real-time production monitoring software - …rockwarecorp.com/downloads/2014...

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Rockware® Magic™ Manufacturing Execution System

Real-Time Production Monitoring Software

Injection Molding Machine Template

User Guide

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User Guide Content

0.0 Definitions

1.0 Data Overview

2.0 Main Dashboard 2.1 Header – Auto ON/OFF, Date-Shift Selection, Adjust Page Position

2.2 Header – Department/Line Toggle

2.3 Header – System Information, UPDATE to Latest Revision

2.4 Header – Main Menu

2.5 Header – Custom Tab Menu

2.6 Header – Department/Line Summary Data

2.7 Header – Refresh, Print, Legend

2.8 Data Display Area – Machine Blocks

2.9 Data Display Area – Hourly Counts

3.0 System Configuration Step by Step 3.1 Change Current Job Assignment

3.2 Correct Previous Job Assignment

3.3 Add New Part, Tool, Job

3.4 Change Standard Cycle Time

3.5 Shift Configuration

3.6 Shift Hourly Breakdown Configuration

3.7 Add Downtime Groups and Codes

3.8 Add Scrap/Reject Codes

3.9 Machine Dashboard Order and Color Code

4.0 Shift Recap™

5.0 Bulk Scrap Entry

6.0 Downtime Group and Code Entry 6.1 Splitting Downtime Instances

7.0 Historical Drill-Down™ Logs and Reporting 7.1 How to use Drill-Down™ Logs

7.2 Report Type Examples

7.3 Standard Drill-Down™ Logs

8.0 Preventative Maintenance (PM) Mold Tracker

Appendix A Touchscreen Friendly Controls (TSF™)

Appendix B Cash Register™ Real-Time Machine-Side Entry

Appendix C Live Schedule™

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0.0 Definitions

Availability (AV) – Calculated by dividing total scheduled run time by total actual run time. Scheduled

downtime is removed from this calculation. Availability is a component of overall equipment efficiency (OEE).

Cash Register™ – All-in-one touch screen computer application used primarily for scrap entry and downtime

category entry. A Cash Register™ unit can be mounted at each machine to ensure scrap and downtime can be

entered real-time.

Cavities-Standard (Std Cav) – The number of physical cavities available for each job.

Cavities-Actual (Act Cav) – The number of cavities actually ran for each job. Jobs can be added for each tool to

run only selected cavities if needed (I.E. RH Only). Handed tools sometimes have cavity shut-offs to balance

inventory which can impact OEE calculations.

Cycle – Sequence of events from start to end to complete a job and create a predefined set of parts.

Cycles (Calculation) – The number of times a machine completes a full cycle.

Cycle % – The percent of cycles completed compared to the target. The real-time cycle % does not include

real-time scrap in the calculation.

Dashboard – Real-Time display and user interface. The Main Dashboard provides the user with a tool for

quickly viewing the status of each individual machines and the department as a whole. It also provides links to

other system interfaces and reports.

Date-Shift – A unique combination of a business date and specific shift. Displayed in the following format

YYYY/MM/DD-S, S stands for shift.

Display – Information or graphics that can be viewed on a computer screen.

Downtime (DT) – The total amount of time a machine is not cycling and is unavailable each shift.

Drill-Down™ Logs – Interface with complex filtering aids for cycles, downtime, scrap, shift metrics, etc. Logs

provide optimal filtering capabilities to allow efficient drill-down analysis of data. Data can be viewed in

preconfigured reports. Data from these logs can also be exported to Excel for further analysis. New Drill-

Down™ Logs can be added upon request.

E-Dart – Hardware and software processing tool developed by RJG, Inc. for injection molding process analysis

and control. RJG provides an ActiveX control for capturing data which can be utilized by Rockware® for cycle

data collection.

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First Run (FR) – Calculated by dividing total parts by the sum of total parts plus total scrap. First run is a

component of overall equipment efficiency (OEE).

Interface – A display that allows the user to view and interact with the system. Interfaces provide the user

with options for modifying data. They also provide the user with links to other interfaces and reports.

Job – A Job is a unique combination of Tool/Mold, Tool/Mold Inserts when applicable, Materials, Colorants,

Manning, and Cavities. A Job produces a predetermined number of specific Parts each Cycle.

Manning – The number of machines handled per each operator. This may influence what the Standard Cycle

Time will be for certain Jobs.

Material – Raw substances including resin and colorant used to manufacture Parts.

Mold – The physical piece of tooled steel used to make parts. Each mold has a unique ID. Multiple jobs can be

set up for each mold. Multiple molds may make the same part. Mold is also referred to as a tool.

OEE – Overall equipment efficiency calculated by the following equation: Availability (AV) x Speed Ratio (SR) x

First Run (FR).

Open Platform Communications (OPC) - Machine controllers that are OPC compliant provide data collection

capability to Rockware® Magic™ Systems.

Part – A manufactured component with a unique name and number that is produced on completion of a cycle.

Parts (Calculation) – Calculated by multiplying the number of cycles by the number of cavities and subtracting

the number of entered scrap.

Report – A printable and emailable document that displays tables, bar charts, and trends or a combination of

the three. Reports render data into a useful format for efficient interpretation.

