FIELD OF USE:■ TECHNOLOGICAL DATA COLLECTION AND DOWNLOADING OF CONTROL PROGRAMS■ PRODUCTION CONFIRMATION, USE OF OPERATOR TERMINAL■ OEE, KEY PERFORMANCE INDICATORS■ PRODUCTION VISUALIZATION■ MAINTENANCE MANAGEMENT■ CAPACITY PLANNING■ MANAGEMENT OF INJECTION MOLDS

MANUFACTURING EXECUTION SYSTEM FOR MOLDING SHOPSFOR HIGHER PRODUCTION EFFICIENCY

FIELD OF USE:■ TECHNOLOGICAL DATA COLLECTION AND DOWNLOADING OF CONTROL PROGRAMS■ PRODUCTION CONFIRMATION, USE OF OPERATOR TERMINAL■ OEE, KEY PERFORMANCE INDICATORS■ PRODUCTION VISUALIZATION■ MAINTENANCE MANAGEMENT■ CAPACITY PLANNING■ MANAGEMENT OF INJECTION MOLDS

FOR HIGHER PRODUCTION EFFICIENCYFOR HIGHER PRODUCTION EFFICIENCY

UNIS, a.s., Jundrovská 33, 624 00 Brno, Czech Republic, tel.: +420 541 515 603, fax: +420 541 210 361 www.pharis.cz, e-mail: info@pharis.cz

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MES PHARIS® – GENERAL DESCRIPTION

MANUFACTURING EXECUTION SYSTEM (MES) PHARIS®

MES PHARIS® is a unique manufacturing execution system developed by UNIS. MES PHARIS® covers complex

spectrum of functions enabling optimization of the production process from the moment of issuing a manufac-

turing order to production planning, production control, monitoring including documentation of production to

the release of final or semi-finished products. It is an information system from the category of manufacturing

execution systems. It is the interface between injection molding machines and ERP system (SAP, NAVISION, K2,

HELIOS, ENTRY …).

MES PHARIS® uses two-way online com-

munication with molding machines of

many manufactures – Engel, Arburg,

KraussMaffei, Battenfeld, Demag …

MES PHARIS® provides technological

data collection from molding machines

along with uploading/downloading of

approved control programs into/from

molding machines.

The main task of the manufacturing

execution system PHARIS® is to improve

the efficiency of production, electroni-

zation and distribution of production

documentation, and documentation of

production process in the form of EBR

(Electronic Batch Record). MES PHARIS®

is intended to show quality of final

products, and also of single production

order operations including reporting of

used materials and personnel involved

in the production order operations.

MES PHARIS® is a modular web-based

system. Customers can select

individual modules according their

needs; starting from the simplest

configuration for data collection and

central uploading/downloading of

control programs to a complete

configuration covering all the

production processes, i.e. planning of

a production order, production

control and monitoring, final release

of products and key performance

indicators.

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ERP SYSTEMS

PRODUCT CONFIRMATION(YIELDS, SCRAPS, TYPE OF SCRAP)

PRODUCT DEFINITIONS

WORK ORDER

CONSUMPTION OF MATERIALS

■ HELIOS■ QI■ ENTRY■ NAVISION■ K2■ SAP …

MES PHARIS® – PRODUCT OVERVIEW

SUPPORTING CLASSIFIERS(MACHINES, MOLDS, EMPLOYEES, MATERIALS)

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CAPACITYPLANNING

PRODUCTION CONTROL AND MONITORING

MAINTENANCE

DISPATCH LIST(PLANNED PRODUCTION OPERATIONS, METHODS OF OPERATIONS)

.

.

.

FILE ATTACHMENTS(SETTINGS SHEET, SCRAP LIST, DWG, VIDEO)

TECHNOLOGICAL DATA COLLECTION(INJECTION CUSHION, TEMPERATURE, ACTUAL CYCLE TIME ...)

