oee toolkit rc revised manualus

RemoteCollect Manual

5.4

12th of September 2007

FullFact [email protected]

© 2007 FullFact

X RemoteCollect Manual

RemoteCollect Manual OEE Toolkit 5.4 FullFact – Your Partner in Productivity 2-50

X 0 Introduction and table of contents

Introduction RemoteCollect is a system for collecting OEE data in an efficient and accurate way. This manual contains information regarding different areas of application, electrical diagrams, configuration and the daily use of RemoteCollect. The information regarding the electrical diagrams and the configuration has been written for a public with a technical background.

X RemoteCollect Manual X-3

X 0 Introduction and table of contents............................................................................X-3X 1 Before starting..........................................................................................................X-4X 2 Technical specifications...........................................................................................X-6X 3 Connecting the I/O module......................................................................................X-7X 4 Installation and configuration.................................................................................X-13X 5 Using RemoteCollect.............................................................................................X-30X 6 Functionalities of RemoteCollect...........................................................................X-35X 7 Appendix 1 X-42


X 1 Before starting

RemoteCollect RemoteCollect has been developed to make OEE data collection easier and more accurate. RemoteCollect can be used on all production processes, whether discrete production or continuous processes. In the RemoteCollect software various different types of measurement have been defined.

Where to measure

The measuring point must be installed as close to the location where value is added as possible .

Kinds of Signal RemoteCollect can manage 3 kinds of signal: “Output counter”, “Machine status” and “Heartbeat”. These 3 signals are described below. The reasons for stops are standardized by the users in a predefined table. If RemoteCollect detects a stop it is then possible to choose the reason for this stop from the table.

Output counter The 'Output counter' uses 1 input signal. This signal is linked to the product. The pulse provides information about the number of products produced. RemoteCollect detects that the machine is in production because there is output of products.

Production times; with a bottle filler for example, it is usually possible to count the number of products when the line is producing. Counting the bottles (1 pulse = 1 product). RemoteCollect has the capability to factor this signal.For example, if 6 bottles are filled at the same time the product factor is 6.

Machine status 'Machine status' uses 1 input signal. This signal is linked to the status of the machine. RemoteCollect only detects whether the machine is producing or not. Stops can be defined and their lengths configured for each machine. The pulses are not related to the number of products. The pulse is continuous when using 'Machine status'. For example, if a milling machine produces 1 product during 5 hours, when the milling machine is running the machine signal (RemoteCollect input signal) is continuous. In this way RemoteCollect detects that a machine is producing. If the signal changes to 0 RemoteCollect has detected a stop.

Heartbeat The 'Heartbeat' signal is very similar to the 'Machine status' signal. There is one difference. In the heartbeat mode RemoteCollect gets a pulsing signal instead of a continuous signal. However, these pulses are not related to products. The data processing is the same as the 'Machine status' signal.


Sensor Decide whether RemoteCollect needs to detect an external signal.

RemoteCollect needs a signal to determine if the machine is producing or has stopped. This can be done by counting products coming out of the machine. If there is a sensor, then a relais signal or a PLC signal containing this information can be used. No other external sensor is necessary. The electrical diagrams are included in this manual.

Computer Location of the operator panel (computer).The operator panel has 3 functions:

1. Manual input of the reasons for stops.2. Dislay of real time OEE graphs updated every second.3. Connection of the machine signal (sensor).

The operator panel should be located in a place where it is easy for the operator to process the data. If it is dirty and wet an IP 65 touchscreen could be a solution.

Remote-Collect configuration

Before configuring RemoteCollect certain issues should be dealt with. The checklist below can be used as a guide during the configuration.

Remote-Collect checklist

Utilities Execution Who When

Computer near machine Touchscreen, normal PC

Remote I/O module COM, USB

Machine signal External sensor

Connecting hardware to PC

Remote I/O and signal

OEE Awareness Management

OEE Awareness Operations team

OEE Toolkit knowledge Managing OEE Toolkit

OEE Toolkit knowledge Processing data

OEE Toolkit knowledge Analyses


X 2 Technical specifications

Operating system

PC with Windows 2000 or Windows XP

Processor CPU 600 MhzInternal memory 512 MBHard disk 50 MB

Screen Touchscreen or screen with 1024 x 768 resolution

Network LAN 100Mb

Remote I/O modules

Connection of the PC to the I/O module is possible in 2 ways, RS232 or USB)Signal to other modules RS 485Maximum length between the modules: 3000 meters

Input of I/O Connections on Remote I/O moduleInput signals activitated with “0”Output relais max 1 A, 220 VPNP (1 per module) and NPN sensors can be connected.