Revision – Displayed in the header of the Main Dashboard. Designates what revision level the opened

application is at. If the opened application is not the most current revision level the Latest Revision text box

will display in red text along with a Blue Arrow Update button appearing above. Click the Blue Arrow Update

button to update to the latest revision.

ROCKBOX X7™ – Rockware Corp’s PLC based machine Cycle data collection module. X7 Models can collect

data from up to 7 machines.

ROCKBOX SQL™ – Rockware Corp’s embedded computer solution that functions as both a database server and

data collection device.

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Rockware Corp – A company that provides software and related products and support. Rockware Corp has

three divisions: Magic™, Rockbox™, and Justice™.

Rockware® Magic™ - Division of Rockware Corp. that provides solutions for automated data collection, real-

time displays, user interfaces, and complex reporting options primarily aimed at automotive manufacturing

departments and lines.

Rockware® Magic MES™ – The Magic Manufacturing Execution System is a Windows based application

(Microsoft Access 2010/2003) that is a tool for efficiently managing operation of a manufacturing department.

Modules for real-time overview, scheduling, shift recaps, and historical reporting are integrated tightly into a

single application that is ultimately designed to improve OEE. The MES improves efficiencies by increasing the

speed of reaction to real-time issues through improved awareness and by accurately quantifying historical

issues to allow affective prioritization of resources. Web based version is currently under construction.

Rockware® Magic MET™ – Molding Engineering Tools is a Windows based application (Microsoft Access

2010/2003) that can integrate with data from the Rockware® Magic MES™. The Engineering tools suite

includes Process Database, Capacity Planning Tool, Machine/Mold Testing Tool, and Mold/Machine Matching

Tool.

Roster – A list of operators and the machines they worked on during a shift for shift reporting and future

reference. This function can be added to Shift Recap module on request.

Scheduled Down Time – Machine downtime that does not negatively impact OEE and Availability (AV)

calculations. Machines can be scheduled down for mold sets, maintenance, engineering, dunnage shortage,

end item scheduling, etc.

Scrap – Defective parts that are discarded or rejected. Scrap is subtracted from total parts produced.

Shift Recap™ – A tool for supervisor and managers. Combines automated data, operator input, and supervisor

input to provide a full report on shift activity that can be emailed to all applicable recipients or printed out for

review. The data generated from these reports is used in Drill-Down™ Log reports also.

Speed Ratio (SR) – Calculated by dividing the standard cycle time by the actual cycle time. Speed ratio is a

component of overall equipment efficiency (OEE).

Standard Cycle Time (Std CT) – Cycle time assigned to each mold and manning combination which is required

to achieve 100% OEE.

Switchboard – The common portal where all Rockware Application and any other applications can be

accessed. The Switchboard also works as a tool to allow updated applications to be automatically loaded onto

end user’s computers.

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Target - It is the number of cycles or parts required at any point in time during a shift or at the end of a shift to

equal the standard. It is calculated by dividing the amount of run time that has elapsed during a shift divided

by the average standard cycle time.

Team Ray Technologies, LLC – A company that specializes in controls engineering and integration primarily for

automotive manufacturing facilities. Team Ray Tech is the primary integrator for all Rockware Corp products.

Tool – The physical piece of machined steel used to make parts. Each tool has a unique ID. Multiple jobs can

be set up for each Tool. Multiple tools may make the same Part. Tool is also referred to as a mold.

TSF™(Touch Screen Friendly) – Interfaces with controls that allow data to be entered or retrieved efficiently

with a Touchscreen device. TSF™ controls can be added to any interface upon demand.

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1.0 Data Overview

Rockware® uses a relational database to integrate automated machine cycle data with business configuration

data and daily user input to generate advanced real-time and historical calculations, displays, interfaces, and

reports. Below are examples of specific data streams collected and/or stored:

o Automated machine cycles collected from ROCKBOX X™, RJG eDart™, or OPC compliant controller

o Automated downtime with beginning and ending timestamps without codes.

o Department shift start and stop times and hourly breakdown

o Department metric and color coding set point configuration

o Machine configuration

o Part and part number configuration

o Tool/mold and preventative maintenance (PM) set point configuration

o Job and standard cycle time configuration

o Job cavity configuration

o Material configuration

o Machine dashboard order and configuration

o Downtime codes

o Scrap codes

o Job selection and correction

o Downtime code entry

o Scrap real-time entry (Cash Register™)

o Scrap bulk entry

o Schedule entry

o Live Schedule™ entry

o Shift Recap™ comments entry

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2.0 Main Dashboard

The main real-time dashboard is the home page and the gateway to all other interfaces and reports.

Dashboards can be custom made to display pertinent data and provide applicable color coding for every type

of manufacturing operation. Graphs and charts can also be integrated into a dashboard displays. The default

data displayed is the current date and shift. Machine color coding and live cycle time updates once every

second and summary production calculations update once every 10 minutes. Dashboards consist of a header

section along with a data display area.

