IRIS Custom Solutions - InduSoft Custom Solutions MVS Overview-1.0.pdf · IRIS Custom Solutions...

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IRIS Custom Solutions

10216 Werch Drive, Suite 116

Woodridge, IL 60517

Phone: 630-634-7702

Fax: 630-634-7701

Email: [email protected]

mailto:[email protected]

IRIS Custom Solutions LLC – 10216 Werch Drive, Suite 116, Woodridge IL 60517 www.IRIScs.com

IRIS Custom Solutions Manufacturing Visualization System

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Manufacturing Visualization System The IRIS Manufacturing Visualization System was developed to provide manufacturers the ability to capture,

store, and visualize information in a way that enables them to make educated decisions to improve their

products and processes through the power of real time information.

Although the system was developed on the backbone of the widely known OEE calculation, its design flexibility

can also enhance our clients understanding of their machines by providing information on items like raw

material yield, specific downtime tracking codes, operator performance, and a host of other key production

metrics.

With the ability to communicate to over 220 different types of control devices, as well as nearly unlimited

flexibility in the collection and visualization of information, the IRIS MVS system provides a cost effective and

comprehensive solution for our clients process improvement needs.

HOW DO I KNOW IF MVS IS RIGHT FOR ME?

If you find that your organization can relate to the below statements, MVS may be exactly what you’ve been looking for:

We’re collecting data, but were not utilizing it because it’s not easily viewed and deciphered.

We’re unable to collect information at the machine level. We don’t have a grasp on how to improve our operator’s performance. We aren’t sure if we’re producing as much as were capable of. We don’t have a good understanding of if we’re utilizing our labor appropriately. Our production requirement is increasing and we don’t know where we can improve our

current production to avoid purchasing new machinery. If you’re facing these challenges, you’re not alone. That’s why IRIS has released our MVS System. The goal was to provide clients a simple, rugged, and cost effective way to start to understand where they are losing out on manufacturing efficiencies, and more specifically where they’re losing money.



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HOW MVS WORKS:

OEE

The backbone of the MVS system is the fundamental calculation of OEE. OEE is defined as AVAILABILITY x

PRODUCTIVITY x QUALITY

AVAILABILITY is a measure of how often the machine is actually running vs how often it is available to run.

Essentially this number takes into account the total time a machine is intended to run minus planned

breaks and downtime and then compares that to the actual runtime for a given time period.

PRODUCTIVITY is a measure of how many parts per minute a machine is producing as compared to how

many parts per minute it is capable or more importantly expected to produce.

QUALITY is a really a function of yield. This number is defined by how many good parts are being

produced as compared to the number of parts being produced overall.

Data Logging

Under normal operating conditions MVS will collect the below information:

Time

Location

Line

Machine (Cell)

Uptime

Downtime

Cycle Speed

Expected Cycle Speed

Lost Product

Good Units

Bad Units

Total Units

Availability (Target & Actual)

Performance (Target & Actual)

Quality (Target & Actual)

OEE (Target & Actual)

Product

Shift

Week



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Regarding downtime, there are two distinct downtime conditions, and MVS knows the difference

between those occurrences and handles the information differently for each case.

Planned Downtime

o In the case of planned downtime the MVS will not count planned downtime against the overall

performance of the machine. However, in the case where the machine is expected to be down

for a given time interval (which is pre-defined) and that time interval is exceeded, MVS will

begin to count that downtime as unplanned. Common contributors for this include:

Operator is not available or prepared

Incoming goods are not available

The machine wasn’t stopped properly prior to the planned downtime which leads to

longer startup

o Conversely if the machine begins to run sooner than expected, MVS will begin to collect

machine data immediately

Unplanned Downtime

o In the case of unplanned downtime, MVS will immediately log the downtime as unplanned and

it will count against the overall OEE. MVS will also prompt the operator or technician to

provide a reason on why the system was down and store that information for viewing and

reporting.



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SYSTEM CONFIGURATION OPTIONS:

The IRIS MVS system has three primary configuration options. Our goal was to provide our clients the

flexibility of having the system either Stand Alone, Machine Integrated, or Plant Integrated.

STAND ALONE:

1. By simply deploying a stand-alone MVS system and interfacing the two provided sensors to the client’s

equipment, our clients have the ability to interface with the MVS system to be able to enter other key

metrics that will then be rolled up into the OEE of the machine. This configuration is ideal for clients

with legacy equipment that either doesn’t have a control platform or has a platform that is not easily

communicated with. This solution can also be moved between different machines if the desire to

collect information from each machine is more of a short term need.