MOLD MACHINES STATUS MONITORING(AUTOMATIC CYCLE, SETTING UP, BREAKDOWN…)

CONTROL PROGRAMS(UPLOAD/DOWNLOAD OF CONTROL PROGRAMS)

■ TECHNOLOGICAL DATA COLLECTION AND DOWNLOADING OF CONTROL PROGRAMS■ PRODUCTION CONFIRMATION AT THE MOLDING MACHINES, USE OF OPERATOR TERMINAL■ OEE, KEY PERFORMANCE INDICATORS■ PRODUCTION VISUALIZATION■ MAINTENANCE MANAGEMENT■ CAPACITY PLANNING■ MANAGEMENT OF INJECTION MOLDS

WEB APPLICATION SERVERWEB APPLICATION SERVER

MANUFACTURING EXECUTION SYSTEM PHARIS®■ CENTRAL DATABASE OF CONTROL PROGRAMS FOR MOLDING MACHINES.■ CENTRAL DATABASE OF DOWNLOADED TECHNOLOGICAL PARAMETERS.

LAN

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Examples of realized injection molding machines

connections:

■ Connection via existing control system of an injection

molding machine.■ Connection via the molding machine protocol. The most

common communication standard for connection of

injection molding machines is Euromap 63 (Demag,

Engel, KraussMaffei…).

■ Connection via the manufacturer's proprietary protocol

of injection molding machine (Arburg).

■ Scanning a table of quality over printerport.

■ Connection via the machine control system signals.

Technological parameters are

stored in MES PHARIS® data-

base. The manufacturing

system PHARIS® in each cycle

(or interval) offers the possibil-

ity to monitor the values of

selected technological param-

eters (e.g. injection cushion),

and evaluates whether the

values are within the

defined tolerance

limits, or if there are

any unauthorized

changes parameter

values, or change in

the calculated values

over the allowed limit. In

the case of non-standard

parameter changes, the manufactur-

ing system automatically notifies an

accounted person via a text message, or

an e-mail. This feature leads to an early

detection of potential problems, and it

predicts the possibility of a quick and

operative reaction by accounted workers.

The manufacturing system PHARIS® is

also opened for communication with

other devices (granulate dryers, digital

measuring equipment, molding

machines water cooling systems …).

COMMUNICATION WITH INJECTION MOLDING MACHINES

The way of connecting manufacturing execution system PHARIS® with injection molding machines is

dependent on the type of communication supported by a specific molding machine.

The use of selected options of communication between MES PHARIS®

and the molding machines:

■ Monitoring and storing selected technological parameters (from the set of 2 000

parameters) – injection cushion, plastification time, cylinder temperature, actual

cycle time ... ■ Central controlled upload/download of authorized control programs into/from

molding machines.

■ Downloading and storing of change protocols of the molding machines set up.

■ Downloading of molding machines status (setting up, breakdowns, automatic

cycle …).

■ Online cycles monitoring related to tool (injection molds) management.

■ Remote downloading of actual print screens of the molding machines control system.

CONTROL PROGRAMS MANAGEMENTMES PHARIS® contains a central database of control programs. The basic entities of this management are control

programs with a link to the molding machine and the injection mold. For every control program it is possible to

create and store its versions. Users can go back in history to older versions.

For every control program, basic attributes such as name, version, description, and file attachments representing

the program itself are recorded. Uploading and downloading of programs into/from molding machines can be

carried out using mobile or operator terminals. The operator identifies the machine, injection mold, and control

program, which should be transferred into/from the injection molding machine, and then the operator performs

the action.

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TRENDS OF TECHNOLOGICAL PARAMETERS FROM MOLDING MACHINES

This module is used for graphical presentation of

values of technological parameters in time. Techno-

logical values can be displayed in predefined groups.

Each group may include several graphs, or the user can

use the chart, into which the user can define the tech-

nological variables according to his current needs.

Central management of

control programs is imple-

mented with strict require-

ments of quality management

standards for automotive

suppliers. According to these

standards, the system fulfills

the requirements for the

creation, authorization,

versioning and distribution of

controlled central distribution

of control programs to injec-

tion molding machines.

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The implementation of manufacturing execution system PHARIS® into production usually (not required)

precedes the plant equipping with operator terminals that offer the following functionalities to their operators:

■ Select and login to the planned manufacturing operation.■ Production confirmation (number of pieces, including yields and scraps, type and count of scrap).

■ Possibility to display the production documentation related to current running operations of the order

(scrap list, instructional video, setting sheet, checklist, packing list, DWG ...).

