SENSE AUTOMATED INSPECTION
VISUALIZE DATA ACQUISITION
ENHANCE CONTINUOUS IMPROVEMENT
IRIS Custom Solutions
10216 Werch Drive, Suite 116
Woodridge, IL 60517
Phone: 630-634-7702
Fax: 630-634-7701
Email: [email protected]
IRIS Custom Solutions LLC – 10216 Werch Drive, Suite 116, Woodridge IL 60517 www.IRIScs.com
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Manufacturing Visualization System The IRIS Manufacturing Visualization System was developed to provide manufacturers the ability to capture,
store, and visualize information in a way that enables them to make educated decisions to improve their
products and processes through the power of real time information.
Although the system was developed on the backbone of the widely known OEE calculation, its design flexibility
can also enhance our clients understanding of their machines by providing information on items like raw
material yield, specific downtime tracking codes, operator performance, and a host of other key production
metrics.
With the ability to communicate to over 220 different types of control devices, as well as nearly unlimited
flexibility in the collection and visualization of information, the IRIS MVS system provides a cost effective and
comprehensive solution for our clients process improvement needs.
HOW DO I KNOW IF MVS IS RIGHT FOR ME?
If you find that your organization can relate to the below statements, MVS may be exactly what you’ve been looking for:
We’re collecting data, but were not utilizing it because it’s not easily viewed and deciphered.
We’re unable to collect information at the machine level. We don’t have a grasp on how to improve our operator’s performance. We aren’t sure if we’re producing as much as were capable of. We don’t have a good understanding of if we’re utilizing our labor appropriately. Our production requirement is increasing and we don’t know where we can improve our
current production to avoid purchasing new machinery. If you’re facing these challenges, you’re not alone. That’s why IRIS has released our MVS System. The goal was to provide clients a simple, rugged, and cost effective way to start to understand where they are losing out on manufacturing efficiencies, and more specifically where they’re losing money.
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HOW MVS WORKS:
OEE
The backbone of the MVS system is the fundamental calculation of OEE. OEE is defined as AVAILABILITY x
PRODUCTIVITY x QUALITY
AVAILABILITY is a measure of how often the machine is actually running vs how often it is available to run.
Essentially this number takes into account the total time a machine is intended to run minus planned
breaks and downtime and then compares that to the actual runtime for a given time period.
PRODUCTIVITY is a measure of how many parts per minute a machine is producing as compared to how
many parts per minute it is capable or more importantly expected to produce.
QUALITY is a really a function of yield. This number is defined by how many good parts are being
produced as compared to the number of parts being produced overall.
Data Logging
Under normal operating conditions MVS will collect the below information:
Time
Location
Line
Machine (Cell)
Uptime
Downtime
Cycle Speed
Expected Cycle Speed
Lost Product
Good Units
Bad Units
Total Units
Availability (Target & Actual)
Performance (Target & Actual)
Quality (Target & Actual)
OEE (Target & Actual)
Product
Shift
Week
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Regarding downtime, there are two distinct downtime conditions, and MVS knows the difference
between those occurrences and handles the information differently for each case.
Planned Downtime
o In the case of planned downtime the MVS will not count planned downtime against the overall
performance of the machine. However, in the case where the machine is expected to be down
for a given time interval (which is pre-defined) and that time interval is exceeded, MVS will
begin to count that downtime as unplanned. Common contributors for this include:
Operator is not available or prepared
Incoming goods are not available
The machine wasn’t stopped properly prior to the planned downtime which leads to
longer startup
o Conversely if the machine begins to run sooner than expected, MVS will begin to collect
machine data immediately
Unplanned Downtime
o In the case of unplanned downtime, MVS will immediately log the downtime as unplanned and
it will count against the overall OEE. MVS will also prompt the operator or technician to
provide a reason on why the system was down and store that information for viewing and
reporting.
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SYSTEM CONFIGURATION OPTIONS:
The IRIS MVS system has three primary configuration options. Our goal was to provide our clients the
flexibility of having the system either Stand Alone, Machine Integrated, or Plant Integrated.
STAND ALONE:
1. By simply deploying a stand-alone MVS system and interfacing the two provided sensors to the client’s
equipment, our clients have the ability to interface with the MVS system to be able to enter other key
metrics that will then be rolled up into the OEE of the machine. This configuration is ideal for clients
with legacy equipment that either doesn’t have a control platform or has a platform that is not easily
communicated with. This solution can also be moved between different machines if the desire to
collect information from each machine is more of a short term need.
