Post on 29-Mar-2015
SFCShop Floor Control
Systems
SEKA GmbH, Rodgau, Germany
© SEKA GmbH - 2004 SFC Presentation- 1 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
Typical available General Ledger System Portfolio
in Production Industries
SAP® PeopleSoft ® Siebel ® Navision ®
SFC Systems - Why ?
© SEKA GmbH - 2004 SFC Presentation- 2 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
need Data
need Data
need Data
need Data
© SEKA GmbH - 2004 SFC Presentation
SFC Systems - Why ?
- 3 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
need more Data
need more Data
need more Data
need more Data
SFC Systems - Why ?
© SEKA GmbH - 2004 SFC Presentation- 4 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
need good Data
need more
Productivity
need less Waste,
less Reclaims
need more
Reliability
SFC Systems - Why ?
© SEKA GmbH - 2004 SFC Presentation- 5 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
We need good Data
We need more
Productivity
We need less Waste,
less Reclaims
We need more
Reliability
SEKAShop Floor Control
Systems for Convertingsince 1994
SEKAShop Floor Control
Systems for Productionsince 1999
SEKADataEntry & Qualitysystems since 1989
Interfaces for Data up/down-load
PLC (Plant Control Systems)
SFC Systems - Why ?
© SEKA GmbH - 2004 SFC Presentation- 6 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Vision
© SEKA GmbH - 2004 SFC Presentation
• Good data (automatic data collection)
• Good quality (on hold functionality)
• More productivity (control material flow)
• More transparancy (easy data access, WEB)
• More effectiveness (less required operator input)
• Less Reclaims control (shop floor logistics)
• paperless production - complete documentation and reporting
• Configurable and modular System
• easy Integration (Interfaces to any systems)
Shop Floor Control
- 7 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SEKAShop Floor Control
- Production -
SFC-Production - The Environment
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
- 8 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
SFC
SFC Database• holds all Setup/Material/ Time/ Quality data
• Logic programmed in stored procedures
• Triggers for event based data processing
• holds temporary work flow data
• holds all historical tracing data
• Replication possible
- 9 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
SFC
DataConnector (DC)• Connects to datasources (DDE,OPC,TCP,...)
• reads, writes and processes data
• sends Events to database (line down, splice,..)
• validates values (Out of Limit, corr. action)
• script language for recalculation and charting
• free setup of tag attibutes (Target, Min, ...)
- 10 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
SFC
Workcenter• operator Interfaces & operator log on/off
• shop order (set material, recipes, sampling...)
• disposition and pack of material & labeling
• enter downtime codes (DC detects downtime)
• Raw material consumption & scanning
• reports, data views, tracing,...
- 11 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Packaging
SFC
Packaging• operator interface
• pack, repack, unpack material
• list of all packages and contents
• reprint lables
• fill up partial bundles
- 12 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Laboratory Packaging
SFC
Laboratory• list of all samples taken at workcenters
• scan sample label
• enter quality data, based on Quality Standards
• display Out of Spec, Out of Acceptance
• Retesting (future)
• SPC-charts (future)
- 13 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
ShippingLaboratory Packaging
SFC
Shipping• operator interface
• scan all packages
• verify material and quality status of each unit
• verify CoA, print/eMail CoA’s automatically
• save shipping data (date,customer,PO,Truck)
• send shipping lists by eMail
- 14 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
ShippingLaboratoryReceiving Packaging
SFC
Receiving (future)• verify material
• verify Certificate
• sampling for lab
• labeling
- 15 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
ShippingLaboratoryReceiving WarehousePackaging
SFC
Warehouse
• currently available for SFC-Converting- Systems only
- 16 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
ShippingLaboratory
Processto Quality
Receiving WarehousePackaging
SFC
Process to Quality (background system)
• extracts data from Historian database and calculates quality property results
• automatically set quality status and set material on hold if it fails specification
- 17 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
ShippingLaboratory
CognexAdd-On
Processto Quality
Receiving WarehousePackaging
SFC
Cognex Add-on System (background system)
• processes cognex ICN inspection data and recommends material disposition
• recipe setup for different ICN stations, different Cognex recipes, different products
- 18 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
ShippingLaboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
CoA System (can be used as background system-
interactive frontend necessary for CoA’s which do not meet release criteria)
• creates customer specific CoA’s
- 19 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
SFC Setup• configure workcenters, lines, shifts, crew,...
• material item master, BOM’s, alternate output
• downtime & waste codes
• configure workcenter functionalities
- 20 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
Fine Planning• shop order sequence planning
• automatic end time calculation
• automatic Yield/Runtime/OEE calculation
• shop order related instructions to operators
• combine shop orders to one production order (future)
- 21 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
AS/OC System
AS/OC System (internal quality audit system)
• handling out of spec/control material
• routing material and actions
• data reports
- 22 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
AS/OC SystemProcess Engineers
Process Engineers• enter process specific rules
• inspection recipes
• PLC recipes target, range of operator changes
• product standards
• work instructions
- 23 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
AS/OC SystemProcess Engineers
QA Egineers
Quality engineers• enter quality standards
• enter sampling plans
• enter customer specific CoA setup
• create CoA
• release material
- 24 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
Analysis
AS/OC SystemProcess Engineers
QA Egineers
Data Analysis• flexible access data with ODBC clients
- 25 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
Analysis
AS/OC SystemProcess Engineers
QA Egineers
WEB Display WEB Display• display Yield, Outout, Runtime, OEE data
• display raw system data
• standard WEB pages planned, currently customized WEB pages only
- 26 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
InterfacesAnalysis
AS/OC SystemProcess Engineers
QA Egineers
WEB Display System Interfaces• eventbased triggered interfaces
• easy integration of existing stored procedures with new interfaces
- 27 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Modules
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
InterfacesAnalysis
AS/OC SystemProcess Engineers
QA Egineers
WEB Display Multilingual System• easy to add new language in DB table
• dynamic language change (no program restart necessary)
• use of operators language, not system phrases
• data display screens configurable
- 28 -
Human Resource
Finance Invoicing
Order Mgt. Procurem.
InventoryMaterial
Supply Chain
Customer Service
Unit CostCalculation
Supplier Service
SAP ® PeopleSoft ® Siebel ® Navision ®
SFC-Production - The Overview
© SEKA GmbH - 2004 SFC Presentation
Line 1 : Extruder Line 2 : Coater Line 3 : Slitter Line 4 : Rework
InlineTestunit
InlineTestunit
PLCSCADA PLCSCADA PLCSCADA PLC
Database
Historian- iHistorioan- WW InSQL
ServerDatabase
DC DC DC DC
Workcenter CWorkcenter E Workcenter S Workcenter R
Shipping
Setup
Laboratory
CognexAdd-On
Processto Quality
CoASystem
Receiving WarehousePackaging
SFC
FinePlanning
InterfacesAnalysis
AS/OC SystemProcess Engineers
QA Egineers
WEB Display
- 29 -