■ Interactive downtime entering by the operator (scrap input material, defect of molds...).

■ Time prediction of completion the operation, display of delay (+/-).

■ In the case of logging into the service mode, the terminal provides the ability to upload/download the current

authorized control program or put on mold.

■ Displaying the technological parameters of the last cycle.

PHARIS® MOBILE CLIENTS

For easy, effective, and operational work in production it is advisable to

use a mobile operator's terminal. This is usually the client Motorola or

PDA with WiFi eventually equipped with RFID tag reader.

Functionalities available within the application

PHARIS® MOBILE CLIENT:

■ Sending and receiving products to/from cooperation.

■ Tools (molds) management.

■ Entering the consumption of material (batch of material ...).

■ Confirmation of the finished production to the warehouse.

USING THE OPERATOR TERMINALS, PRODUCTION CONFIRMATION

According the standards of quality management for automotive suppliers MES PHARIS® offers man-

agement of trained users to manufacturing operations. MES PHARIS® do not allow log on to manu-

facturing operation to operator, which was not trained on this operation.

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PRODUCTION CONFIRMATION

Production confirmation on the operator terminals fully replaces manual filling out of the preprinted forms,

which leads to errors and delays. Outdated and inefficient way of handling production confirmation using

preprinted forms also requires manual entering of data from the forms into a superior ERP system.

Production confirmation through operator terminals leads to a complete replacement of personnel responsi-

ble for production confirmation, and it eliminates all manual entering of statements of work into the superior

system. For a confirmation of scraps, the operator terminal offers online viewing of the scrap list.

The operator of the injection molding machine has an easy way of handling the production confirmation,

including scraps, eventually selecting the type of scrap on the operator terminal. The number of pieces during

production confirmation is automatically checked with the number of cycles of the molding machine.

The advantage of electronic production confirmation on the terminal is an automatic online transmission of

the work to the ERP system, including packaging units. Each production confirmation also requires identifica-

tion of the operator who made the confirmation.

CONTROLLED PROCESS WITH PRODUCTION DOCUMENTATION

MES PHARIS® offers a complex distribution of production documentation in electronic form. The goal of this

controlled process is ensuring current and authorized manufacturing documentation easily accessible

on-screen of the operator terminal directly by injection molding machines. The documentation can be sorted

into user-defined groups. Subsequently, it is possible to assign individual documents to the injection molding

machine, product definition or manufacturing operation.

The benefits arising from implementing

the process of controlled production

documentation:

■ Replacement of paper documents with

an electronic form.■ Availability of current and approved

manufacturing documentation on

operator terminals directly at injection

molding machine.

■ Easy modification of production docu-

mentation by authorized personnel

from a centralized location.

■ Possibility of delegating personnel

responsible for the preparation of

documentation.

■ Ensuring the access to production

documentation only for authorized

personnel.

Operator terminal screen preview

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VISUALIZATION OF PRODUCTION PLANTS

Production visualization allows the users of PHARIS® to monitor machines states (mode) of injection molding

machines. Visualization may include technological and production data. The role of visualization is to provide

prompt and clear online preview of the production plants. They are available on workstations and usually also

on large screens directly in the production halls.

The strong point of this module is the possibility of a user definition screens. The customers have the

option to create the screens by themselves in an easy user interface system of PHARIS®. The background

of screens with visualization is usually the layout of the production halls.

On production visualization it is possible to display

injection machines for which there is a graphic presen-

tation of basic collected information such as:

■ Molding machine status (off, manual, service, semi-

automatic, automatic, breakdown ...).■ Technological parameters of the machine (injection

cushion, temperature, pressure, plastification time…).

■ Production data (order, plan, yields, scraps, ID of

operator ...).

The visualization is

represented by an

interactive Web page

on MES PHARIS®

server, which uses

online connectivity to

the injection molding

machines, and to

which you connect

from any available

location on the

network through a

web browser (IE,

Mozilla).

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Manufacturing Execution System PHARIS® offers module "Key Performance Indicators" which provides a com-

prehensive view of the finished production. The results of the analysis can be displayed in a graphical form or

table, eventually in the report. At the same time data can be exported for further use in XML and CSV formats.