MACHINE INTEGRATED:
2. By integrating the MVS system directly to the machine control, we can provide a much more
comprehensive and automated collection of information. In this case the MVS would connect directly
to the machine PLC, monitoring specific data memories to collect all required information for OEE and
other key metrics. This doesn’t require any change to the existing PLC program, and simply acts in a
supervisory fashion. In this case we can connect one or many machines to one interface station.
Sensor counting all parts
being produced
Sensor counting rejected
product
Machine 1
Machine 2
Machine 3+
Machine 3
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PLANT INTEGRATED:
3. When our clients have multiple machines and their primary focus is to have the OEE displays and
reporting in the front office or overhead on the plant floor, we offer them the option of running MVS
on a plant based server.
This gives our clients the scalability they need in that they can add additional machines to the MVS
system as desired. It also reduces the overall cost of the system by eliminating the need for stand-
alone MVS hardware at each machine.
Machine 1
Machine 2
Machine 3
Machine 4
Machine 5
Machine 7
Machine 6
Machine 7+
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WHERE CAN I SEE THE INFORMATION?
View information real time at a local
machine data collection terminal
View Information on overhead or
wall mounted AndOn displays
View information real time in the
front office on multiple stations
View information real time on
tablets and other mobile devices
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Features and Benefits
Understand downtime in terms of:
o Planned Downtime
Preventative Maintenance Functions
Operator Breaks
o Unplanned downtime
Quantification to the second of specific machine error codes
Quantification of type and length of maintenance functions
Understanding of downtime due to operator unavailability
Ability to Sort, Quantify, Visualize, and Report production metrics by:
o Operator
o Shift
o Product
o Machine
o Line
o Incoming Material
Ability to capture and visualize Automated Inspection Device failure codes
o Why a part was rejected
o How many of each reject occurred
Ability to quantify final production yield vs. incoming raw materials
Automate and expedite shift reporting for items like:
o Total Good Parts
o Total Bad Parts
o Uptime
o Downtime
Ability to display live data directly to operators so they understand their performance to
expectation real time
Ability to email technicians or front office staff in the case of manufacturing anomalies
Ability to produce immediate historical reports based on user selected time period for any
and all information being gathered
Ability to generate “at a glance” reports for last hour, last 4 hours, last shift, last week, etc.
Ability to interface with an existing customer database to tie back production data to
existing customer job numbers, part numbers, and raw material
Ability to view the system display on the plant floor, at your desk, or from a mobile device
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SCREEN DISPLAYS AND FUNCTIONS
OEE Statistics Screen
The OEE Statistics Screen is the main screen of the application. Here an operator can select a date/time
range, product, job, and shift in order to see the Overall Equipment Efficiency of the system for those
selections. This provides the ability to not only see “current” OEE, but be able to get “at a glance” reports
and displays for other historical time intervals.
As additional criteria the user can further segregate information by:
o Cell - View the data for that cell/machine
o Line - View the data for multiple cells
o Location - View the data for all of the lines and cells
Figure 1.0
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In the figure 1.0 above, Cell #1 data is being shown. For the date/time selection, the user would use the
following sequence to populate the fields.
o FROM OR TO FIELD - DATE/TIME PRESSED
Popup will occur which allows an operator to select these via a calendar view.
o START OF SHIFT BUTTON PRESSED
FROM FIELD = Start of Shift Time
TO FIELD = Current Time
o LAST 4 HOURS BUTTON PRESSED
FROM FIELD = Current Time – 4 Hours
TO FIELD = Current Time
o LAST 2 HOURS BUTTON PRESSED
FROM FIELD = Current Time – 2 Hours
TO FIELD = Current Time
o LIVE BUTTON PRESSED
FROM FIELD = Previous date/time selection remains
TO FIELD = Current Time
The target and actual values for availability, performance, quality, and OEE are shown graphically and
numerically. In addition, an operator can see the:
Total parts made
Rejected parts
Uptime
Downtime
All for the given parameters entered (date/time, product, etc.). An operator can also press the “Export
Data” button, which will save the data shown to a csv file on a USB thumb drive.
Figure 1.1
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OEE Details Screen
The OEE Details Popup Screen is accessed from the OEE Statistics Screen and is used to give an operator
information about OEE and how it is calculated.
In addition, the Expected Parts Per Second field (entered on the OEE Settings Screen) is shown. From
the OEE Details screen, a user can press the “OEE TUTORIAL” button, which will show a document
covering specifics about OEE (definitions, calculations, etc.). When the “CLOSE” button is pressed, the
popup will close.