Header Section

Data Display Area

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2.1 Header – Auto ON/OFF, Date-Shift Selection, Adjust Page Position

1. Auto Update Button

This buttons purpose is to allow users to temporarily shut off automatic updates so data from previous

dates and shifts can be viewed without interruptions. The Auto Update button can be toggled

between ON and OFF by clicking. ON is the default. If the Auto Update button is toggled to ON, the

date and shift will automatically update to the current production shift once every minute and current

production summary calculations will update once every 10 minutes. When the Auto Update button is

toggled to OFF, the date and shift do not change and production summary calculations do not update.

It is recommended to always leave the Auto Update button toggled to ON unless the user is viewing

data from previous dates and shifts. When looking at previous dates and shifts, it is recommended to

toggle the Auto Update button to OFF to prevent the selected date and shift from automatically being

replaced by the current date and shift.

2. Date to display

The default Date displayed is the current production date. The Date field can be changed to view

previous date and shifts by typing date in or double-clicking to pop up the date selector shown below.

3. Shift (Date-Shift) to display (YYYY-MM-DD-S)

The default Shift displayed is the current production shift. When a new date is entered the first shift

for a specific date will automatically fill in. All shifts for the selected date will be available to select

from pull-down.

2. Date to display

3. Shift (Date-Shift) to display (YYYY-MM-DD-S)

4. Adjust Page Position Button

1. Auto Update Button

Toggled to OFF

Date Selector

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4. Adjust Page Position Button

For computers with resolutions greater than 1024 x 768 pixels a feature is available to allow the

Rockware® Application Window position to be moved relative to the desktop. To move the application

window, click the Adjust Page Position button to open the adjustment tool. When Left Adjust = 0 and

Top Adjust = 0 the application window will be in the top left hand corner of the desktop. Click the blue

and white buttons in the direction you would like to move the application window. The next time the

application is opened, the application window will be located in the new location.

2.2 Header – Department/Line Toggle

1. Department/Line Toggle

Some systems are set up for multiple departments. This is advantageous for area managers who have

multiple departments to be able to quickly move from one department to another along with allowing

historical data to be combined in reports if desired. If a system only has one department, this button

does not function. To toggle, click Big Brother button.

Adjustment Tool

1. Department Toggle Button

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2.3 Header – System Information, UPDATE to Latest Revision

1. Department PXID (Production Cross-Reference ID) and Department Name

The PXID number is a Rockware® identification number assigned to each applicable independent

department or line. Each number is unique per plant. The corresponding line or department name is

listed in the adjoining text box.

2. Computer Name and Default PXID Number

The computer name is displayed along with the default PXID currently assigned for the computer. For

systems with more than one department or line, this setting will determine which department or line

will display when the system initially opens. The user can toggle between all applicable departments

or lines by clicking the Big Brother button (See Section 2.2).

3. Revision of Local Application and Latest Revision

The revision level of the local application is shown in the text box to the left. This number should

always be equal to the Last Revision text box to the right. If the number does not match the local

application is out of date. When the local application is out of date a Blue Arrow Update button will

appear with a red instructional label shown below. Click the Blue Arrow Update button to download

the latest revised application. Wait up to 1 minute for update to take place and reopen application.

Plant Name

2. Computer Name and Default PXID Number for Computer Security Level and Security Level Name

1. Department PXID and Department Name

3. Revision of Local Application and Latest Revision

Blue Arrow Update Button

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2.4 Header – Main Menu

1. Exit Application Button

To close application click the Exit Application button.

2. Minimize Application Button

To minimize application click the Minimize Application button.

3. Historical (Drill-Down Logs and Report) Button

To select and view data with advanced filtering and reporting options, click the Historical button. See

Section 7.0 for more detail.

1. Exit Application Button

2. Minimize Application Button

Historical Drill-Down Log and Reporting Interface

6. Schedule Button

7. Live Schedule Button

8. PM Button

3. Historical Button

4. Configure Button

5. Shift Recap Button

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4. Configure Button

To view and edit system configuration data, click the Configure button. See Section 3.0 for more detail.

5. Shift Recap™ Button

To utilize the Shift Recap™ reporting tool for supervisors, click the Shift Recap button. See Section 4.0

for more detail.

Configuration Interface

Shift Recap Tool Interface

Pull-Down

Department or Line

to View

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6. Schedule Button

To view or edit the weekly schedule, click the Schedule button. See Section 3.5.

7. Live Schedule™ Button

To view or edit the Live Schedule™ tool, click the Live Schedule button. See Appendix C for more

detail.

8. PM Button

To view or edit the PM (Preventative Maintenance) Mold Tracker, click the PM button. This is a tool

for tracking cycle counts and preventive maintenance on molds. See Section 8.0 for more detail.

Shift Schedule Tool Interface

PM Mold Tracker Interface

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2.5 Header – Custom Tab Menu

Up to 10 custom tab menu buttons can be used to provide a link to custom interfaces or provide quick

links to standard interfaces that can be accessed in other areas of system. These can be added upon

request. If tab buttons are not linked to anything they will not be visible.

2.6 Header – Department/Line Summary Data

Department or line summary calculations for a specific date-shift are displayed in the dashboard

header. See Section 0.0 (Definitions) to get specific detail on what each metric is and how it is

calculated. Different metrics can be displayed in this area upon request.

