the central production data hub · rolling enables graphic control elements for visualisation and...

PIMS

CMMS

ADEXAM

PRM/PEP

MDE

KPI

BDE

PPS

OEE

MM

PMC EWI/EAA

DCA/EDM

EMI

GEN

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ERP

MACHINES INSTALLATIONS

SENSORS MEASUREMENT SYSTEMS

MANAGEMENT

ASSEMBLY MAINTENANCE

DESPATCH CUSTOMERS

PRODUCTION CONTROL

S O F T W A R EP R O C E S S E S WITH PASSION

TRANSPARENT PRODUCTION, CONTROL, ALARMS

ADEX THE CENTRAL PRODUCTION DATA HUB

AREA OF APPLICATIONADEX “Automation Data Exchange” is a mo-dular software system which can be used in various industries to connect all employees and systems which are involved in produc-tion.

ADEX can complement the existing produc-tion system with the functions production planning, personnel resource planning, re-source management, data recording, control and alarms or be implemented as a complete MES system.

Each of the ADEX modules can be assem-bled individually according to the existing re-quirements and be extended when required. ADEX can be implemented in small produc-tion firms as well as in large industrial groups.

Due to its service-orientated web structure ADEX can also be used as a cloud applica-tion at any time.

OBJECTIVESADEX‘s primary goal is a smooth and effici-ent production process. For example, it as-sists the structured production configuration, resource-conserving planning and controls the whole production process independent-ly. Production errors can be detected early and reject rates reduced.

In addition to the smooth production the trouble-free use of the MES system is of primary importance. This is the reason why ADEX has been based on multi-channels. By using ADEX the following objectives are reached:

An increase in product quality

Reduction in reject rates

Shorter downtime through immediate alarms

Highly available system due to the server cluster and automatic fall-back

Production planning

Personnel planning

Resource planning

Maintenance planning

Machine data entry

Data validation in real-time

Machine control

Personnel time recording

Direct visualisation of production data

Production analysis / OEE figures

Product traceability

Maintenance and disruption

management

Alarm handling via test message

and e-mail

Time remaining indicator

Restoration of installation parameters

Platform independent through

web-based interface

Access via mobile devices

Good scalability

COMPACT


CUSTOMISEDADEX is delivered tailor-made according to customer requirements. Not only the individual compilation of the individual modules leads to the optimal integration for the customer but also their flexible alignment. Each detail of the ADEX module can be adapted exten-sively to suit the corporate processes, from matching the corporate design, through individual fields and screens to specific communi-cation protocols of proprietary controls.

SCALABLEThe whole system can be extended from a single server solution to a cluster of servers as required. The data recording systems can be distributed and operated in the local network to ensure an equal load distribution.

FAIL-SAFEAll system components can be used redundantly and therefore offer a high level of system stability and serviceability. In the case of error, the lost functionality is automatically taken over by the configured fall-back systems within seconds.

INDEPENDENTThe whole user interface from ADEX is web-based and works with every current browser with enabled JavaScript, i.e. Microsoft Inter-net Explorer Version IE 7.0 and higher, and does not require additi-onal software. The interface is completely independent of an opera-ting system and can, for example, also be used from industrial panel PCs, thin-clients or mobile devices.

SECUREThe access to the user interface from ADEX is only possible after successful authentication and with the corresponding rights. The system offers comprehensive administration of users, user groups and rights, and also allows the individual configuration of user au-thentications.

UP-TO-DATEAs a result of the web-based interface all work stations are always equipped with the current version. In addition, the system has on-line documentation which can be easily extended so that all of the necessary information is readily available.

INTEGRABLEADEX enables order, process, production and quality data to be im-ported and exported through common interfaces, e.g. web-services and stored procedures. ADEX can be integrated into the current sys-tem landscape and connected to further systems.

TRANSPARENTIf required, all user activities can be logged in the system automati-cally for documentation purposes and can be viewed by the admi-nistrator. The system fully documents changes made by each user providing full transparency.

EXTENDABLEAll modules have been designed so that an extension of the system is possible at any time without having to stop production. The sys-tem grows with the customer´s requirements. The configurations which are necessary, e.g. additional production lines, installations, parameter or quality assurances, can be easily carried out by the system administrator through the user interface.

CLOUDYADEX can be used as a cloud solution with Microsoft Azure. As a result of this systems distributed worldwide can be connected or the customer can be integrated directly. Consequently ADEX is ready for “Industry 4.0”.

FLEXIBLEADEX has a flexible licence model. In addition to the economical, industry specific editions Sternico also offers leasing. In this case an “all inclusive“ package with servers and support is available if requested.

