Black Box

Environment

Over 323.839 lines or source code

Over 1.000 unit files

Debug lifecycle since 1995

General concepts

& Modules

bbeproject1995@libero.it

Fax ref:(Italy) 02 700432967

BBE in a factory -Real Cases

The simplest BlackBox installation can occupy an only personal computer and so be very cheap.

We now consider three concrete cases.

Case A)

Company of 18 molding machines (of several producing houses) certified injection, working in the motor sector.

The company uses BlackBox installed on 10 personal computers.

IPC server is installed on Pentium III WIN NT 4.0; this computer is directly connected to the 18 machines with 4 different interfaces (corresponding to various communication devices). IPC server directly communicates with most these machines with the controller (PLC) and in other cases with some outside terminals through electric contact (relay).

IPC server real-time tests all the machines of the plant, and makes the data available to all the programs in the net. IPC server registers the changes for event, and the data for turn and job order; IPC executes the sampling for the control of real-time process, on a few measures (temperature, pressure, quotes screw…).

The job orders are sent by IPC on the terminal of the machine. The operator, always from the terminal of the machine, sets up the end of the jobs, the number of defective pieces and the causal of defects.

The server database is installed on a Pentium 4 Windows XP Professional. IPC server registers the "static" data inside the database. LAN is to 100 Mbit.

A PC with Win 95 installed, in the production department, is used to print the labels, through the module "IPC Label". Labels are associated automatically to the current productions.

In the packing department, a PC with Win98 installed is used to load the ready goods, with code bars technology, through the "EnterPoint” application.

In the office programming and quality, A PC, with BBE modules, is used for planning production and to perform quality control.

Job orders are planning through the "IPCProclient.exe" and "Plan View.exe" application. Quality control is made through the module "Pulsar”.

In the commercial office the modules "Plan View", "Analyses", "Tea", and “VideoImpianto" are installed on various computers. Through "Plan View" and "Videoimpianto" is possible to see the situation of the productive plant on real-time, and the implications on the future programming.

Through “Analysis” the researches are made about the tractability, the history and requested reports are created daily/ weekly/ monthly.

Through Tea you can manage orders for customers and suppliers, and also the store.

Case B)

Company of about 30 molding machines, with several processing on the raw material and the printed product (included the assembly); the company is active in various sectors of technology and of commerce.

The company uses BlackBox on 8 computers.

The job orders are sent on the terminal connected to the machine. The operator, always on terminal next to the machine, imposes the end of the jobs; he sets up the number of defective pieces and the causal of defects.

IPC server is real-time connected to 30 machines; through the module “Enterpoint” it acquires information about the secondary manufacturing. Enterpoint is installed on PC in various departments (raw material, mold, product printed control, packing departments).

Through the module “Plan MP”, it is managed raw material preparation and programming, in relation to the real need, shown by the production advancement state.

The exits and returns of mixture are managed directly associated to the job order.

The worker, responsible for the programming, uses IPC Programming and Plan View, while the plant manager uses analysis.

Case C)

Company of about 15 machines uses BlackBox installed on two computers. In this case the programming of the production is not executed, because the company produces for store.

Through IPC Server the company registers all the production data, with a simplified link to the machines.

Through analysis the owner prevalently studies the machinery block reasons and every production block reason.

Through Videoimpianto the company has the real-time data of the production.

Considerations

BlackBox was realized to satisfy various demands as in the three mentioned cases, very different for organization and for use of internal resources.

IPC SERVER

IPC server is the most complex program of the whole system.

For matters of speed and immediate answer to determinate situations, IPC Server keeps structures data, also complex, in memory, and has the priority access to the database.

IPC server engine include four great managers

1) Plant manager

2Job manager

3) Store Manager

4) SPC Manager

1) Plant manager

Plant manager is the general manager and it includes the collection of machines, drivers, events container, decision objects and much more. Plant include adapter for DCOM connections. The plant service is responsible for monitoring and testing the machines connected, through a continuous polling. It keeps the information about all machines. The outside devices (PLC, PC, and interfaces of hardware communication) interact with the through system of the suitable driver. The driver can be built by third parts, and implemented according to the necessities.

Normally the drivers provided with BlackBox are clever.

Like that, the driver itself makes part of the work of communication and interpretation of the data. The driver works as separate process by IPC Server. Therefore the driver can be executed on the same computer of IPC Server, or remote workstation.

It is possible to divide the data communication line; to extremely accelerate the communication managed, by a petition of the driver, with consequent parallel interrogation of several devices. These characteristics make BlackBox able to check business realities, established by a multitude of different hardware devices .

2) Job Manager

This object manages orders job in memory for real-time answer. It provides direct access by Dcom adapter. Most of the operations concerning the job orders take place through this manager. This service has priority on database access. Normally the operation is accomplished inside IPC Server, and it is subsequently up-to-date in the database. The necessity of a service, with its structures in memory, is given by the request for immediate availability of the data, by the real-time system. Also the service dispatches job events to the system and IPC clients. So connected application known the immediate variations of jobs state. For example, when the job is closed into machine, Job manager catch the message, close job and dispatch this event to clients.

