Inventory management with WEB-VV

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Contents

Simple inventory monitoring with WEB-VV 3

Transparency reduces costs 4

Process optimisation over and beyond company walls 5

Optimal inventory management with WEB-VV 7 6

How WEB-VV works 8

Hosting WEB-VV 10

Application example: Mill – Bakery 12

Application example: Tank farm 14

Application example: Mobile transport container 16

The on-site components 18

plics® – the idea with a future 20

PLICSCOM and PACTware 22

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Simple inventory monitoring with WEB-VV

On the safe side with VEGA

WEB-VV is the ideal interface between the measuring technology on the one side and the user interface on the other. Measurement readings are unfailingly recorded and made available worldwide in a very short time. The Internet-capable software WEB-VV supplements VEGA level and pressure transmitters with a web portal conceived for the most modern Internet technologies. VEGA holds a broad range of measurement technologies and mea-suring principles ready for application to level measure-ment of bulk solids and liquids of every kind.

WEB-VV has all data under control

Convenient visualisation, long-term data storage, extensive notification functions and interfaces to common merchan-dise management systems – that is WEB-VV. The soft-ware, based on modern web technologies, enables simple and reliable monitoring of all tank data both locally in the company network as well as worldwide over the Internet. This extends from visualisation of levels for simple manual stock control to completely automatic recording and processing of inventory data in merchandise planning and control systems (ERP systems). Perfect interaction with the on-site measurement technology is the basis for its opera-tion.

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Classic approach: high personnel and administrative costs

The classic approach generates higher costs

With the classic approach for procurement of materi-als, both customer and supplier must keep cost-inten-sive stocks where necessary: the customer, to ensure that his production is not endangered; the supplier, to always be in a position to deliver what is required. This generates higher warehousing costs because too much capital is tied up in that area. The concerned companies also incur considerably higher administra-tive and personnel costs, since many processes are involved, many of which have to be carried out manu-ally. And despite all this effort, it is still difficult for the supplier to plan exactly and effectively on the basis of these data.

Traditional supply control

How does a supplier learn of his customer’s needs? The traditional approach always starts out with an enquiry from the customer, which as a rule initiates an order. For this, the processor, i.e. buyer, must gather information on the levels of his stock and inform the supplier of his requirements correctly and, most impor-tantly, in good time. This might occur at the ideal time, but could also occur unnecessarily early or so late that an expensive special delivery is required or production is interrupted. Here, the supplier is dependent on the information from his customer and can only react.

Transparency reduces costs

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Optimised logistics through direct dovetailing of demand and supply

VMI – Advantages for everyone involved

Advantages for the buyerAlways sufficient stocks for smooth production ■No time and effort spent determining stock levels ■and ordering replenishmentsReduced procurement and storage costs ■Free capital for investments ■

Advantages for the supplierOptimised transport logistics through long-term ■planning Efficient consolidation of transport routes ■“Real time” overview and long-term records allow ■more reliable demand forecastsOptimal scheduling and production planning ■

VMI – The supplier takes care of the logistics

In the VMI strategy (Vendor Managed Inventory) the supplier takes over the monitoring of his customer’s inventory and autonomously controls the delivery of replenishments. Product scheduling is thus offered as a service by the supplier. Depending on what is agreed on, the product can belong to either the customer or the supplier. The partner companies make explicit arrangements beforehand which, among other things, ensure that “sensitive” data do not fall into the wrong hands or that the supplier does not deliver more than is needed.

Exactly these requirements are fulfilled by WEB-VV. VEGA relies on state-of-the-art security technology and a sophisticated access authorization concept. A user strategy that allocates hierarchised user rights via user roles ensures that only authorized persons on both the supplier and the customer side have access to data.

Process optimisation over and beyond company walls

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WEB-VV provides supply and demand information for manufacturers and buyers

Optimal inventory management with WEB-VV

Easy access to inventory data

WEB-VV enables inventory supervision and management directly in the office without expensive software installations on company PCs. Internet or Intranet access with a stan-dard browser is all that’s needed. The web server powering WEB-VV processes the stock data graphically as tables, bar charts and history presentations. Stock limit values are actively monitored and reported via event-controlled mes-sages, e.g. e-mails or SMSs. Inventory data can of course also be sent on a time-controlled basis.