TAILOR-MADE THE CORRECT MODULE FOR EVERY REQUIREMENT

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ADEX | MODULE OVERVIEW


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DATA RECORDING AND CONTROL

Machine Control: Control and monitoring of machines

Personnel Time Recording: Recording of personnel working hours

Machine Data Recording: Recording of machine, process and production data

ANALYSIS AND QUALITY ASSURANCE

Visualisation:Visualisation of the recorded production and process data

Production Analysis: Visualisation of the effectiveness of the whole plant (OEE) and further key figures

Quality Assurance: Planning and implementation of quality assurance measures

MONITORING AND ALERTING

System Monitoring: System monitoring and data validation

User Alarms: Notification of users via test message, e-mail or instant screen message

Time Monitor: Indicator for forthcoming events or upcoming machine setups

EXTENSIONS

Data Security: Securing and restoring important installation parameters

OPC-Server: Standardised data access via OPC clients

Proxy-Server: Secure access to production systems with integrated web-server

Secure Data Transfer: Secure data transfer to other systems

Excel Plug-in: Simple data access through Microsoft Excel

Electronic Documentation: Versioning of important production documents

PLANNING AND ADMINISTRATION

Production Planning: Configuration of products and detailed planning of production

Personnel Planning: Shift and detailed planning of personnel

Resource Planning: Administration of installations, machines and other resources

Maintenance Planning: Planning of service and maintenance of resources


WITH SYSTEMThe module Production Planning has the possibility of configuring products, production recipes and the preparation of manufacturing orders in a structured manner. Changing or adding parameters al-ways takes place with versioning. The individual versions can be compared with each other at any time. Product improvements are therefore easily defined.

VERIFIED SCOPECustomers have a growing demand for more individual products, which can lead to an increasingly complex configuration of indivi-dual installations and production lines. In ADEX connections and verifications can be configured between the individual products, product recipes and order parameters preventing invalid configura-tions being made with the flexible production design, which could in some circumstances block the production line for hours.

FLEXIBITY IN PLANNINGManufacturing orders and planned maintenance are assigned to production lines and changed simply by the drag and drop function. During operation, the resources available in the course of produc-tion and parameter restrictions are permanently monitored. Pro-blems are reported to the planner directly over the user interface which is updated cyclically. If the planner does not react to the pro-blem and automatic alarm is sent.

DIRECT FEEDBACK TO THE PRODUCTION LINEThe employees on the production line always see the planned pro-duction for their line and if necessary can move orders, enter pro-duction interruptions or log order cancellations. In case the machine status is not recorded automatically, the employees can enter the status manually through their own user interface and can confirm work progress.

Graphic production planning with manufacturing orders and planned production stops

PLANNING AND ADMINISTRATIONPRODUCTION PLANNING

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ALWAYS THE CORRECT EMPLOYEETo ensure efficient production the correct qualified employees has to be allocated to the right machine on every shift. Personnel Plan-ning offers configuration possibilities for employees‘ qualifications, their machine training and work schedules. Shift allocation can be easily catered for using definable week day combinations. Collective wage agreements can be stored in the system which are checked with every change in shift. In the subsequent detailed planning (per-sonnel/machine allocation) the necessary qualification and training of personnel are controlled. In case of personnel shortages the sys-tem can recommend employees for multiple tasks.

INVOLVEMENT OF EMPLOYEESIn addition to planning shifts the module Personnel Planning has helpful functions to take the preferences and requests of the emplo-yees into consideration. An employee can, for example, manage his regular and special requests for leave during each shift online. The shift planner can accept the requests or send back alternative dates.

In addition, the employee can also define his preferred machines and shifts. The shift planner therefore has all of the information to create an most employee-friendly plan.

PERSONNEL PLANNING

Definition of measurement values for a resource

MEANS OF PRODUCTION

TRACEABLE CHANGESResources are often modified for different product types. The indi-vidual resources and their modifications are versioned so that the production of each product is exactly documented.

ALWAYS THE CORRECT EQUIPMENTAll validation rules for parameter and measurement values can be defined for each resource. For example diagrams, on which the measurements which have to be controlled are noted, can be stored. These diagrams can be complemented through input fields which allow the employee to input the measure values. This ensures that only valid resources are taken into production.

ON-SCHEDULE MAINTENANCEADEX allows maintenance work to be planned and monitored for all components, e.g. resources, measuring devices, installations and conveying systems. The maintenance which is necessary for each element can be defined for production planning according to fixed intervals, actual operating time, production quantities, or planned

MAINTENANCE PLANNING

on the system automatically. The technicians always have access to the latest necessary maintenance instructions and control plans due to the documentation being online. Machine maintenance is cont-rolled because all of the work which has been carried out has to be acknowledged by the operator.

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INSTALLATION VISUALISATIONWithout any programming knowledge the module Machine Cont-rolling enables graphic control elements for visualisation and con-trol processes to be configured. A control device can be connected directly to the appropriate data field in the respective controls. The process values can be shown through the control element or be set by it.