MACHINE INTEGRATED:

2. By integrating the MVS system directly to the machine control, we can provide a much more

comprehensive and automated collection of information. In this case the MVS would connect directly

to the machine PLC, monitoring specific data memories to collect all required information for OEE and

other key metrics. This doesn’t require any change to the existing PLC program, and simply acts in a

supervisory fashion. In this case we can connect one or many machines to one interface station.

Sensor counting all parts

being produced

Sensor counting rejected

product

Machine 1

Machine 2

Machine 3+

Machine 3



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PLANT INTEGRATED:

3. When our clients have multiple machines and their primary focus is to have the OEE displays and

reporting in the front office or overhead on the plant floor, we offer them the option of running MVS

on a plant based server.

This gives our clients the scalability they need in that they can add additional machines to the MVS

system as desired. It also reduces the overall cost of the system by eliminating the need for stand-

alone MVS hardware at each machine.

Machine 1

Machine 2

Machine 3

Machine 4

Machine 5

Machine 7

Machine 6

Machine 7+



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WHERE CAN I SEE THE INFORMATION?

View information real time at a local

machine data collection terminal

View Information on overhead or

wall mounted AndOn displays

View information real time in the

front office on multiple stations

View information real time on

tablets and other mobile devices



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Features and Benefits

Understand downtime in terms of:

o Planned Downtime

Preventative Maintenance Functions

Operator Breaks

o Unplanned downtime

Quantification to the second of specific machine error codes

Quantification of type and length of maintenance functions

Understanding of downtime due to operator unavailability

Ability to Sort, Quantify, Visualize, and Report production metrics by:

o Operator

o Shift

o Product

o Machine

o Line

o Incoming Material

Ability to capture and visualize Automated Inspection Device failure codes

o Why a part was rejected

o How many of each reject occurred

Ability to quantify final production yield vs. incoming raw materials

Automate and expedite shift reporting for items like:

o Total Good Parts

o Total Bad Parts

o Uptime

o Downtime

Ability to display live data directly to operators so they understand their performance to

expectation real time

Ability to email technicians or front office staff in the case of manufacturing anomalies

Ability to produce immediate historical reports based on user selected time period for any

and all information being gathered

Ability to generate “at a glance” reports for last hour, last 4 hours, last shift, last week, etc.

Ability to interface with an existing customer database to tie back production data to

existing customer job numbers, part numbers, and raw material

Ability to view the system display on the plant floor, at your desk, or from a mobile device



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SCREEN DISPLAYS AND FUNCTIONS

OEE Statistics Screen

The OEE Statistics Screen is the main screen of the application. Here an operator can select a date/time

range, product, job, and shift in order to see the Overall Equipment Efficiency of the system for those

selections. This provides the ability to not only see “current” OEE, but be able to get “at a glance” reports

and displays for other historical time intervals.

As additional criteria the user can further segregate information by:

o Cell - View the data for that cell/machine

o Line - View the data for multiple cells

o Location - View the data for all of the lines and cells

Figure 1.0



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In the figure 1.0 above, Cell #1 data is being shown. For the date/time selection, the user would use the

following sequence to populate the fields.

o FROM OR TO FIELD - DATE/TIME PRESSED

Popup will occur which allows an operator to select these via a calendar view.

o START OF SHIFT BUTTON PRESSED

FROM FIELD = Start of Shift Time

TO FIELD = Current Time

o LAST 4 HOURS BUTTON PRESSED

FROM FIELD = Current Time – 4 Hours


o LAST 2 HOURS BUTTON PRESSED

FROM FIELD = Current Time – 2 Hours


o LIVE BUTTON PRESSED

FROM FIELD = Previous date/time selection remains


The target and actual values for availability, performance, quality, and OEE are shown graphically and

numerically. In addition, an operator can see the:

Total parts made

Rejected parts

Uptime

Downtime

All for the given parameters entered (date/time, product, etc.). An operator can also press the “Export

Data” button, which will save the data shown to a csv file on a USB thumb drive.

Figure 1.1



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OEE Details Screen

The OEE Details Popup Screen is accessed from the OEE Statistics Screen and is used to give an operator

information about OEE and how it is calculated.

In addition, the Expected Parts Per Second field (entered on the OEE Settings Screen) is shown. From

the OEE Details screen, a user can press the “OEE TUTORIAL” button, which will show a document

covering specifics about OEE (definitions, calculations, etc.). When the “CLOSE” button is pressed, the

popup will close.