2.7 Header – Refresh, Print, Legend

1. Refresh Button

The Refresh button initiates the summary production calculations on demand. These calculations run

every 10 minutes automatically behind the scenes. The Refresh button allows the user to view values

to the nearest second if needed. After clicking the Refresh button it may take 30 seconds to one

minute to finish running all calculations and display updated data.

2. Print Dashboard Button

The Print button prints a snap shot of the Main Dashboard for the selected date-shift to the default

printer set up on computer system is running on. To change what printer, change computer’s default

printer prior to clicking Print button.

1. Refresh Button

2. Print Dashboard Button

3. Legend Button

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3. Legend Button Click the Legend button to get a quick reference for Rockware® Objects, dashboard color coding, and

dashboard Machine Block Detail.

Dashboard Legend and Color Coding may Change from System to System

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2.8 Data Display Area – Machine Blocks

Most dashboard display areas consist of a group of machine blocks laid out in a configurable order.

The order of machines can be changed on the main configuration page - See Section 3.8. Each

machine block contains the current job running, summary data, and quick machine based links for

changing jobs, viewing cycle log, viewing and entering downtime, viewing and entering scrap, and

viewing hourly count graphs. Machine blocks are also color coded based on machine status. Machine

blocks and links can be customized as needed. To view the latest on dashboard color coding and

explanations of summary data, review the system legend by clicking the Legend button, see Section

2.7.3.

2.9 Data Display Area – Hourly Count Graphs An hourly count graph can be displayed for each machine to display performance of machine for 24

hour period for current date or selected date. Hours are displayed from the first hour of the business

day to the last hour of the business day. The first two numbers of an hour represent the order from 1-

24. The second two numbers represent the hour in military format. Real-time scrap can also be

displayed when scrap is inputted via Cash Register™. The target is calculated based off of the average

standard cycle time of the job assigned to each cycle for each hour.

Example Machine Block

Hourly Count Graph Interface

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3.0 System Configuration Step by Step Rockware® Systems provide interfaces and store relational data for all applicable configuration items. This

section gives step by step instructions on how to perform specific configuration tasks. Navy blue

labels/buttons are links to TSF™ Controls – See Appendix A.

3.1 Change Current Job Assignment There are two methods for changing the job running in each machine. The first method involves

clicking on the applicable job link in the machine block or the Jobs|Change Button from the Shift

Recap™ interface and selecting the current job from the pull-down.

The first method is recommended when changing an individual machine. The second method involves

clicking on the Configure button and changing the current job for each applicable machine. This

method is recommended when changing more than one machine.

Click Job Link

Select Current Job from Pull-Down

4. Configure Button

Click Jobs|Change Button

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3.2 Correct Previous Job Assignment When jobs are not changed on time, cycles and downtime get allocated to the incorrect jobs. Follow

instructions below to correct.

1. Click the Job link from the Main Dashboard or click the Jobs|Change button from the Shift

Recap™ interface, Downtime Entry interface, or Bulk Scrap Entry interface.

Select Current Job from Pull-Down

Click Job Link

Click Jobs|Change Button

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2. Select the job from the Previous Job pull-down

3. Change Start Time to before first cycle and change End Time to after last cycle if needed.

4. Click Change Job in All Cycles between Start and End Times button. The list of jobs will

adjust to show corrections.

Select Previous Job from Pull-Down

Change Start and End Time if Needed

Click Button to Change Job for Cycles

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3.3 Add New Part, Tool, Job Relational data tables for part, jobs, cavities, tools/molds, and materials (Optional) are architected so

cycles and scrap can be identified at the cavity level. This is imperative for tracking inventory for

handed tools and for determining cavity specific scrap issues. Below shows how the data tables relate

to each other.

To add a new part, tool, and job follow the six ordered steps below.

Step 1: Click the Configure Button from Main Dashboard Header

Links to all applicable interfaces reside on the Configuration interface.

Jobs Tools Parts Cavities 1 1 1 Many Many 1

Materials

1

1

Configure Button

Material List Button

Part Name List Button

Mold | Tool Configuration Button


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Step 2: Add Materials if not in already in list (Optional)

If materials are being linked to each job follow instructions below. If not, disregard and go to Step 3.

Click Material List button shown in Step 1. Click Add New Button on header of Material List Filter

interface and enter material detail.

Step 3: Add Part Name and Part Number if not already in the list

Click Part Name List button shown in Step 1. Click Add New Button on header of Part Name Filter

interface and enter part detail. To the filter list, type partial names or pull-down full part names

and/or numbers into the blue filtering pull-downs. This can be done for all filter interfaces.

Add New Button

Material List Filter Interface

Add New Button

Enter string fragments or full names into Blue Pull-Downs

Number of Records in List

Double-Click Brown Underlined Headers to Sort

Part Name Filter Interface

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Step 4: Add Tool if not already in list

Click Mold|Tool List button shown in Step 1. Click Add New Button on header of Mold|Tool Filter

interface and enter tool detail. After entering Tool ID and other detail click Jobs|Detail button to finish

tool configuration and add applicable jobs and cavities.