Measurement data via Intranet and/or Internet

The VEGA level measurement technology used in the tanks and silos is connected via signal conditioning instruments either to the telephone network or to an Ethernet network. The on-site signal conditioning instruments make contact with WEB-VV and deliver the corresponding measured values to the software. Technically speaking, an Internet connection, or better, a TCP/IP connection, is always made, independent of whether the communication is carried out via telephone connection (analogue, ISDN, GSM) or via an existing company network (e.g. an Intranet).

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Simple processing of inventory data

WEB-VV visualises levels both for the simple, manual inventory management by the user and for the automatic processing of inventory data in merchandise planning and control systems. ERP (Enterprise Resource Planning) systems can access the inventory data via standard interfaces with common data formats like ASCII, CSV, XML, HTML.

Depending on the functionality of the logistics software, orders, deliveries and billings can be initiated where required.

Diverse application possibilities

WEB-VV is just as suitable for local visualization of a tank depot in the company network as it is for worldwide record-ing of stock data. For local application, an already existing infrastructure in the form of an own network is first choice for measured data transmission. To expand the WEB-VV system for remote transmission of data, a standard modem in the tank depot is, in principle, all that’s needed.

WEB-VV – the basis for remote enquiry and VMI

The VEGA services covering the requirements of inventory control and VMI extend from the installation of the software on customer platforms; to support of its integration into the control and planning system; to completely taking over the job of retrieving and processing the stock data and making them available on the VEGA server. The integration into plan-ning and control systems is quite straightforward because WEB-VV offers standard interfaces like OPC, FTP and VPN as well as e-mail and standard data formats like ASCII, CSV, XML, HTML.

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Use the demo access to WEB-VV and get a direct impression of the WEB-VV portal.Enter the URL https://web-vv.vega.com and then click on the button “Visit demo plant”.

Self-monitoring, notification and diagnosis

If disturbances occur in the measurement chain or on the transmission link, they are outputted visually in every presentation window. Details of the respective events are recorded in message lists. Via the adjustment tool PACTware, a more exact analysis and diagnosis reach-ing down to the individual sensor can be carried out from a central location.

Interfaces to application programs and ERP systems

An OPC interface connects WEB-VV with other applica-tion programs, e.g. ERP systems like SAP. Additional common interfaces for machine-to-machine commu-nication can be easily realised thanks to the modular concept of WEB-VV. Data exchange via current data formats such as text, ASCII, CSV, XML is also provided for.

User management and user roles

Every user is given access by the WEB-VV administra-tor to all inventory data relevant for him, however, he cannot make any changes. Only a power user can make certain changes and also set up access rights for additional users. Every user receives a password and a user name for access to the WEB-VV portal. Like in online banking, the system sets up a secure connection with HTTPS.

Managing the instrument network

Master data sheets are drawn up for every instru-ment and every instrument constellation. This device management guarantees a smooth and reliable data exchange with the on-site measuring instruments.

Processing the inventory data

The transmitted data are stamped with the date and time in the WEB-VV database and permanently archived. Transferred are both the actual physical measured values as well as the linearised and scaled values that have already been processed into percent, volume and weight information by the signal condition-ing instrument.

How WEB-VV works

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History Chart

Measured values with time and date information ■Available as an Excel file for further processing ■Available in PDF format for archiving ■

History graphic

Inventory data from the past as trend line or hydrograph ■User-definable display periods ■Graphic presentation individually adaptable ■

Bar chart graphic

Up to 8 measured values in one view ■User-definable order of measured values, number ■of measured values per diagram, bar colour, coor-dinate axes markings, colour change when alarm thresholds are reached and colour of fault signalling Several bar charts for different stock data ■

Visual formatting for the user

Only a standard browser is needed for visualization of the inventory data. The current stocks can be visualised in the form of bar charts and as a table. History data can be represented as a trend line or as a hydrograph spanning adjustable time periods and also as a table.

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WEB-VV for worldwide inventory control

Well prepared: central hosting at VEGA

The modern data processing centre and associated infrastructure at VEGA provide the ideal conditions for operating the WEB-VV portal. Redundant, continuously available broadband Internet access ensures that no bottlenecks arise in the data exchange. A highly quali-fied IT staff makes sure that operation is smooth and uninterrupted, guaranteeing availability 24 hours a day, 365 days a year. A round-the-clock hotline guarantees that questions are answered quickly.