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OEE Trending Screen

The OEE Trends Screen is accessed from the OEE Statistics Screen and is used to show the OEE values in

trend format. The date/time, product, job, and shift selections from the OEE Statistics Screen are retained,

but also can be modified if needed as described in the OEE Statistics Screen section. The trend can show all

or a combination of the following statistics by selecting or deselecting the checkbox next to that statistic:

Availability

Performance

Quality

OEE

When the cursor on the trend is moved, these values change for that specific point in time, shown in the

CURSOR DATE/TIME field. The target values for these fields are shown on the trend as dashed lines,

while the actual values are shown as solid lines.



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OEE Settings Screen

The OEE Settings Popup Screen is used to enter target values for Availability, Performance, and Quality,

which are shown on the OEE Statistics and Trends Screens. In addition, the expected parts per second values

for each cell are entered on this screen.

This value is used in the OEE calculations as described on the OEE Details Screen. When the “CLOSE” button

is pressed, the popup will close.



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Current Week

When first starting the application and when the week prompt date/time has occurred, the supervisor

will be prompted to select the current week (1-4). This will adjust the current shift settings to be the

settings saved for that week and determine when a shift is occurring and when a scheduled downtime

is occurring.

In addition, the supervisor will set the date/time to be prompted again for the week change. No data

will be logged until a week is selected by the supervisor.



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Select Product Screen

The Select Product Popup Screen is used to select the current product running, so that this can be logged to

the database when the OEE data is logged. An operator will click on the product, which will highlight that

line, and then press the “RUN PRODUCT” button. This will also close the popup.

If the operator does not want to change the product selection, then the “CANCEL” button can be pressed to

close the popup with no changes being made. The current product running is also shown on this screen.



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Select Job

The Select Job Popup Screen is used to select the current job running, so that this can be logged to the

database when the OEE data is logged. An operator will click on the job, which will highlight that line,

and then press the “RUN JOB” button. This will also close the popup.

If the operator does not want to change the job selection, then the “CANCEL” button can be pressed to

close the popup with no changes being made. The current job running is also shown on this screen.



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Down Time

The Downtime Screen is used to show the current downtime statistics (cell number, alarm name, and

number of minutes in a downtime) for the current shift. These are populated when downtimes occur

and the reasons are selected by the operator or provided by the PLC (see description in Downtime

Reason Popup section). The values are reset when a shift change occurs, or when the “RESET DOWN

TIME” button on the screen is pressed.

In the case of the system being interfaced to the machine PLC, the collection and quantification of these

codes will be automated.



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Reject Table

The Reject Table/Statistics Screen is used to show the current part rejection statistics (cell number, reject

reason, and number of rejected parts) for the current shift. In order to log a rejected part, the following

sequence will occur:

“LOG REJECTED PART” button pressed. This will increment the “Undefined Rejects” field.

Enter the number of rejects for each reject reason, with the total equal to the “Undefined

Rejects” field. If the total does not match, an error will appear which will prompt the operator

to fix the values before updating.

When the values are correct, the “UPDATE REASONS” button is pressed. This will update the

database for the rejected parts and will show these rejections on the upper half of this screen for

the current part rejection statistics.

If the rejected parts were all rejected without a known reason, the “RESET ALL TO UNKNOWN”

button can be pressed to update the reason for all undefined rejects to “Unknown Reason”.

The values are reset when a shift change occurs, or when the “RESET REJECT TOTALS” button on the

screen is pressed. Note: Logging of rejects can be automated, if desired, however the reason selection

will still occur as described above.



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Reports

The OEE Reports Screen is used to show the downtime values in trend format. The date/time, product, job,

and shift selections from the OEE Statistics Screen are retained, but also can be modified if needed as

described in the OEE Statistics Screen section.

The downtime alarm type is selected and then the total minutes for the date/time range and alarm type is

shown. When the cursor on the trend is moved, the downtime minutes for that specific point in time will

be shown.

An operator can also press the “Export Data” button, which will save the data to a csv file on a USB thumb

drive. In the case where the MVS is networked this information can also be accessed remotely.



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Configuration

When the “CONFIG” button is pressed on the side bar, the “SHIFT CONFIGURATION” Screen is opened.

This screen is only accessible by a supervisor. From this screen, all of the other configuration screens

can be accessed. The screens are described as follows:

Shift

The Shift Configuration Screen is used to show the shift configuration for up to 5 shifts. This

screen also shows which shift the system is currently in, with that shift highlighted in green.

When an operator presses the “SET” button next to a shift, the Shift Settings Screen will appear

in order to modify the shift.

In addition, this screen shows the current week selected and the date/time that the week change

should be prompted to a supervisor. When the “WEEK PROMPT DATE” field is pressed, a calendar

will appear to allow the supervisor to select when the week change should be prompted in order

to allow the week selection to change.