OEE, KEY PERFORMANCE INDICATORS

OEE (OVERALL EQUIPMENT EFFECTIVENESS)

Efficiency of production machines in MES PHARIS® is focused on monitoring and evaluation of equipment for a

certain period of time, such as last year, month. Based on the monitoring and evaluation of production, the

equipment can then be traced back even to predict the behavior of the production equipment to define the

impact of equipment on actual production, or adapt the production capacities to production plans.

For user defined group of injection molding

machines the system allows you to graphically

display dynamic timeline of each device event

(automatic cycle, breakdown, setting up...),

type of downtime and the actual injection

molding cycles. This is a quick and arranged

view of the real state of the production facili-

ties including a look into history.

Monitoring of loading and efficiency of injec-

tion molding machines in MES PHARIS® is also

an effective tool for finding bottlenecks in

production. The module provides calculations

for the timely predictive response to potential

capacity problem. In the early detection of

critical bottlenecks in production the manage-

ment is able to respond and resolve the insuffi-

cient capacity and overloading of injection

molding machines in advance. On the other

hand, MES PHARIS® calls attention to unused

and thus operationally and economically

expensive equipment.

Among the most commonly used indicators are

the following:

■ OEE – Overall Equipment Effectiveness.■ BGE – batch genealogy.■ Monitoring of users – evaluation of performance, quality

and downtimes.■ Injection machine cycles, history of cycles – count, mean

cycle time, maximal cycle time, minimum cycle time.

■ Work evaluation – qualitative and quantitative characteris-

tics based on the user defined criteria (analysis of yields and

scraps).

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MAINTENANCE MANAGEMENT

Maintenance module is used for electronic journal management, maintenance scheduling and automatic

evaluation of the requests for maintenance on individual pieces of equipment.

A part of MES PHARIS® is a complex management of production equipment and its events. Production equip-

ment can be any technological equipment - injection molding machine, granulate dryer, therms, CNC machine,

and others. The individual states of production equipment are transmitted into operational journal automatically,

or they are entered manually.

The system PHARIS® automatically monitors the scheduled requirements for maintenance, automatically evalu-

ates the conditions for maintenance requirements and notifies the operators accordingly (e-mail, internal report

MES PHARIS®, text message).

MES PHARIS® provides functionalities for monitoring and evaluation of the maintenance process. Individual

pieces of equipment and workplaces can be sorted into user defined groups in the Models of maintenance. The

Model of maintenance is the user filter over equipment that is included in maintenance.

Maintenance Module Options:

■ Management of production equipment,

hierarchical classification of machines

and workplaces, creation of one´s own

models of maintenance.■ Logical division of equipment into groups

according to types of equipment.

■ Planning of calibration schedule, mainte-

nance, setting-up.

■ Automatic retrieval of cycles, operating

hours.

■ The possibility of operational look into

the history of the equipment.

■ File attachments (instructions manual,

setting sheet, calibration sheet, data

sheet, installation photographs,

diagrams, etc.) can be linked to each

piece of production equipment.

■ Automatic notification to the selected

user about the planned event or alarm

(via email, text message, client) in defined

time. These events are then recorded and

kept in an electronic operation journal.

■ Using connectivity to the machines for

automatic recording of their status into

an electronic operation journal.

■ Balance of repair costs (total time spent

on maintenance, technician’s time spent

on maintenance, prices ...).

■ Management of methods of operations.

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INJECTION MOLDS MAINTENANCE

Injection molds management module of MES PHARIS® offers transparent management of injection molds. This

module uses the communication with injection molding machines and automatically retrieves and stores the

number of cycles for each form. Maintenance of injection molds is included in maintenance management

Module.

Selected functionalities of Injection

molds maintenance module:

■ Management of injection molds.■ Maintenance Scheduling of molds

based on actual cycle count.■ Definition of events for given

molds.■ Online event storing for the mold

(manufacture, setting-up, service).■ Entering text comments for molds.■ Entering the location of the mold

location.■ Management of file attachments

for given molds.

■ Manual correction of cycle count –

total number of cycles or cycles

from the last maintenance.

For easy, effective and operational work with the Injection molds man-

agement, it is advisable to use the mobile operator's terminal. There

are Motorola mobile computers, or PDAs with WiFi and RFID tag reader.