LINKED ACTIVITIESActivity lists can be generated so that several process values can be set in complex sequences. These can be started through the control elements in the user interface. In addition to simple networks, acti-vity lists can also contain pre-conditions for individual work steps.

AUTOMATIC ACTIVITIESIn addition to the manual control of machines by the user, ADEX also has the possibility of configuring activities automatically. Acti-vities or activity lists can be activated automatically by the system if the necessary conditions occur. For example, this mechanism is employed in the following scenarios:

Data transfer between two installations with the simultaneous acknowledgement to production planning and resource management

Secure transfer of the current production recipe parameters through signalling from an installation

Installation Control

DATA RECORDING AND CONTROLMACHINE CONTROL

RECORDINGThe module Personnel Time Recording enables the employees to acknowledge the work time and attendance. The confirmation can take place online or with RFID-based terminals. The connection to other existing devices is possible.

PERSONNEL TIME RECORDING

ACKNOWLEDGEMENTThe accrued work time can be shown and taken into consideration during shift planning. Furthermore, the recorded time can be provi-ded to other systems with web-services. The wage accounting de-partment can be connected, for example.

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SIMPLE CONFIGURATIONThe machine, production and process data which have to be re-corded can be easily configured and tested through an assistant in the web-based interface without any programming knowledge. The system also assists with the creation or integration of the database tables which are suitable for recording the data required.

SECURE DATA RECORDING The recording of machine data takes place automatically through redundant Windows services which can be spread across the net-work and have an automatic load distribution. After transfer to the database all data can be read back and controlled automatically. The data is therefore logged exactly as it is in the machine. Even if the connection to the database fails the production data is still recorded and saved locally until the connection is restored.

EFFICIENT BACKUP Cyclic recording of process data requires large storage volume in the long run. For this reason a tolerance level has been defined so

that only relevant changes are recorded, saved in the database and if required compressed. In addition, old versions are archived auto-matically but they remain fully accessible.

EXTERNAL CONFIGURATION SOFTWARE An external configuration software is also supplied in ADEX with which the machine connections and the data to be recorded can be set up and tested, without being connected to the ADEX system. With this solution, suppliers of machines can create the appropriate configuration file at the time of delivery of the machine and present it with the documentation generated. The configurations can subse-quently be easily imported into ADEX.

NO ADDITIONAL HARDWAREThe system can read data directly from the control system supplied without additional hardware, providing the control system can be accessed via Ethernet. The following controller types are already supported:

MACHINE DATA RECORDING


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Allen Bradley

Beckhoff

Fanuc

MANUFACTURER

SLC-5/03; SLC-5/04; SLC-5/05; PLC-5/20; PLC-5/30; PLC-5/40; PLC-5/46; PLC-5/60; PLC-5/80

(Note: When using DH-485 and DH+ an Ethernet gateway is necessary for each bus)

CONTROLLER TYPES

All controller types with TwinCAT Runtime

Fanuc Series 15i/16i/21i/30i/31i

OPC All controller types via OPC Server DA Version 2.0 or 3.0

Rockwell ControlLogix (1756-L55M-12/ 13/ 14/ 15/ 16/ 22/ 24; 1756-L-61 /61S /615 /62 /62S /625

/63 /63S /64 /72 /73 /74 /75; 1756-LM60M03SEv)

CompactLogix (1769-L-23E /32E /35E /43E /45E)

SoftLogix 5800 (1789-L-10 /30 /60)

Siemens S7-200; S7-300; S7-400; S7-1200 each with use of an Ethernet capable CP

Further controller types as well as measurement systems, sensors, camera systems etc. are feasible.


ANALYSIS AND QUALITY ASSURANCE

FILTER AND EXPORTThe visualised data can be filtered. Target areas can be defined so that historical process and production data can be accessed. This data will be visualised and displayed in graphic form. In the export functions the files can be sent as Excel, test or PDF files.

GRAPHIC VISUALISATIONThe recorded process values can be visualised in different types of diagrams. The individual diagrams can be summarised in pre-configured websites. These websites can be shown to all authorised users as online reports. Because of the cyclic actualisation the online reports allow live-visualisations.

DATA VISUALISATION

EFFECTIVENESS OF THE PLANTThe module Production Analysis offers the possibility of determi-ning and visualising the effectiveness of the whole plant (OEE), the production progress of the individual shifts, the error and stoppage times, as well as the error and reject rates of each of the installations or production lines.

ANALYSIS OF THE PRODUCTION HISTORY Production data can be analysed retrospectively in the module Production Analysis. The central element is the graphic production history which delivers target-performance information on current production orders, errors and planned maintenance. If the actual time is taken over target or error rates are exceeded they can be highlighted in the visualisation.

