SFC Shop Floor Control Systems SEKA GmbH, Rodgau, Germany © SEKA GmbH - 2004 SFC Presentation - 1 -

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 ?


Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


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


InventoryMaterial

Supply Chain

Customer Service


Supplier Service


need more Data

need more Data

need more Data

need more Data

SFC Systems - Why ?


Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service


need good Data

need more

Productivity

need less Waste,

less Reclaims

need more

Reliability

SFC Systems - Why ?


Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service


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


Systems for Productionsince 1999

SEKADataEntry & Qualitysystems since 1989

Interfaces for Data up/down-load

PLC (Plant Control Systems)

SFC Systems - Why ?


Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service


SFC-Production - The Vision


• 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


InventoryMaterial

Supply Chain

Customer Service


Supplier Service



- Production -

SFC-Production - The Environment


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


InventoryMaterial

Supply Chain

Customer Service


Supplier Service


SFC-Production - The Modules



InlineTestunit

InlineTestunit


Database


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


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


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


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


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Packaging

SFC

Packaging• operator interface

• pack, repack, unpack material

• list of all packages and contents

• reprint lables

• fill up partial bundles

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


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)

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


ShippingLaboratoryReceiving Packaging

SFC

Receiving (future)• verify material

• verify Certificate

• sampling for lab

• labeling

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


ShippingLaboratoryReceiving WarehousePackaging

SFC

Warehouse

• currently available for SFC-Converting- Systems only

- 16 -

Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


ShippingLaboratory

CognexAdd-On

Processto Quality


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


ShippingLaboratory

CognexAdd-On

Processto Quality

CoASystem


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

SFC Setup• configure workcenters, lines, shifts, crew,...

• material item master, BOM’s, alternate output

• downtime & waste codes

• configure workcenter functionalities

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


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)

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning

AS/OC System

AS/OC System (internal quality audit system)

• handling out of spec/control material

• routing material and actions

• data reports

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning


QA Egineers

Quality engineers• enter quality standards

• enter sampling plans

• enter customer specific CoA setup

• create CoA

• release material

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning

Analysis


QA Egineers

Data Analysis• flexible access data with ODBC clients

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning

Analysis


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning

InterfacesAnalysis


QA Egineers

WEB Display System Interfaces• eventbased triggered interfaces

• easy integration of existing stored procedures with new interfaces

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service





InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning

InterfacesAnalysis


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

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Human Resource

Finance Invoicing


InventoryMaterial

Supply Chain

Customer Service


Supplier Service


SFC-Production - The Overview



InlineTestunit

InlineTestunit


Database


ServerDatabase

DC DC DC DC


Shipping

Setup

Laboratory

CognexAdd-On

Processto Quality

CoASystem


SFC

FinePlanning

InterfacesAnalysis


QA Egineers

WEB Display

- 29 -

SFC Shop Floor Control Systems SEKA GmbH, Rodgau, Germany © SEKA GmbH - 2004 SFC Presentation - 1 -

Documents

Transcript of SFC Shop Floor Control Systems SEKA GmbH, Rodgau, Germany © SEKA GmbH - 2004 SFC Presentation - 1 -