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OEE Trending Screen
The OEE Trends Screen is accessed from the OEE Statistics Screen and is used to show the OEE values in
trend format. The date/time, product, job, and shift selections from the OEE Statistics Screen are retained,
but also can be modified if needed as described in the OEE Statistics Screen section. The trend can show all
or a combination of the following statistics by selecting or deselecting the checkbox next to that statistic:
Availability
Performance
Quality
OEE
When the cursor on the trend is moved, these values change for that specific point in time, shown in the
CURSOR DATE/TIME field. The target values for these fields are shown on the trend as dashed lines,
while the actual values are shown as solid lines.
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OEE Settings Screen
The OEE Settings Popup Screen is used to enter target values for Availability, Performance, and Quality,
which are shown on the OEE Statistics and Trends Screens. In addition, the expected parts per second values
for each cell are entered on this screen.
This value is used in the OEE calculations as described on the OEE Details Screen. When the “CLOSE” button
is pressed, the popup will close.
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Current Week
When first starting the application and when the week prompt date/time has occurred, the supervisor
will be prompted to select the current week (1-4). This will adjust the current shift settings to be the
settings saved for that week and determine when a shift is occurring and when a scheduled downtime
is occurring.
In addition, the supervisor will set the date/time to be prompted again for the week change. No data
will be logged until a week is selected by the supervisor.
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Select Product Screen
The Select Product Popup Screen is used to select the current product running, so that this can be logged to
the database when the OEE data is logged. An operator will click on the product, which will highlight that
line, and then press the “RUN PRODUCT” button. This will also close the popup.
If the operator does not want to change the product selection, then the “CANCEL” button can be pressed to
close the popup with no changes being made. The current product running is also shown on this screen.
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Select Job
The Select Job Popup Screen is used to select the current job running, so that this can be logged to the
database when the OEE data is logged. An operator will click on the job, which will highlight that line,
and then press the “RUN JOB” button. This will also close the popup.
If the operator does not want to change the job selection, then the “CANCEL” button can be pressed to
close the popup with no changes being made. The current job running is also shown on this screen.
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Down Time
The Downtime Screen is used to show the current downtime statistics (cell number, alarm name, and
number of minutes in a downtime) for the current shift. These are populated when downtimes occur
and the reasons are selected by the operator or provided by the PLC (see description in Downtime
Reason Popup section). The values are reset when a shift change occurs, or when the “RESET DOWN
TIME” button on the screen is pressed.
In the case of the system being interfaced to the machine PLC, the collection and quantification of these
codes will be automated.
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Reject Table
The Reject Table/Statistics Screen is used to show the current part rejection statistics (cell number, reject
reason, and number of rejected parts) for the current shift. In order to log a rejected part, the following
sequence will occur:
“LOG REJECTED PART” button pressed. This will increment the “Undefined Rejects” field.
Enter the number of rejects for each reject reason, with the total equal to the “Undefined
Rejects” field. If the total does not match, an error will appear which will prompt the operator
to fix the values before updating.
When the values are correct, the “UPDATE REASONS” button is pressed. This will update the
database for the rejected parts and will show these rejections on the upper half of this screen for
the current part rejection statistics.
If the rejected parts were all rejected without a known reason, the “RESET ALL TO UNKNOWN”
button can be pressed to update the reason for all undefined rejects to “Unknown Reason”.
The values are reset when a shift change occurs, or when the “RESET REJECT TOTALS” button on the
screen is pressed. Note: Logging of rejects can be automated, if desired, however the reason selection
will still occur as described above.
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Reports
The OEE Reports Screen is used to show the downtime values in trend format. The date/time, product, job,
and shift selections from the OEE Statistics Screen are retained, but also can be modified if needed as
described in the OEE Statistics Screen section.
The downtime alarm type is selected and then the total minutes for the date/time range and alarm type is
shown. When the cursor on the trend is moved, the downtime minutes for that specific point in time will
be shown.
An operator can also press the “Export Data” button, which will save the data to a csv file on a USB thumb
drive. In the case where the MVS is networked this information can also be accessed remotely.
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Configuration
When the “CONFIG” button is pressed on the side bar, the “SHIFT CONFIGURATION” Screen is opened.
This screen is only accessible by a supervisor. From this screen, all of the other configuration screens
can be accessed. The screens are described as follows:
Shift
The Shift Configuration Screen is used to show the shift configuration for up to 5 shifts. This
screen also shows which shift the system is currently in, with that shift highlighted in green.
When an operator presses the “SET” button next to a shift, the Shift Settings Screen will appear
in order to modify the shift.
