graphical interactions with the workpiece to be tested. GRIPS is a revolutionary test system that redefines the concept of "quality assurance".

PMÜ: Inspection equipment monitoringMeasurement systems analysis in accordance with VDI/VDE/DGQ2618 assesses inspection equipment for its suitability for SPC applications. Integrated calibration planning allows individual test instructions to be produced.

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EMP: Initial sample inspectionWith GRIPS initial sample inspection reporting, you can generate initial sample inspection reports quickly and efficiently in accordance with VDA and other standards as required. The inspection reports can be entered directly or transferred from the inspection plan management. Initial sample inspection also includes date monitoring of initial samples to be requalified. A report generator facilitates printing on pre-printed forms. It is also possible to print on plain paper.

QDE: Quality data recordingGraphical interactive dialogs guide the machine operator reliably through the measuring process, irrespective of which platform (standard measuring equipment, multipoint measuring system, measuring projector, 3D measuring machine) is being used for measurement. A control card is embedded in the measuring process. The measurement window opens and shows the part to be tested with the measuring equipment, as defined during inspection planning. In addition, inspection orders can be generated, machines assigned and lots defined from the measuring station. Remarks and measures are entered on the control cards and provide information on process changes and their causes.

QST: Quality statisticsDuring all measurement operations the machine operator can perform all statistical analyses as part of his self-check. Control cards, histograms, probability plots and process indices, as well as measures and remarks entered, can be displayed at the touch of a button at any time. GRIPS has interfaces for qs-STAT.

PMF: Inspection equipment capabilityPMF makes it possible to carry out measurement systems analysis using methods 1, 2, 3 and 6.

REKLA: Complaint managementThe complaint management system manages and monitors internal and external complaints. After a complaint has been recorded, an 8D report is produced detailing the specific error description and the measures to be taken. In the event of an external fault, the customer complaint can be forwarded directly to the supplier. To achieve systematic and consistent quality improvements, complaints can be analysed by supplier, customer or other criteria and visualised at any time.

FMEAFailure mode and effects analysis allows complex processes and system structures to be presented in a simple way. Weak points can be avoided prior to production by taking appropriate measures.

• Process and system structures are presented clearly in a tree hierarchy.

• Before/after analysis regarding the rise in quality• All information about manufacturing processes

contained in a central knowledge base

All analyses in accordance with the VDA standard

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NC-TEC2000 by GEWATEC is a modern object-oriented development for the generation of CNC programs for turning, long-turning, milling and profile grinding. With NC-TEC2000, the user generates CNC programs for all current

CNC programmingNC-TEC

Geometry determinationAt the beginning, the parts geometry of the turning workpiece is generated. Existing geometries in the DXF format can be imported during this. Any contour lines can also be constructed with the integrated geometry processor. Tools are defined and operating sequences such as scrubbing and finishing are carried out directly on the geometry.

Tool selectionDuring the processing, the tools or grinding disks are selected first. The selection box for the tools can include as many tool or grinding disks as desired. On the basis of the combination of tools and cutting material, the values for feed and cutting speed are proposed from the technology database.

CNC controls in a short time, even with complex processing. The operation of NC-TEC2000 is identical for all technologies for turning, milling and profile grinding.

Thread cutter in an individual set

Target point

Length-wise scrubbing cycle

End point Finished contour Q

Scrubbing sections

Starting point

Starting point of finished contour P

Milling level length-wise cut / chord surface

Milling radius compensation ON

Interior treatment

Exterior treatment

programmingCNC

General


Bid calculation


control

Capacity planning

Production facility

management

Quality management

CNC Program

transmission

Industrial computer

Document management



DNC (Direct Numeric Control) refers to the transmission of data between computers and CNC-controlled machine tools. Extensive DNC concepts are available to connect the machine to the GEWATEC system.

DNC program transmission

3D simulation At the end of the treatment, the part can be presented three-dimensionally. This presentation can take place in any spatial angles desired.

TreatmentWith the geometry processor, the user can construct complex contours of his own or import them in DXF-format via the CAD-interface.The auto-router function generates the CNC sets for your NC program from the contour lines in the background. The integrated NC editor specifies the set format for the respective machine, allowing for the PC to be programmed just like on the control.For frequently recurring treatment steps the corresponding CNC sets can be generated very quickly and automatically via the macro function.