For more details about this, reference the Current Week section of this document.



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Shift Settings

The Shift Settings Screen is used to modify the shift configuration for a selected shift.

The settings are as follows:

The default week shown is the current week.

The shift name, start time, and end time are entered at the top of the screen for

the week selected.

The days of the week that the system is run for this shift and week are selected

using checkboxes.

The scheduled downtimes are enabled for the shift and week selected, with the

start time and duration in minutes entered. If only one downtime occurs for a

shift, then DOWNTIME 1 would be the only field enabled. If two downtimes

occur for a shift, then DOWNTIME 1 and 2 would be enabled. This is

customizable for up to 5 downtimes per shift and week.



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To change the shift configuration for a different week, the week can be changed using

the week selection box. When the week is changed, a popup will appear (see below) to

prompt a supervisor to save the values before continuing.

If the supervisor presses “SAVE WEEK SETTINGS”, then the settings will be saved and the

selected week will change. If the “CANCEL” button is pressed, then the week selection

will return to the previous selection and no changes will be saved.

When the updates to the shift are completed, the “SAVE AND CLOSE” button will be

pressed to save these settings and close this screen. If changes have been made that

should not be saved, then the “CANCEL” button will be pressed to close this screen.



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Product

The Product Configuration Screen is used to configure the products. This is done as follows:

Update Existing Product - Select the product, which will highlight it in the table and show

the name, part number, and parts/second in the “EDIT PRODUCT ATTRIBUTES” box. A

supervisor can then enter the updated values and then press the “UPDATE PRODUCT”

button to update the product in the database. Delete Existing Product – Select the product, which will highlight it in the table. A

supervisor can then press the “DELETE PRODUCT” button to delete this product from the

database. If a product is deleted, the OEE data for this product will no longer be

accessible, other than when “ALL PRODUCTS” are selected for the OEE data. Add Product – Enter the name, part number, and parts/second fields and then press the

“ADD PRODUCT” button. This will add the product to the database and allow it to be

selected as the current product running (see the Select Product Screen section).



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Job

The Job Configuration Screen is used to configure the jobs. This is done as follows:

Update Existing Job - Select the job, which will highlight it in the table and show the name

and part number in the “EDIT JOB ATTRIBUTES” box. A supervisor can then enter the

updated values and then press the “UPDATE JOB” button to update the job in the

database. Delete Existing Job – Select the job, which will highlight it in the table. A supervisor can

then press the “DELETE JOB” button to delete this job from the database. If a job is

deleted, the OEE data for this job will no longer be accessible, other than when “ALL JOBS”

are selected for the OEE data. Add Job – Enter the name and part number and then press the “ADD JOB” button. This

will add the job to the database and allow it to be selected as the current job running (see

the Select Job Screen section).



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Downtime

The Downtime Configuration Screen is used to configure up to 10 downtime reasons. To update

a downtime reason, the reason is selected, which will highlight it in the table and shown the

reason in the “EDIT DOWNTIME REASON” box.

A supervisor can then enter the updated reason and then press the “UPDATE REASON” button to

update the reason in the database. The “Unknown Reason” and “Changing Products” reasons

cannot be updated as they are required for the system.

In addition, the downtime prompt time can be modified, which determines how long the system

is not running before the downtime is logged and a reason is required.



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Reject

The Reject Configuration Screen is used to configure the 5 part rejection reasons. To update a

rejection reason, the reason is selected, which will highlight it in the table and shown the reason

in the “EDIT REJECTION REASON” box.

A supervisor can then enter the updated reason and then press the “UPDATE REASON” button to

update the reason in the database. The “Unknown Reason” entry cannot be updated as it is

required for the system.



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Downtime Reason Popup

The Downtime Reason Popup Screen is automatically opened when a downtime has occurred. The

operator must select the downtime reason and then press the “SELECT REASON” button, which will log

the downtime to the database and close the popup.

If the reason is not selected and the downtime is no longer active and then becomes active again, then

“Unknown Reason” will be logged as the initial downtime’s reason and the popup selection will be for

the current downtime.

If the reason for the downtime is due to changing a product, then the “PRODUCT CHANGEOVER” button

can be pressed instead of selecting a reason. This will set the reason to “Changing Products” and will

open the Select Product screen so that the operator can select a new product.

For more information on MVS and other products and services IRIS has to

offer please contact us at 630-634-7702 or [email protected]

IRIS Custom Solutions - InduSoft Custom Solutions MVS Overview-1.0.pdf · IRIS Custom Solutions...

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