Step 5: Add Jobs

Click Jobs|Detail Button for applicable Tool ID (Mold) to add or modify jobs. Job ID and Part

Description will default to Tool ID and Part Description. Multiple jobs can be added for variations in

material, cavities, tooling inserts, and other model variations. Standard cycle time (Std CT) and

Standard cavities (Std Cav) are important values for OEE calculations and are required for new entries.

Red – # of Standard

Cavities do not equal # of

entered Cavities

Click Jobs|Detail Button

to Modify Configuration

Tool Filter Interface

Enter New Job in Row with Star Standard Cycle Time

Tool Configuration Interface

Standard Cavities

Entered Cavities

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Step 6: Add Cavities

Click Cavities|Parts button for applicable job to add or modify cavities. This is where cavities get linked

to specific part numbers to allow cycles and scrap to be identified at the cavity level.

3.4 Change Standard Cycle Time Changing standard cycle times for an existing job can be done the quickest by doing the following.

Click the Configure button from the Main Dashboard header to open the Configuration interface.

Click the Job List button on the Configuration interface.

Enter Cavity to Identify Part

Attach Applicable Part Number

Job List Button

Configure Button


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Add a string fragment or full Job ID into blue filtering pull-down to find applicable Job. Overwrite Std

CT (standard cycle time) with updated standard cycle time.

3.5 Shift Configuration

Click the Configure button from the Main Dashboard header to open the Configuration interface.

Click the Shift button on the Configuration interface to open the Default Shift Configuration interface.

Click Jobs|Detail Button

to Modify Configuration

Search for Job by adding string fragment of

Job ID into Blue Filter Pull-Down or Full Job ID

Job Filter Interface

Configure Button

Shift Button


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Configuration fields are explained below:

Active checkbox is used to make a shift active or not. If moving from a three shift to a two shift

operation one shift should be inactive.

Shift Pattern has been implemented to handle shifts that require four alternating 12 hour shifts for 24

hour 7 day coverage. In any other cases Shift Pattern should always be 1.

The Shift Number is the order that each shift occurs.

The Shift field is the name for each shift.

Start\End are the default start time and default end time of each shift.

Min Start\Max End is used by the system to determine what the current shift is. In most three shift

operations these settings should match the Start\End settings. In two shift operations in which a shift

could potentially work overtime the Min Start\Max End would include the regular shift and maximum

overtime. The Start\End would only include the regular shift.

Business dates many times do not start at 12:00 AM. The Day Add field is in place to handle these

situations. If a business day starts at 10:00 PM than the Day Add field should be -1 on the Start to

adjust the actual Start date and time one day less. For example: if the business date is 6/25/2014 the

Start date and time should be 6/24/2014 10:00 PM and not 6/25/2014 10:00 PM.

Adjust allows shift department or line Targets to be Adjusted for OEE calculation purposes. This is

usually not applicable for Injection Molding operations.

The Hour Type field is also needs to be set to a Type that has hour start and stop times defined for

each shift along with what shift each hour is allocated to. This setting will determine on how hourly

count or hourly breakdown interfaces function. See Section 3.6.

To change default schedule modify the Date Range in the as needed and click the Update Shift and

Scheduled Down Defaults button.

Default Shift Configuration Interface

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Individual dates and shifts can be changed by clicking the View|Modify Schedule Button to view the

Line/Department Schedule Interface. This can also be accessed from the Main Dashboard from the

Schedule Button.

Select week to view in blue pull-down at top. Modify fields as needed for specific date and shift.

Unchecking the Active checkbox removes all data from historical reference.

3.6 Shift Hourly Breakdown Configuration

Click the Configure button from the Main Dashboard Header to open the Configuration Interface.

Click the Hour Config Button on the Configuration Interface to open the Hour Configuration Interface.

Hour Configuration Button

Line/Department Shift Configuration Interface

Configure Button


Hour Configuration Interface

Add New Configuration Type

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Click the Hour Configuration Type magnifying glass button that requires modification or add a new

Hour Configuration Type at bottom of list and click corresponding magnifying glass button. Clicking

magnifying glass button will open applicable Hour Configuration Detail Interface.

Configuration fields are explained below:

Order is the order the Hour is relative to the business day. Hours should be numbered 1 -24.

Shift is the Shift that the Hour is contained within.

HR is the military representation of Begin Time of an Hour.

Description is literal for each hour that can be used in Hour breakdown reports.

Begin Time is the actual time for start of an Hour.

End Time is the actual time for end of an Hour. End Times should match Begin Time of subsequent

Hour.

Day Add Beg is an adjustment for Begin Time when the actual date of an hour does not match the

corresponding business date. If the date of Begin Time is one day less than business date, enter 1. If

the date of Begin Time is one day more than business date, enter -1.

Day Add End is an adjustment for End Time when the actual date of an End Time does not match the

corresponding business date. If the date of End Time is one day less than business date, enter 1. If the

date of End Time is one day more than business date, enter -1.

Hour Configuration Detail Interface

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3.7 Add Downtime Groups and Codes To add or edit downtime groups or codes, click the Configure button from the Main Dashboard header

to open the Configuration interface.

To add or edit downtime groups, click the Downtime Group button on the Configuration interface to

open the Downtime Group interface.