Touchscreen* IP 65 Fanless stainless steel casing 17 Inch screenIntegrated PC

* RemoteCollect is developed for Touchscreen but functionates also with a normal PC.


X 3 Connecting the I/O module

Before starting

This chapter includes the electrical diagrams for RemoteCollect. Some technical knowledge is recommended.

Types of Remote I/O modules

RemoteCollect usually works with 2 types of Remote I/O modules depending on the connection to the PC. There is one for the serial port (COM, RS 232) and one for an USB port (pictures below).

COM type USB type

Connecting the remote I/O module

The connection of the remote I/O modules is explained in the electrical diagrams and in writing. The electrical diagrams for both COM and USB connections are followed by explanatory texts.

Connecting the sensor

The connection of the sensor is explained after the instructions for the COM and USB connections.


COM Electrical Diagram

The electrical diagram below shows the COM type module. The diagram has 4 drawings.

COM (RS232) Components

Network adapter – 24V ACAdapter to COM connection EX 9520RS 232 cableRemote I/O module EX 9065 D

COM (RS232)


COM (RS232) (continued)


USB Electrical Diagram

The electrical diagram below shows the USB type module. The diagram has 4 drawings. Attention: install the USB driver, C:\Program Files\OEE Toolkit 5\Drivers

USB Components

Network adapter – 24V ACAdapter to USB connections EX 9530Remote I/O module EX 9065 D

USB


USB (continued)


Explanatory text for Remote I/O Connection

Below are the explanatory texts for both COM and USB connections.

COM (RS232)Connection

* Use the information under the heading “Connecting sensor" if an external sensor will be used instead of a contact for the signal.

USB Connection Attention: install the USB driver, C:/program files/OEE toolkit 5/drivers

* Use the information under the heading “Connecting sensor" if an external sensor will be used instead of a contact for the signal.

Connecting Sensor

Standard PNP (sourcing) type sensors have a voltage pulse if they detect something. Connect this sensor as follows.

IN 1 (B)GND 10 (gives pulse)IN COM Black sensor cable (pulse)Brown sensor cable 24VBlue sensor cable 0V

Standard NPN (sinking) type sensors have a voltage drop if they detect something. It is possible to connect more NPN sensors to one EX 9065D module. Connect this sensor as follows.

IN 1 Black sensor cable (gives pulse)IN COM 24V Brown sensor cable 24VBlue sensor cable 0V


Connection of the EX 9520Serial cable to COM Port

(B)GND 10 0V(R)+Vs 24VData+ Data+(EX 9065D)Data- Data-(EX 9065D)

Connection of the EX 9065D

(B)GND 10 0V(R)+Vs 24V(G)Data- Data - (EX 9520)(Y)Data+ Data+ (EX 9520)IN 1 * (B)GND 10 (gives

pulse)IN COM * (R)+24V

Connection of the EX 9530USB cable to USB Port

(F)GND 10 0VTX+/D+ (Y) Data+(EX 9065D)TX-/D- (G) Data- (EX 9065D)

Connection of the EX 9065D

(B)GND 10 0V(R)+Vs 24V(G) Data- TX-/D- (EX 9530)(Y) Data+ TX+/D+ (EX 9530)IN 1* (F)GND 10 (gives pulse)IN COM * (R)+24V

X 4 Installation and configuration

Installation Installation of OEE Toolkit and RemoteCollect is quite simple. Both programs are installed by the OEE Toolkit setup. Choose the 'standard installation' option during installation.

Sequence OEE Toolkit and RemoteCollect use the same database. The masterdata must be completely configured in the OEE Toolkit before using it with RemoteCollect. Information about this configuration can be found in the OEE Toolkit manual. Also check the licence code because RemoteCollect must be activated using this code. Contact FullFact or your retailer for this code.

It is important for RemoteCollect that the following definitions are added to the OEE Toolkit masterdatabase:

In activities: Minor stops, a name for a category of stops which are too short to

justify a reason. This kind of minor stop must be configured in the 'Idle' category.

Undefined stops, a name for a category of stops which are not justified when RemoteCollect is closed. This kind of undefined standstill must also be configured in the 'Idle' category.

Hardware failure, a name for a category which accounts for the duration of a problem with the remote I/O module. This kind of standstill must be configured in the 'Failure' category.

In products Undefined products, if products which have been produced are not

justified.

Open the Machine-Time-Product table in the OEE Toolkit masterdata and link the newly defined names of stops and products to the related machines.