PRODUCTION ANALYSIS

Visualisation of the Production History

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Visualisation of the Daily Production


AUTOMATIC ERROR RECOGNITIONThe system is equipped with configurable automatic error recogni-tion so that errors can be identified at the earliest possible stage. If production errors on a production line accumulate or increase with the same resources, automatic warnings can be created to highlight the need for urgent maintenance.

PLANNING AND IMPLEMENTATION The module Quality Management enables quality assurance mea-sures and controls to be defined. For this purpose, graphic control dialogues can be configured which allow the technician’s results to be recorded at a later stage. In addition, the quality measurement results can be fed back automatically via the system interface.

VISUALISATIONIn this module, it is possible to the technician‘s results and errors for each individually workpiece produced or summarise the individual production orders.

QUALITY ASSURANCE

Implementation of Manual Quality Controls

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Daily Production (3rd February 2013)

Total

Production Line 1

Production Line 2


EARLY ERROR DETECTIONCurrent monitoring systems on machines often send alarms when it is actually too late. Besides the central configuration of alarms and alarm sources, the module System Monitoring also offers the possibility of data validation in real-time or at the time of recording to recognise critical conditions at the earliest possible stage. The employee responsible would receive the alarm message when the values changes are too high, rejects are produced or the resource storage capacity is nearly empty.

The alarm handling takes place centrally in the system so that only one employee is despatched to solve the problem. Descriptive cor-rection and maintenance instructions can be saved for each warning so that all of the necessary information is always available in its cur-rent form. Alarm Log

MONITORING AND ALERTINGSYSTEM CONTROL

SENDING THE ALARM TO THE PERSON RESPONSIBLEIn the module User Alarm the person responsible receives the alarm immediately. Consequently, an error message with the appropriate instructions for rectification can be sent via text message or e-mail directly to the maintenance technician’s mobile phone. Production

control can in this case also be informed via e-mail and therefore adjust the production planning in time. In case the user has not ac-cepted the error within the set time frame the system has the option of automatically sending a second alarm message.

USER ALARMS

WHERE AND WHEN DOES IT CONTINUE?The time remaining on a machine is usually only visible at the ma-chine itself. Particulary with multiple tasking, unplanned machine stoppage time often occurs. For this purpose the module Time Re-maining Indicator has the possibility of recording machine status and the time remaining on various machines so that the results are displayed on large displays. This display can also be used for other areas where the technician waits for machine results:

Manual input on packaging lines Manual implementation of quality controls Carrying out cyclic maintenance jobs

TIME MONITOR

Visualisation for the Next Retooling

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In current control systems, further storage areas are remanent so that the data is maintained if the independent power supply fails. If the control is defect, or has to be changed, the current valid para-meters have to be available in the new control. The ADEX Backup

Service secures cyclically the relevant storage areas of all controls in the secure and mirrored database or directly on the hard drive. In an emergency these snapshots can be restored at the touch of a button.

EXTENSIONSBACKUP SERVICE

The module OPC Server consists of an independent Window ser-vice which can be used to provide the recorded production and pro-cess data through OPC DA V2.0 and V3.0 to external systems. This

server is also used to connect PC based machines and installations without their own OPC server to the system.

OPC SERVER

Many modern control units and devices have internal web-inter-faces for maintenance and diagnosis. Access to this interface is se-cured. For it to be accessed through the internet an additional user

authentication with user name and password can be added in the module Proxy Server.

PROXY SERVER

The system‘s own Microsoft SQL Database can either be used to store data permanently, or for temporary data buffering if the customer‘s own database fails. In order to exclude data loss reliably this database can also be mirrored in two databases. The module Secure Data Transfer offers the possibility of coding the existing

production, process and order data, transferring it to other databa-ses or to external web-services. This enables, for example, quality data and OEE figures to be transferred automatically each month to the central company system or to the company’s own internet site.

SECURE DATA TRANSFER

In addition to the visualisation supplied all order, production, pro-cess and disruption data can be exported through an Excel Plug-in

from the ADEX system to Microsoft Excel and be processed further as required.

EXCEL PLUG-IN

The documents and files which are relevant for production can be versioned through the ADEX’s web interface in this module. Each of the versions can be easily downloaded over the web-interface,

edited locally and added as a new version. The current files and the whole history are always readily available.

ELECTRONIC DOCUMENTATION

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OUR PRODUCTS ARE USED IN THE FOLLOWING FIELDS:

Automotive industry Automotive supply industry Food industry Chemical industry Air conditioning technology Steel industry

Steel industry Manufacturers of consumer electronics Railway industry Constructors of power stations ICT companies Mechanical engineering and construction

sternico.de/industrial-automation

YOUR POINT OF CONTACT

Dipl.-Inform. Werner MagerTel.: +49 (5303) 9794 - 180E-mail: [email protected]

the central production data hub · rolling enables graphic control elements for visualisation and...

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