Hosting WEB-VV on site at a company location

If a company has its own data processing centre, a logical solution is to install WEB-VV right there. The system administration is then carried out by the customer and the complete database with inventory data is located on his system. To make the setup of an inventory management system easier, VEGA has established a support centre: it provides extensive support for the installation of the software and the integration and transfer of inventory data into an existing merchandise management system.

Hosting WEB-VV

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Cost transparency through clear structuring

A substantial advantage of the WEB-VV portal at VEGA is the clearly arranged structure and the associated cost transparency. The customer is billed a single installation flat rate for the setting up of inventory accounts on the WEB-VV server. For normal operation we distinguish between the maintenance costs of the WEB-VV server and the connec-tion costs, i.e. between the measurement technology and the WEB-VV server. Through clear structuring of the regular maintenance costs, the customer gets a quick overview of the costs arising from his application. The connection costs are dependent on the connection technology that is chosen.

The advantages of hosting at VEGA

If the customer decides to use the WEB-VV portal at VEGA, he only needs Internet access in his familiar Windows environment to access his stock data. The WEB-VV server supports the most popular browser types. Hosting WEB-VV in the computer centre at VEGA saves investments in IT infrastructure. The work that is otherwise involved in installing and caring for the software as well as administering the system is also dispensed with. WEB-VV operates with proven, state-of-the-art Internet technologies. Problems that can arise when the customer changes the operating system or moves to other hardware platforms are thus a thing of the past. Inventory management can be carried on without interruption.

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Mill (supplier)

Increasing profitability

There is considerable potential for optimisation, and there-fore cost-cutting, in storage and logistics processes. This becomes especially obvious in the example of transporting flour from the mill to the bakery. Such optimisations are, how-ever, also transferable to many other products and lines of business. Environmental taxes, like tolls or heavy-load traffic taxes, as well as rapidly rising fuel prices bring about higher and higher transport costs. Smaller production lot sizes, greater product variety, short-term orders, product trace-ability and rising energy costs in production all represent additional challenges. The central compilation of customer inventory data by the supplier via WEB-VV makes far more efficient logistics possible and offers considerable advan-tages for both sides.

Application example: Mill – Bakery

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Bakery (customer)

Reliable inventory data acquisition

VEGA level measuring and signal conditioning instruments for communication are installed in the flour silos of the bakeries. Experience has shown a telephone or GSM/GPRS connec-tion to be the simplest form of communication with WEB-VV. The data transmission cycle for time and event-controlled data transmissions to WEB-VV is determined by consumption and consumption fluctuations, however, it can be changed and adapted any time with the help of remote parameterisa-tion. The signal conditioning instruments are also able to send, in addition to regular inventory data, a notification that a minimum stock level has been reached.

The mill looks after the bakery’s flour silos

When the mill takes over management of stocks in the flour silos of the bakeries, both supplier and customer profit. Thanks to the central data acquisition by WEB-VV, bakeries can forget the work of managing the flour stocks as well as the administrative burden of scheduling and ordering. At the same time, continuous production is assured through appro-priate delivery agreements. In turn, the transparent inventory and consumption information allows the supplier to optimally control and exploit his transport capacities and plan efficient routing.

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With WEB-VV, company-owned platforms can be used for inventory data evaluation

Direct access to inventory data

For larger tank farms, operating the software WEB-VV on company-owned platforms is a solution that readily presents itself. The already existing infrastructure of com-pany network and servers in conjunction with VEGA level measurement technology enables simple inventory data acquisition: the Ethernet interfaces of the signal condi-tioning instruments are quickly and easily integrated into the company network with standard technology. Every authorised person can access the stock information via WEB-VV. Distant or difficult-to-access measurement points can be very simply incorporated into this concept with the wireless communication system PLICSRADIO.

Working flexibly and economically

Production, storage and logistics systems that lead to considerable improvements in the parameters cost, time and quality are the future of tank farms. Inventory data processing with WEB-VV provides the basis for streamlined production control and logistics that allow companies to operate more flexibly and at the same time more economi-cally. With the help of VEGA processing systems, the levels of the tanks are collected centrally by WEB-VV. These data are then made available to all authorised persons within the company for further planning of processes.