Configuration The configuration of RemoteCollect is executed by a wizard. The wizard has two parts. In the first part the general settings of the computer are configured. In the second part the specific settings of a machine are configured.


Computer settings

Configuration of the computer which deals with the machine signals.

The first time RemoteCollect is used the wizard will open.

Activating the Wizard

To reconfigure the settings again the wizard can be activated by modifying the shortcut.

Click with the right mouse button on the shortcut to modify the properties.Attention: the extension /init must be inserted after “the” with a space between. Close this window and start RemoteCollect.

Don't forget to delete /init after reconfiguration of the settings.


RemoteCollect Verify that the hardware is connected to the computer before proceeding.Configuration

COM port Configuration

The Baudrate, databits, Parity and Stopbits settings are already OK. Click 'Detect Hardware'. The scan will detect which port the Remote I/O module is connected to. Double click on this port to save this setting.


COM port Configuration(continued)

Double click on this port to save this setting. Click ‘Next’. Attention: If theRemote I/O module is connected via USB then the USB driver must be installed. See C:/program files/OEE Toolkit 5/drivers.


Computer Settings

Local user settings/preferences of the computer connected to RemoteCollect can be configured here.


Configuration of user rights

Configuration of the user rights can be modified if there are any preferences. These settings can be modified later for each machine.


AddingMachines

Click on 'Add..' Choose the machine(s) which will use RemoteCollect.Click ‘Next>’


ConnectingMachines

If there is a connection between the I/O module and the computer then the !019065D text will be displayed. If this is not the case, click ‘back’ and refer to appendix 1. Once the connection is made, the machine settings can be configured.Click ‘<Prior’.


ConfiguringMachines

Select the machine which needs to be configured.Click 'Edit...'Repeat this procedure for the other machines if more than one machine is connected to one computer.


Machine settings

Configuration of the machines connected to the computer.

Hardware Sheet

1. “Sensor-style” setting: “Output counter” if output is counted in products. “Machine status” if the status of the machine is monitored. ”Heartbeat” if the machine gives pulse signals when it is running.

2. Address: the default setting of 1 is OK. Modify this setting only if more I/O modules are connected.

3. Product Sensor port: the default setting is 1. Modify this if there is another I/O module input, e.g. more than one machine.

4. # undefined activities allowed: this setting defines the maximum number of activities which can be undefined.

5. Signal-output: if the allowed undefined activities number is reached then an output signal will be activated. This output port number can activate an audiovisual signal (lamp or horn).

6. Sample size: this setting defines the frequency at which the velocity is measured. The velocity of the machine is shown in real time on the machine screen. Refresh every: refresh period of the machine velocity.


Unresolved Activities Sheet

It is possible to define reasons to minor stops, which are not justified and/or when RemoteCollect itself has a hardware problem, automatically. In this way those time periods can be analyzed. It is also possible to select a default product category for production runs without a defined product.Attention: these stops must be configured in the OEE Toolkit before including them in the 'Unresolved Activities' setup.


Threshold time Sheet:

Configuration of minor stops and stopcode.

Rule: the time between 'Minor stop 5 Sec.' and 'Stopcode 10 Sec'. will be automatically counted as minor stops.If there is a stop of more than 10 seconds then the operator should justify this stop by choosing a reason.If there is a stop shorter than 5 seconds, then this stop will be counted as production time.


Product-multipliers Sheet

Configuration of Product-multipliers. Attention: if the number of decimal places is configured at 0 then it is not possible to set the factor to 0.5 for example. Go back to the beginning of the wizard and adjust the number of decimal places.

Example: the sensor counts the number of machine strokes. Every stroke is 2 products. In this case adjust to 'Default multiplier 2'. Exceptions can be configured in the 'Default multiplier' table below.


Activity Grouping Sheet

Activities can be configured in groups to improve visualization.Every group may include a maximum of 14 activities. Click on the activity (or stopcode) on the right-hand side, then click on 'Add Activity' to move the activity to the group on the left-hand side.The default categories are based on: idle, line restraint, failure and unscheduled.


Activity Grouping Sheet(continued)

By clicking on a group with the right mouse button, the colour and edit options appear. It is possible to edit the display name and the colour.Attention: Only activities defined in the OEE Toolkit are available. Activities should first be added in the OEE Toolkit.


Out of Specs Grouping Sheet

Out of specs. output can be configured in groups to improve visualization. Every group may include a maximum of 14 scrap or rework reasons. Click on the scrap or rework reason on the right-hand side, then click on 'add Out of Spec' to move this reason to the group on the left-hand side.By clicking on a group with the right mouse button, the color and edit options appear. It is possible to edit the display name and the colour.