Modify or add downtime groups as needed.

To add or edit downtime codes, click the Downtime Code button on the Configuration interface to

open the Downtime Code interface.

The DT radio button signifies whether downtime with this code is counted against machine availability

and OEE. Scheduled down codes usually have DT unclicked to prevent scheduled down events from

negatively impacting OEE. Modify or add downtime codes as needed.

Configure Button

Downtime Group Button

Downtime Code Button


Downtime Group Interface

Downtime Code Interface

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3.8 Add Scrap/Reject Codes To add or edit scrap codes, click the Configure button from the Main Dashboard header to open the

Configuration interface.

To add or edit scrap codes, click the Scrap Codes button on the Configuration interface to open the

Scrap Code interface.

The Order field will change the order of where scrap codes will appear on a Cash Register™ interface if

applicable. Modify or add scrap codes as needed.

Configure Button

Scrap Code Button


Scrap Code Interface

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3.9 Machine Dashboard Order and Color Code To add or edit machine order on Dashboard or modify times for color coding, click the Configure

button from the Main Dashboard header to open the Configuration interface.

To modify dashboard position of a machine, Change number in Dash Position field. Positions on Main

Dashboard go from left to right, top to bottom. If two machines have the same number only one will

appear on Main Dashboard. Each machine needs a unique Dash Position number.

To modify dashboard color times click the Dashboard Color Configuration button.

Values are in seconds. Changing values will modify when machine blocks will change color.

Configure Button

Dashboard Color Configuration


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4.0 Shift Recap™ The Shift Recap™ combines automated data, operator input, and supervisor input to provide a full report on

shift activity that can be emailed to all applicable recipients or printed out for review. To open the Shift Recap

interface, click the Shift Recap button from the Main Dashboard header to open the Configuration interface.

From the Shift Recap Interface the user can do the following:

1. View hourly count graph interface by clicking Hourly Counts button.

2. Change or view jobs by clicking Jobs|Change button. See Section 3.1 and 3.2

3. Enter comments by typing in the Comments blue outlined text box or clicking navy blue button or

by using TSF™ (Touch Screen Friendly) keyboard.

4. Add scrap by clicking blue underline scrap value. See Section 4.1

5. Enter downtime codes by clicking blue underline DT value. See Section 4.2

6. View or print Scrap Report™ by clicking Scrap Report button.

7. Export Shift Recap™ data to Excel by clicking Excel button

8. Email Shift Recap™ report by clicking Email button.

9. Print or View Shift Recap™ report by clicking Print Preview button. See Example of Report below.

Shift Recap Button

1 2

3

4

5

6 7 8 9

Downtime with no Code added yet

Shift Recap™ Interface

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An example of the Shift Recap™ report is displayed below.

To print, right-click the report to open pop-up menu.

The data from the Shift Recap™ report is used to populate the following Drill-Down™ Logs and Reports. See

Section 7.2 for more detail.

1. Shift Recap Machine

2. Shift Recap Jobs

3. Shift Recap Department

4. Scrap

5. Downtime

Shift Recap™ Report

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5.0 Bulk Scrap Entry Interface Scrap can be entered from the Scrap Bulk Entry interface or the Cash Register interface. When machine-side

touch screen computers are available, typically the Cash Register interface is used to allow operators to enter

scrap real-time – See Appendix B. When machine-side touch screen computers are not available scrap can be

entered via the Scrap Bulk Entry interface which is usually entered by supervisors at the end of a shift while

they are completing their Shift Recap™ report. This Interface allows scrap to be grouped by machine, job,

cavity, and scrap code and to be counted and added in a summarized record at the end of the shift. The Bulk

Scrap Entry interface is primarily accessed from the Shift Recap interface – See Section 4.0 Item 4. This

interface can also be accessed from the Main Dashboard if requested. Navy blue labels/buttons are links to

TSF™ Controls – See Appendix A.

1. The Job pull-down is populated with all jobs that ran cycles during date-shift. If no automated

cycles have been collected all jobs populate pull-down.

2. If the jobs present in the job pull-down are incorrect, they can be corrected by clicking on the

Job|Change button. It has been added to this Interface for convenience purposes. See Section 3.2

on how to correct previous job assignments.

3. The cavity pull-down is populated with cavities configured for a selected job or all jobs. If no

cavities are configured for a job, all cavity types are provided for selection.

4. The Scrap Code pull-down is populated with all active scrap codes.

5. The bulk count is entered for each applicable job, cavity, and scrap code combination.

Scrap Bulk Entry Interface

Add New Entry – Job, Cavity, and Scrap Code are required to complete an Entry

Click to Delete Applicable Entry

1

2

3 4 5

35

6.0 Downtime Group and Code Entry Downtime is automatically calculated based off zero cycles being detected in a configurable amount of time or

a machine going into manual mode. Operators or supervisors only have to enter codes for each downtime

instance. The Downtime Code Entry interface can be accessed from the Main Dashboard, Shift Recap

interface, or the Cash Register interface. Navy blue labels/buttons are links to TSF™ Controls – See Appendix

A.