In addition, this screen shows the current week selected and the date/time that the week change
should be prompted to a supervisor. When the “WEEK PROMPT DATE” field is pressed, a calendar
will appear to allow the supervisor to select when the week change should be prompted in order
to allow the week selection to change.
For more details about this, reference the Current Week section of this document.
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Shift Settings
The Shift Settings Screen is used to modify the shift configuration for a selected shift.
The settings are as follows:
The default week shown is the current week.
The shift name, start time, and end time are entered at the top of the screen for
the week selected.
The days of the week that the system is run for this shift and week are selected
using checkboxes.
The scheduled downtimes are enabled for the shift and week selected, with the
start time and duration in minutes entered. If only one downtime occurs for a
shift, then DOWNTIME 1 would be the only field enabled. If two downtimes
occur for a shift, then DOWNTIME 1 and 2 would be enabled. This is
customizable for up to 5 downtimes per shift and week.
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To change the shift configuration for a different week, the week can be changed using
the week selection box. When the week is changed, a popup will appear (see below) to
prompt a supervisor to save the values before continuing.
If the supervisor presses “SAVE WEEK SETTINGS”, then the settings will be saved and the
selected week will change. If the “CANCEL” button is pressed, then the week selection
will return to the previous selection and no changes will be saved.
When the updates to the shift are completed, the “SAVE AND CLOSE” button will be
pressed to save these settings and close this screen. If changes have been made that
should not be saved, then the “CANCEL” button will be pressed to close this screen.
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Product
The Product Configuration Screen is used to configure the products. This is done as follows:
Update Existing Product - Select the product, which will highlight it in the table and show
the name, part number, and parts/second in the “EDIT PRODUCT ATTRIBUTES” box. A
supervisor can then enter the updated values and then press the “UPDATE PRODUCT”
button to update the product in the database. Delete Existing Product – Select the product, which will highlight it in the table. A
supervisor can then press the “DELETE PRODUCT” button to delete this product from the
database. If a product is deleted, the OEE data for this product will no longer be
accessible, other than when “ALL PRODUCTS” are selected for the OEE data. Add Product – Enter the name, part number, and parts/second fields and then press the
“ADD PRODUCT” button. This will add the product to the database and allow it to be
selected as the current product running (see the Select Product Screen section).
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Job
The Job Configuration Screen is used to configure the jobs. This is done as follows:
Update Existing Job - Select the job, which will highlight it in the table and show the name
and part number in the “EDIT JOB ATTRIBUTES” box. A supervisor can then enter the
updated values and then press the “UPDATE JOB” button to update the job in the
database. Delete Existing Job – Select the job, which will highlight it in the table. A supervisor can
then press the “DELETE JOB” button to delete this job from the database. If a job is
deleted, the OEE data for this job will no longer be accessible, other than when “ALL JOBS”
are selected for the OEE data. Add Job – Enter the name and part number and then press the “ADD JOB” button. This
will add the job to the database and allow it to be selected as the current job running (see
the Select Job Screen section).
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Downtime
The Downtime Configuration Screen is used to configure up to 10 downtime reasons. To update
a downtime reason, the reason is selected, which will highlight it in the table and shown the
reason in the “EDIT DOWNTIME REASON” box.
A supervisor can then enter the updated reason and then press the “UPDATE REASON” button to
update the reason in the database. The “Unknown Reason” and “Changing Products” reasons
cannot be updated as they are required for the system.
In addition, the downtime prompt time can be modified, which determines how long the system
is not running before the downtime is logged and a reason is required.
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Reject
The Reject Configuration Screen is used to configure the 5 part rejection reasons. To update a
rejection reason, the reason is selected, which will highlight it in the table and shown the reason
in the “EDIT REJECTION REASON” box.
A supervisor can then enter the updated reason and then press the “UPDATE REASON” button to
update the reason in the database. The “Unknown Reason” entry cannot be updated as it is
required for the system.
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Downtime Reason Popup
The Downtime Reason Popup Screen is automatically opened when a downtime has occurred. The
operator must select the downtime reason and then press the “SELECT REASON” button, which will log
the downtime to the database and close the popup.
If the reason is not selected and the downtime is no longer active and then becomes active again, then
“Unknown Reason” will be logged as the initial downtime’s reason and the popup selection will be for
the current downtime.
If the reason for the downtime is due to changing a product, then the “PRODUCT CHANGEOVER” button
can be pressed instead of selecting a reason. This will set the reason to “Changing Products” and will
open the Select Product screen so that the operator can select a new product.
For more information on MVS and other products and services IRIS has to
offer please contact us at 630-634-7702 or [email protected]