Application example: Tank farm

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Hosting at VEGA

The central data acquisition with WEB-VV and, thus the hosting, can also be carried out completely on VEGA servers. The measured values from the signal conditioning instruments are transmitted via the Internet to the central WEB-VV server at VEGA. Here, a modern computer centre stands ready round-the-clock on every day of the year to ensure smooth operation. Hosting at VEGA saves on-site investments; VEGA also takes care of the servicing and administration of the system. Measured values can be accessed conveniently and easily via the Internet by means of a standard Internet browser – and thus from practically anywhere in the world.

Further processing of inventory data in other systems

When measurement readings are coupled to the system via the Ethernet, parallel transmission of inventory data to control and guidance systems is particularly easy to carry out. This is because VEGA processing systems have at their disposal corresponding Ethernet interfaces with the com-mon protocol standards. This saves additional bus structures because even for diagnosis and parameterisation tasks, the existing network topology can be used. Connecting to merchandise management systems is also easy through WEB-VV using OPC services.

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With WEB-VV, the routes of transport vehicles can be optimised via history data

Mobile transport containers become transparent

On the basis of WEB-VV history data, the requirements of the respective building sites can be determined quite precisely. If the levels of the silos are known, the right quantities can be delivered at the right time – this allows routes to be optimised. If no changes are reported over some length of time, the silos can be picked up from the building sites a good deal earlier. Through this accelera-tion of silo circulation, investments in silos are considerably reduced.

Mobile silos and level data acquisition

Everywhere where handling is simplified by using loose bulk goods instead of packaged products, processing industries are relying more and more on mobile containers. Especially in the building industry, transporting dry mortar, plaster and floor screed in mobile silos on special silo vehicles makes sense. To be able to plan the right delivery quantities for the right time, and deploy vehicles and drivers efficiently, exact level information from the building site is indispensa-ble. From the viewpoint of data acquisition, mobile silos are therefore treated simply like stationary silos. This is where WEB-VV, together with VEGA measurement technology, provides ideal solutions.

Application example: Mobile transport container

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Level measurement technology for transport silos

An especially robust measurement technology is required for mobile silos because of the rough treatment it gets already during silo transport. First choice for mobile transmission of levels to WEB-VV is GSM or GPRS technology. Another special feature of level measurement in mobile silos is the problem of energy supply to the measurement setup and the communication units. This makes necessary a measurement and transmission technology that maintains data transmis-sion over longer periods of time without external energy. Solutions from VEGA attain a transmission period of several years through effective energy management. Another advan-tage is that a simple, cost-effective installation of VEGA measurement technology on the silo requires only very few units.

Further applications with mobile measure-ment points

There are many other possible applications for battery- powered measurement technology and measurement data transmission via GSM. Because it delivers continuous, up-to-date level information, WEB-VV is especially advantageous for, among other things, gauging river levels, measuring levels in waste oil collection points of recycling companies and level measurement in deep wells.

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The on-site components

The right solution for every application

For data enquiry of individual tanks, there are the VEGAMET signal conditioning instruments, which can also take over simple control functions. If the job only requires collecting measured values and passing them on centrally, the data collector VEGASCAN is the right solution. In large systems the instruments can be combined and interconnected in any way depending on the requirements.

Wireless extension with radio link

If measurement points difficult to reach by cable have to be integrated into the system, then PLICSRADIO is the right solution. With it, level data can be transmitted wirelessly up to a distance of 500 metres. With PLICSRADIO C62, also these measurement points can be integrated into larger structures without difficulty.

Remote enquiry made easy

For connection of level sensors to the telephone network or to an Ethernet network there are a number of processing units with different interfaces available. The RS 232 interface serves primarily as a simple connection to an analogue, ISDN or GSM modem for worldwide inventory data retrieval. Signal conditioning instruments with an Ethernet interface can be interconnected with current network technologies like hubs or switches and connected directly to an existing PC network. The Ethernet interface also serves to connect sev-eral instruments via router to a mutual telephone connection.