1. The DT Group pull-down is populated with all active downtime group codes.

2. The DT Code pull-down is populated with active downtime codes for selected DT Droup.

3. The DT radio button is automatically populated based on how DT Groups and DT Codes are

configured – See Section 3.7. The DT Radio Button signifies whether downtime is counted against

machine availability and OEE. If the DT radio button is unclicked it is counted as scheduled

downtime and does not negatively impact OEE calculations.

4. If the jobs present in the job field are incorrect, they can be corrected by clicking on the

Job|Change button. It has been added to this Interface for convenience purposes. See Section 3.2

on how to correct previous job assignments.

5. The Split Button allows the user to split Downtime periods with multiple causes into two instances.

See Section 6.1.

6. The ADD DT GROUP AND DT CODE TO SINGLE ENTRY/ALL ENTRIES button can be toggled to allow

individual groups and codes to be entered one instance at a time or to add groups and codes to all

instances from one change.

1 2 3

4

5

6

6

Downtime Code Entry Interface Toggled for Single Entry

Downtime Code Entry Interface Toggled for All Entries

36

6.1 Splitting Downtime Instances The Split button allows the user to split a downtime period into two instances each time it is clicked.

Downtime periods can be split into an unlimited number of instances. To split a downtime period into

two instances, click the Split button of the applicable downtime period. Whether a new downtime

instance is entered after the existing downtime instance or after the existing instance can be changed

by leaving the New Entry Start or End Time pull-down as START TIME or changing it to END TIME.

If New Entry Start or End Time pull-down is START TIME a new entry will be added on the 2nd

half of the

downtime period. The new instance can be deleted by clicking the red underlined DELETE Button.

If New Entry Start or End Time pull-down is END TIME a new entry will be added on the 1st half of the

Downtime period. The new instance can be deleted by clicking the red underlined DELETE Button.

Change Date-Time to New Split Date-Time

Click to Execute Split

Downtime Split with START TIME Downtime Split with END TIME

Downtime Code Entry with Start Time Split of First Entry

Downtime Code Entry with Start Time Split of First Entry

37

7.0 Historical Drill-Down™ Logs and Reporting Rockware Corp has developed a configurable Drill-Down™ Log interface that displays data similar to an Excel

spreadsheet, provides complex filtering tools, and links to complex reports that display the filtered data in

various formats. These logs are a critical component of all Rockware® Software Systems providing the user

with an effective tool for getting their arms around large data sets. Logs can display up to 200,000 records.

7.1 How to use Drill-Down™ Logs To open the Historical Drill-Down™ Log Switchboard interface, click the Historical Button from the

Main Dashboard.

The default for Start and End dates are set to include all data for the Date selected on Main Dashboard.

Set Start date and End Date to the desired date range by typing in dates or by double-clicking and using

Date Picker to select. Click on the desired log to view. The Drill-Down™ Log interface is the same

format for each log. Below shows the header of an example log with detailed description for each

control. Filtering items can be selected from list boxes or typed in as shown below.

Historical Data Drill-Down Logs Button

Main Dashboard Date

Historical Drill-Down™ Log Switchboard Interface

Date Picker

Double-Click to Open Date Picker

38

There are nine filtering Inequality Symbols to choose from. Below briefly explains how to use each of

them.

[=] - Default symbol that can be used with any data type. It can be used with the selection of multiple

filtering items. Multiple Items need to be separated by a comma.

Example: Displays only data for C1, C2, C3, C4, and C5

[Like] – Strictly for text fields. It allows wildcard characters (%) to be used so text fields containing

partial string elements can be isolated.

Example1: Displays data for Machines with first letter “A” like A1

Example2: Displays data for Machines with “A” anywhere like BA1

Example3: Displays data for Machines with last letter “A” like 1A

Dates can be changed

from within the Log

Restores applicable data

with filters to default

order

Clears all filters

and restores all

Data

Filter By

Department or

Select ALL

Click on desired

Symbol than

Click Down

Arrow Button to

Select and/or

Filter

Click Down Arrow

Button to Display

Items for Filtering Click Down Arrow

to Display

Inequality Symbol

List

Summary Calculations

Type value in for

Filtering than Click

Down Arrow Button

to Filter

Select Item or Multiple

Items to Filter. Inequality

Symbol must be “=” or

“<>” for Multiple Item

Selection.

Click Down Arrow

Button to Filter

Change Inequality

Symbol

39

[<>] – Not Equal symbol can be used with any data type. It can be used with the selection of multiple

filtering items. Multiple Items need to be separated by a comma.

Example: Displays all data other than data for D1, D2, D3, and D4

[<] [<=] [>] [>=] – Less Than, Less Than or Equal To, Greater Than, and Greater Than or Equal To

symbols are primarily intended for number and date fields but can be used with text fields for

alphabetical comparison. Multiple filter items should not be entered for these symbols.

Example1: Displays data with Cycles Less Than 50

Example2: Displays data with Cycles Less Than or Equal To 50

Example3: Displays data with Cycles Greater 50

Example4: Displays data with Cycles Greater Than or Equal To 50

[Between] [Not Between] – Between and Not Between symbols are primarily intended for number

and date fields but can be used with text fields which are compared by alphabetical order. These

symbols require two filter items with the lesser of the two items displaying first.