Functionality available within the application for the

mobile client:

■ Specifying the location of the mold.■ Identification of the mold.■ Manual correction of the cycle count for mold.■ Resetting cycles.■ Assigning an RFID tag to the mold.■ Assigning text notes to the mold.

UNIS company is the provider of a complex solution of RFID identification for injection molds. The

proposed solution takes into account high temperatures achieved in injection molds.

The implementation of RFID identification leads to faster and more efficient identification of

molds and minimization of mistakes occurred by manual entering of the code of the mold to the

Injection mold management.

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CAPACITY PLANNING (SHORT-TERM, MEDIUM-TERM)

The planning module of manufactur-

ing execution system PHARIS® works

closely with the available information

in the enterprise information system

ERP and offers the following function-

alities:

■ Display of the plan over resources.

■ Selection of resources for planning.

■ Selection of multiresources for

planning.

■ Selection of job orders for planning.

■ Editing job orders.

■ Setting up plan (plan optimization).

■ Calculation and simulation of

planning.

■ Editing the production plan.

MES PHARIS® offers an optional module for detailed short and medium term capacity planning. The scheduling

module optimizes a calculation based on critical production conditions. With mathematical models it helps to

identify and to simulate the optimal utilization of resources - injection molding machines, or other devices based

on selected criteria.

The calculation of the optimal plan is based on predefined product definitions with defined usual duration for

each operation, the specifications of set-up times, injection molds, necessary materials and packaging units,

injection molding machines and other equipment involved in the production operations, etc.

The system calculates the optimal plan, which is displayed on the timeline and in the calendar including the

individual production operations. System notifies the users about critical points and allows user editing by an

easy method of modification of the plan in graphical interface of the system.

The calculation of the plan usually takes tens of seconds, while during the calculation it with tens of thousands of

variations. After the simulation and generating a set of optimal plans, the planner selects, edits, and accepts the

alternative for the production plan.

The system provides several mechanisms for optimizing the calculation of the production plan from the fast

allocation of resources with input criteria validation to the use of the principle of genetic iterative algorithms for

finding the optimal plan. It is also possible to combine methods of left-sided and right-sided planning depend-

ing on the preferred date of the batch completion.

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SELECTED REFERENCES OF MES PHARIS® USERS

ROBERT BOSCH ČESKÉ BUDĚJOVICE − MOLDING SHOP

MES PHARIS® performs the following tasks:

■ Implementation of the online two-way communication with injection molding machines Engel and

Arburg, data collection.

■ Implementation of technological network.

■ Complex Management of control programs.

■ Management of injection molds.

■ Delivery of mobile Motorola PDA applications (PHARIS® mobile client) with WiFi and RFID readers for

the Injection molds management and central controlled loading control programs into/from the

injection molding machines.

■ Evaluation of Overall Equipment Effectiveness (OEE).

■ Maintenance Management Module.

■ Production visualization.

■ Storing the production parameters of injection molding machines, trends, production parameters,

alarming.

■ Complete implementation of RFID identification of injection molds and machines.

FOREZ, s.r.o. − MOLDING SHOPThe manufacturing execution system PHARIS® provides complex monitoring

and process control of molding shop.

MES PHARIS® performs the following tasks:

■ Two-way communication with KraussMaffei injection molding machines, data collection.

■ Complex management of product definition.

■ Planning module.

■ Control and monitoring of production.

■ Two-way communication between MES PHARIS® and ERP ENTRY.

■ Delivery of operator terminals.

■ Delivery of mobile PDA applications (PHARIS® mobile client) with WiFi and RFID reader for

Injection molds management.

■ Production confirmation.

■ Management of injection molds.

■ Central controlled uploading and downloading of control programs into/from the injection

molding machines.

■ Production visualization of production halls.

■ Evaluation of Overall Equipment Effectiveness (OEE).

■ Complete implementation of RFID identification of injection molds, machines, and users.

UNIS, a.s.

Jundrovská 33

624 00 Brno

Czech Republic

tel.: +420 541 515 603

fax: +420 541 210 361

web: www.pharis.cz www.unis.cz

e-mail: info@pharis.cz