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For huge plants

Combination of several signal ■conditioning instruments and power supply units (e.g VEGAMET 624, VEGAMET 625, VEGASCAN 693, PLICSRADIO C62)For more than 15 levels ■For complex structures ■Connection to Internet via router, also ■via GSM and GPRS

For medium-sized inventories

VEGASCAN 693 data logger ■Digital HART transmission ■

techniqueUp to 15 levels ■All sensors can be connected ■in parallel via a two-wire cable In Ex-areas up to 5 sensors can be ■connected

The “small” solution

VEGAMET 624 signal conditioning ■instrument and power supply unit for a 4 … 20-mA sensorVEGAMET 625 signal conditioning ■instrument and power supply unit for two 4 … 20-mA sensorsUp to two levels ■Switching outputs for easy control ■tasks (pump, valve, signalling)Current outputs for PLC or ■level indication Instruments of other manufacturers or ■other transmitters (e.g. temperature) can be integrated

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plics® – the idea with a future

Lifetime

ServiceOperation

SetupMounting

OrderSelection

Costs

Continuously low costs for a lifetime

Easy is better

plics® makes everything easier – from selecting to ordering, right through to setup, maintenance and service. In this modular system VEGA combines exactly the performance features you need to solve the measurement problem – both technically and economically. Whoever has once worked with plics® can apply the setup, wiring and adjustment concept to any other application, and even to other measur- ing principles. Because of the broad range of the technology and the "easy choose – easy use" concept, plics® brings an element of security and dependability for every application.

plics® – ideal solution for all applications

plics® offers the prerequisites for maximum product qual-ity through reliable and accurate measured values. plics® instruments also have the comprehensive certifications, instrument and material certificates required for responsible handling of all kinds of media.

Easier for user and planner

plics® offers unlimited selection and combination of sensors, process fittings, electronics and housings. For the engineer- ing department, this translates into easy, straigthforward planning and instrument selection. For the plant builder, it means short delivery time, uncomplicated connection and quick setup, and for the user, operational reliability, simplified maintainance and reduced inventory costs.

Other measuringinstruments

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Housings

Pressure

HydrostaticProcess pressure

Switching

CapacitiveVibrationVibration

Level measurement

Guided Microwave

UltrasonicRadar

Explosionprotection

Ship approvals

Hygienic standards

SIL, overfill protection

SanitaryFlangeThread

Level switchFoundationFieldbus

Profibus PA4 ... 20 mA/HART

Aluminium (2 chamber)

AluminiumStainless steelPlastic

PLICSCOM

Sensor types

Approvals

Process fittings

Electronics

Indicating and adjustment module

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PLICSCOM and PACTware

Setup and indication with PLICSCOM

The PLICSCOM, with its entirely new adjustment philosophy, offers extensive practical convenience. To allow easy use from any position, it can be mounted in the housing in four positions 90° apart. Indication and adjustment are carried out via four plastic foil keys and a large, concise, graphics-capable and illuminated dot matrix display. The adjustment menu with selectable language is clearly structured and allows playfully easy setup. After setup, the PLICSCOM serves as indicating instrument: level and pressure values are viewed directly through the screw-on lid with window insert in the desired unit and presentation style.

Diagnosis and service with PLICSCOM

In the unlikely event of failure, the cause is displayed on the PLICSCOM. In addition, instrument data such as measuring range, process fitting, seal material as well as recorded proc-ess data of level, pressure and temperature can be called up. In conjunction with suitable instruments, the PLICSCOM can also display echo curves. When a sensor is replaced, PLICSCOM ensures that the measurement loop is quickly up and running again – all sensor data is saved with a quick keystroke and transferred later to the replace-ment sensor.

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Asset management with PACTware

Because of PACTware's plant-wide failure recognition and evaluation capability, it is an ideal decision platform for main-tenance measures. It makes the data for all communication components and field devices comprehensively and centrally available. After the status of field instruments and other plant components has been recognised and evaluated, proactive maintenance, for example, can be carried out. This in turn increases plant availability and ensures smooth, trouble-free production.

Configuration and parameter adjustment with PACTware

PACTware is the innovative configuration software for all field instruments, from mobile computer to process control centre. As a free of charge and manufacturer-independent software, PACTware supplies the Fieldbus independent interface for data exchange between all current protocols of commu-nication capable field devices, e.g. HART and Fieldbus. In practice this means: all plics® instruments can be set up and operated via one single program with an all-emcompassing user interface.

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VEGA Grieshaber KGAm Hohenstein 11377761 SchiltachGermanyPhone +49 7836 50-0Fax +49 7836 50-201E-mail info@de.vega.comwww.vega.com