Example1: Displays data between 5/1/2014 and 5/7/2014

Example2: Displays all data except data between 5/1/2014 and 5/7/2014

The body of the Drill-Down™ log displays data in a table format and provides quick Sorting Labels at

the top of each column. Double-click once to sort in ascending order. Double-click twice to sort in

descending order. Magnifying Glass buttons are also available at the beginning of each row of data.

These buttons are log specific and generally allow the users to take a closer look at data represented in

a specific row. Data can be exported to a .CSV file by clicking the Excel button. The .CSV file is saved in

My Documents.

Select 2 Items 2 Items should be separated by comma

40

Reports can be accessed by clicking the Report button.

Excel Button:

Export filtered

data to Excel

Report Button:

Opens a list of

reports based

on filtered data

Sorting Label

Magnifying Glass Button

List of Reports Available for This Log

Click Button to Preview Report

Right-Click for Pop-up Menu to Print, Email,

or Export to PDF File

Filter Criteria Displayed on Header of Each Report

Drill-Down Log Interface

Drill-Down Log Report Interface

41

7.2 Report Type Examples To print or email reports, right-click on the report after it is opens to bring up a pop-up menu.

There are several standard report types that are used in most of the standard reports. Custom reports

can always be added upon request. Several common report types are listed below with an example of

each.

Log Report

There is a standard log report for each log.

Pop-Up Menu for Reports

42

Trend Report

Trend reports display values over time to determine if an operation is getting better or worse.

43

Breakdown Report

Breakdown reports are a series of Pareto graphs to help identify what are worst and best performers.

44

TPP Reports

Trend-Pareto-Painter reports contain multiple graphs and charts. They display if an operation is

getting better or worse with trend graphs, what the worst and best performers are with pareto graphs,

and how specific units and time periods play a role in summary calculations with a painter chart.

45

7.3 Standard Drill-Down™ Logs Rockware® Magic MES™ with the Injection Molding Machine template comes standard with 10 logs

along with 38 reports. New logs and reports can be added upon request.

1. Cycle (Live) – Real-time log displaying every cycle with beginning and ending time stamp and cycle

time. Intended to be a real-time troubleshooting tool for determining specifics on how a machine ran

during a shift.

2. Downtime (Live) – Real-time log displaying every downtime period with beginning and ending time

stamp and total minutes down. Provides data for real-time and short-term downtime analysis.

3. Scrap (Live) – Real-time log for displaying scrap entered from a Cash Register™ interface with entry

time stamp. Provides data for real-time and short-term scrap analysis.

Historical Drill-Down Log Switchboard Interface

1

2

3

4

5

6

7

8

9

10

00

46

4. Shift Recap Machine – Main Log for tracking department OEE performance by machine. Calculated

values grouped by shift and machine. Many TPP, Trend, and Breakdown reports are available for this

log.

5. Shift Recap Job – Main Log for tracking department OEE performance by job and machine. Calculated

values grouped by shift, machine, and job. Many TPP, Trend, and Breakdown reports are available for

this log.

6. Shift Recap Dept – Summary log calculating OEE for entire department grouped by shift.

7. Downtime Summary – Summary log for downtime summarized by shift and DT code for each machine

and job combination.

8. Scrap Summary – Summary log for scrap summarized by shift and scrap code for each machine and job

combination.

9. Part Number Counts – Provides shift count for each part number. Jobs must be configured with

cavities linked to part numbers for this to work properly. Intended to be a scheduling tool.

10. Scheduler Mold|Mach – Scheduler tool for seeing what tools/molds have ran in what machines based

on previous machine cycles.

47

8.0 Preventative Maintenance (PM) Mold Tracker A PM Mold Tracker is provided to track cycles for tools and provide historical PM reference information for

each tool. It can be accessed by clicking the PM button from the Main Dashboard.

Red entries are Tools with Cycle counts higher than Stop set point. Yellow entries are Tools with Cycle counts

higher than the Warn set point and less than the Stop set point. Green entries are Tools with Cycle counts less

than the Warn set point.

1. PM Completed button can be clicked when a PM event occurs to open the Enter PM interface.

PM Button

1

2 3 4

PM Mold Tracker Interface

48

Enter Date and Comments and either click Enter PM and Clear Count button or Enter PM and Do Not

Clear Counts button.

2. The Mold Settings button can be clicked to configure Stop, Warn, Actual counts, and Last PM Date for

each Tool.

Enter PM Interface

Mold PM Setting Interface

49

3. The PM Log Button can be clicked to open the PM Log interface.

4. The Print List button opens a report that can be printed by right-clicking on report and clicking Print…

from pop-up menu.

Select Date or Mold to Filter Data

Double-Click to Sort in Ascending or Descending

Order Delete Button will Remove Entries with Errors

Export List to Excel or Print List Report

Click to unlock fields so they can be modified

Preventative Maintenance Log Interface

Pop-Up Menu for Reports

50

APPENDIX A

Touchscreen Friendly Controls (TSF™)

51

APPENDIX B

Cash Register™ Real-Time Machine-Side Entry

52

APPENDIX C

Live Scheduling Tool