Additional information about CNC programming and

DNC, technology database and NC program management

in the NC programming catalogue!

SynchronisationInitially, all operating sequences are recorded as if one were finishing on a spindle. The operating sequences collected in this way are moved by drag & drop to channels or systems that depend on the kinematics of the machine.

CAQ

KALKCNC

DNC

PPS

IPC MDE

BDE


Straight in the feed

Target point

Clockwise circular arc

Counter-clockwise circular arc

Length-wise scrubbing cycle

End point Finished contour Q

Scrubbing sections

Starting point

Starting point of finished contour P

GEWATEC industrial computers are the important connecting link between man, machine and computer. They are used when CNC programs need to be transmitted – or machine conditions recorded, unit volumes counted or inspection equipment connected. With an entire family of industrial computers, GEWATEC provides the user with a universal, comprehensive information system for production on an Ethernet basis. Gewatec industrial computers in their elegantly designed and robust casings with oil-resistant operating parts have a standard interface for an external PC keyboard or a barcode reader, foot switch, Ethernet connection and much more.

Industrial computerIPC

MDE unit volumes

MDE recording of malfunction causes

MDE machine stopped/running

BDE notifications

Barcode reader

DNC program transmission

IC900/IC1100The GEWATEC industrial terminal IC900 is the continued development of the IC800 pro bus terminal. With a duplicate assignment, the 12 freely definable function keys allow for the input of 24 malfunction causes. The numeric input block allows for the logging on and off of production orders.

The IC900/IC1100 is connected to the control station computer by radio. In contrast to the IC900, the IC1100 is equipped with a Linux computer and can be integrated into existing WLAN systems.

- Display 4*20 characters - Barcode scanner (optional) - Radio (range 200m)

IC-800 malfunction cause terminalThe IC-800 malfunction cause terminal was developed for the cost-effective recording of machine conditions, malfunction causes and unit volumes. It can record eight freely definable malfunction causes and report them to the MDE control station. It is connected to the control station via the Siemens pro bus.

Performance characteristics 8 freely definable malfunction cause keys 1 integrated relay 6-digit display to indicate unit volumes Dimensions: (WxHxD:) 232 x 163 x 30 mm

wireless

wireless

wireless

programmingCNC

General


Bid calculation


control

Capacity planning

Production facility

management

Quality management

CNC Program

transmission

Industrial computer

Document management



The IC- 3000 is an industry-standard, 100% compatible PC in a robust IP54 protective housing (IP64 on the front)

Processor: Pent 800 MHzRAM: 128MB (can be upgraded to 512MB or 1GB)Interfaces: 2 x RS232

1 parallel interfacePS/2 for optional mouse/keyboard/barcode reader

LAN: Ethernet LAN 10/100 Mbit or WLAN2 x USB interfaces

Operating system: WIN2000 or WIN-XP 36) Autom. PC-compatible membrane keyboard Display: VGA 15" colour display 1024x768 Mouse: Touch screen display optional

Dimensions: Shell casing: WxHxD: 410 x 387 x 115 Base: WxHxD: 410 x 420 x 1420

With these performance characteristics it becomes a multi-functional hardware component in the production process for:

* BDE: Recording of order data via barcode or keyboard * MDE: Recording of machine conditions and counting functions * PZE: Recording employee timekeeping * DNC: Direct transmission of CNC programs * CAQ: Recording measurement data for statistical process control * PPS: Recording inventory accounting and costs, scale

IC3000

Ethernet cable CAT5e

(max. 150 m)

Maximum computer performanceNo heat problems

The IC-3000-Panel-PC consists of an industrial standard operating part (IP64) with membrane keyboard, (standard PC keyboard), VGA display (15" colour display 1024x768) and touch screen.

The CPU is relocated and is connected to the CPU via the standard interfaces (VGA, KBD, USB/RS232). The maximum cable length for this connection is approx. 2m.

Panel-PC

wireless


Bid calculationJob time calculationProduction planning control Capacity planningRecording of machine dataRecording of operational dataProduction facility managementQuality managementCNC programmingDNC program transmission

78564 Wehingen, Grotz-Beckert-Str. 4, Tel. 07426 / 5290-0, Fax. 07426 / 5290-10, E-mail: [email protected]

Complete solution for turning

workpiece manufacturers

CAQ

KALKCNC

DNC

PPS

IPC MDE

BDE

We boost your productivity!

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