User rightsSheet for each machine

If there are different user rights as the default settings for a certain machine then these settings can be modified.Click ‘OK’.

More than one machine

One machine has been configured.Repeat the procedure if there are more machines connected to the computer.


X 5 Using RemoteCollect

Starting RemoteCollect

Modify the shift and/or team after starting or after a shift change by clicking on the button below on the left-hand side of the screen.


Justifying stops

A stop only needs to be justified if it takes more than the minimum time period configured for the machine.

1. Click on the machine.

Justifying stops

2. Select the category or group to which the stop is related.


1.

2.

Justifying stops

3. Select the reason for the stop.

Justifying stops

4. It is also possible to justify the stop at a later time. Click on the 'undefined' button in the screen below to justify the stop. Every button in the screen below is related to a stop or production time.


3

4.

What is a minor stop?

5. A minor stop is a stop which takes longer than the minor stop time setting configured but shorter than the time setting configured for a stopcode.

6. This time period will automatically be counted as 'minor stops' without interference of the operator.


5.

6.

Selecting Products

It is possible to select products after the start of a production run.7. The purple color and the “Select Product” text indicate that the current

product should still be selected. Click on the machine.

Selecting Products

8. Select the product.These are the basic functions of RemoteCollect. An explanation of these functions can be found in Chapter 6.


7.

8.

X 6


X 7 RemoteCollect Functions

RemoteCollectFunctions

Starting RemoteCollect1. Initializing hardware. RemoteCollect hasn’t defined a production,

minor stop or real stop status yet. This situation will change if a something is produced or a timespan is exceeded.

2. Production? Will there be production?


1.2.

RemoteCollectFunctions

Starting RemoteCollect:3. Minor stop? The production timespan has been exceeded. If the

sensor detects a product then this time period will be counted as a 'minor stop'.

RemoteCollect Functions

Starting RemoteCollect4. Select the activity. The timespan of a minor stop has been exceeded.

The reason for the stop has to be selected.


4.

3.

Main screen, signal lights:5. Background color of the button shows the reason for the stop.6. Yellow light; there are stops which are not defined.7. Red light; there are more undefined stops then the maximum

configured.

8. Selecting the reason for a stop:The stop can be selected on this screen. The reasons buttons are one level below the current activity buttons. See picture below.


5. 6. 5. 7.

8.

Selecting the reason for a stop:9. Select the reason for a stop by clicking on the button.10. Click on the first button to go up one level.

Selecting the reason for a stop:11. Start time of the stop.12. Duration of the stop.13. Total time the machine has stopped for this reason.


10. 9.

12.11.

13.

General buttons.14. Back to main screen (the dashboard).15. Show real time activity graph.16. Show all undefined stops and production issues.


15.

16.

14.

Registered stops.17. Current stop.18. Last activity before the current stop. Click on this 'production' button to

justify the products. See also item 20.19. Stop in the past. Click on the button to modify.

Selecting products:20. It is possible to select products during or after production.


18.19.

17.

Extra options for registered stops:21. Possibility to modify stops which were already justified.22. Possibility to split the current stop. This could be the case if for

example the stop turns into a failure or waiting for material.23. Number of operators.

Extra options for registered stops:24. Possibility to type notes in the logbook.


21. 22.

23. 24.

X 8 Appendix 1

Problemswith USB

The USB port simulates the COM port and this could introduce some problems. Follow the procedure below to solve the problem.

Is the USB driver installed? (c:\program files\oee toolkit5\driver) Is the hardware connected correctly?Is the correct COM port selected?

If these three steps do not solve the problem then select COM 4 for the USB port which is connected to the hardware.

Forcing COM configuration

Windows sometimes doesn't make the COM ports available. Follow the procedure below to force the COM ports.

Open the configuration menu in Windows.Open 'System'.


Select the 'Hardware' sheet and click on ‘Device Manager'.

Click on 'Ports´.


Select the port named 'Prolific-to-Serial Comm Port'.If this port is not available then the hardware is not connected correctly or the driver is not installed.

Double click on 'Prolific-to-Serial Comm Port'.


Select the 'Port Settings' sheet.


Select the ’Advanced…’ option

Open the scroll down menu where the COM port number can be selected.


Select COM 4 in the scroll down menu.

Start RemoteCollect and also select COM 4 in RemoteCollect. Continue following the configuration wizard for RemoteCollect. If there are still any problems, contact the FullFact B.V. helpdesk.

[email protected]


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