Manufacturing control, shop-floor
How is the system composed.
By terminals installed in manufacturing departments, equipped with badge readers (RFID, magnetic, multi-standard, etc.), barcode scanners, digital input/output with operating machines, automatic counters, scales, status signals, analog & digital signals, intelligent label readers/writers (tracking, origin certificates, anti-falsification, etc);
By optional long-range antennas to identify operators and products;
By a PC connection (via Ethernet, wireless, network, modem, GSM/GPRS, etc.);
By Autopro interactive data exchange software application;
By manufacturing management software application.
Who can take benefits from this system.
Any Company with productive departments/units where in-progress production cycles and work orders should be monitored (continuosly in real time or periodically at any given interval);
Any Company with productive departments/units where controls and real time answers should be given to operators in field;
Any Company with productive departments/units where quality control and/or products tracking should be carried out.
The system economic returns
This system can bring to several economic benefits :
Time savings for any operator
Quality and Efficiency improvements in manufacturing process
Real time controlled and tracked production, with any data immediately available
Depending on local laws, also fiscal and financial benefits can be achieved as result from hi-tech investments related to: technologic innovation in manufacturing process;
products quality and tracking improvements.
Main Customer advantages.
This system cuts out any manual operation in the visual and papery data collection, avoiding any error and saving verification times required to human controllers.
The collected data can supply straightly the management software applications, avoiding interferences and manipulations.
Badge and barcode reading is a simple, fast and secure action for the operator.
The automatic data reading (i.e. from product counters, cycle and meter counters, serial connections, automatic scanners) will automatically complement the operator’s data.
The long-range identification (operators and products) can further minimize and automate any required operation.
The best and fast results from the system will be achieved involving in this technologic innovation the manufacturing human resources:
The operators get from terminals automatic answers and immediate controls on correct declarations/operations of their works;
The department persons in charge become professionally advanced hi-tech supervisors and controllers of any production activity, thanks to innovative IT instruments and software;
The Company and production leadership get an impartial control instrument to analyze and survey industrial costs, real time data, and finally the utilization of resources (human and machines).
The system human interface
The operator (i.e. to declare an activity begin or end) will simply press a function key on the terminal (i.e. “Work begin”, “Work end”, “Work suspension”, etc.) then just follow the instructions on display.
A barcode scanner reading can be required (i.e. “Read work order barcode”), or type in a data on the keyboard (i.e. “N. of rejected pieces”), etc.
After any answer, an “OK” message will displayed, or eventually an error message to inform the operator, if an incorrect data was declared.
System interface to machines
Via pulse electric signals (hit counters, piece or meter counters, etc.), coming from machine sensors, who give and electric pulse for each hit, piece, meter of completed machine work. The terminal counts and stores the pulses, and will send them to the central data collection system when required
(ON/OFF machine status) These signals are emitted under status change. The terminal will store the status and transmit to the central software, so that an alarm can be generated if necessary.
(i.e. tachometers, temperatures, chemical variations, and other analog instrument measures)
Serial RS232 interfaces
(i.e. data and codes from machines, weights from scales, data from automatic scanners, etc.) normally received from automatic machinery. The terminal will store any data, and transmit it to the central system.
General system features
The system collects and integrates informations from operators, machinery, and rfid automatic identification of human resources and products.
Any collected data will be stored in the terminal memories and transmitted to a data collection PC via bidirectional communication Autopro software package.
The central management software will process any data, and can give in real time the answers and controls for human manufacturing workers and machines.
The operators can thus know immediately the outcome of their declared works.
The central system will build an electronic image of general manufacturing process, updated in real time.
The persons in charge of any productive department can get manufacturing reports and summaries, with any detailed work order in progress.
The company directors can get summarized views and control reports with general manufacturing results.
The system can also be set to a “batch” operating mode. In this case any single declaration/operation is temporarily stored in the terminal memory. At a given time all these stored data will be sent to the central system. In this case no real time answers will be sent to human operators.
Optional features and integrations.
The manufacturing data can be integrated on the same plant with further management software applications: worktimes, quality tracking, access control, meals / refectory declarations, other security applications, etc.
There mixed / multiple applications can be integrated in transparent mode with an ideal use of existing data transmission facilities and infrastructures (Ethernet cables, wireless networks, phone networks, geographic networks, TCP/IP, ecc.)
For remote sites without any existing data connection, a simple phone cable can be installed, or a wireless network, or even GSM/GPRS communications can be used.
The terminals can be equipped with other optional readers and peripheral units:
RFID readers / wirters
RFID long-range antennas for automatic identification of persons, vehicles and products
Microchip card readers
Magnetic badge readers
Intelligent labels readers / writers (tracking, origin certifications, anti-falsification
The terminals can drive external signals / devices by supplementary outputs:
Relays to enable/disable power external signals, sirens, lights;
digital output to generate pulse signals or electric levels;
acoustic buzzers, amplifiers, others sound signals.