3) Store manager

This service provides multi-thread access to database for recorder data, sampled measures and events.

The data are copied immediately in memory, and placed in stack; a parallel thread subsequently processes the stack. This technology allows leaving free IPC Server the first possible, to make other tasks in "real time".

4) SPC Manager

It elaborates on line-sampled measures, using tolerance control, and statistical control charts and index capability. The degree of complexity of the operation deserves a specific service.

The picture below shows the class structures where these managers are implemented.

Principal IPC Functionality Server

Management real-time data

DCOM Driver technology

Polling real-time plant machines

Sending data configuration and job orders to terminal machines

Physical state management on machine

Logical state management on machine

Production advancement management

Management discard pieces and recoveries of manufacturing

Defective Machine management

Cycle time management

Process control

Measure sampling

Event recording

Sheet storing

Management softly intern of programming

The picture below shows eight real time control charts.

IPC LOADER

Ipc Loader is a separate “exe” application developed with DCOM technology. Normally it is executed in the same computer of IPC Server.

Ipc Loader provides data event communication to all clients. It also provides a service-logon and logoff. Client makes connection by socket TCP-IP or DCOM mode.

The events dispatches by IPC server is received by IPC Loader that provides resend to all clients. The client can send messages through this service.

IPC Supervisor

IPC supervisor is an IPC Client and it allows showing the state of advancement of the single machine (see in the figure below). It is connected in DCOM mode and shows variations in real-time mode. It can be executed in remote workstations.

Real-time situation:

Link state of machine/device

Physical state of machine (automatic, semiautomatic, manual, standby).

Logical state of the machine (ex. Machine stopped / changing oil…)

Job worker

Data of current Job / working progress state

Next job

Period of theoretical cycle time, last cycle time, average cycle

Elapsed time since job start (grouped by states)

List of discards group by cause

Count zones for mold with more zones/ more marks

Remote control of terminal machine.

VideoImpianto

VideoImpianto (VideoPlant) is an IPC Client. VideoImpianto allows the interaction in the throw of the job orders and the declaration of the production data.

VideoImpianto characteristic is the graphic map which represents the on line plant. The program is characterized from several screened simple and intuitive, that shows the real situation (and of the last period) of the whole productive area.

Establishment map

Immediate indication through colors/symbols of the situation of every single machine

Production average (one hour step)

Production Trend

Video range

IPC Programming

IPC programming is a client of IPC. The production programming can be done to two levels.

In the first level the job orders will be put on the machines with several criteria, for instance the compatibility mold or the cycle compatibility.

The second level considers Plan View application. The two levels integrate in a double vision of the production plan: grid and Gantt (two ways).

The implemented technology is sophisticated, and allows every operation with the two levels/modules on separate computers so as to have a parallel vision of the situation, without changing screen.

The programming of the first level includes several possibilities, between which we mention:

Distribution of the job orders on the various machines.

Virtual swap machine.

Drag and drop

Molds Management

Exclusive "Task affinity” tool to combine multi-job in single process

"Tea processor" tool makes jobs from customers order.

Management resources blocking mode

Terminal machine remote control

Detailed information about job order

Module can be executed on remote workstations

Filter and search commands

Visualization directly to display of the color of the article.

Insertion and manual modification of the data.

Import data from external applications like ERP, MRP.

Provides an easy application for direct data entry

IPC Talk

IPC Talk is an IPC Client.

The module is responsible for verbally communication, relative to the principals’ events, (which concern the system and the plant). The communication is realized through an audio device card.

For instance, a disconnection of a XX machine is communicated with the sentence "Attention! Machine XX disconnected".

You can know the important changes of the plant, without necessarily having to check the screen of the computer. So it is useful for who works near the office, to have under control the advancement state.

IPC SMS

IPC SMS is an IPC Client.

Through the link of a mobile phone to the computer, IPC SMS allows the interaction with the BlackBox real-time system, using the technology of the SMS messages.

You can set up the program to receive a warning verifying about situations particulars, for instance when a machine gets stuck.

Besides, through cellular can ask the machine or plant advancement state.

EnterPoint

EnterPoint is an access point to information about phases of advancement of an order/manufacturing, through a personal computer

EnterPoint is normally installed on a few factory fundamental points, what the raw material preparation zone, the zone of end-line/assembly and the packing zone.

The machines are normally real-time tested, through a device, which continuously questions them on the state of advancement.

But the other manufacturing phases, except particular cases, are characterized by jobs, which cannot to be controlled on line, by a terminal, automatically: for instance, the manual quality control phase.

Through EnterPoint you can insert the data of advancement of these phases, directly in production, and so you have, in the central system, the exact advancement of every auxiliary activity.

EnterPoint puts an easy tool for the operator, who will find suitable only those specifically orders, which are associated to that phase. To the operator will be required only the declaration of its identity, the beginning and the end of the phase (for the calculation of the costs).

Through EnterPoint you can insert defective pieces, the amount of product, or declare the advancement state in percent.

The final phase (closing job order) turns out to be the packing, in a lot of cases.

With the packing, the operator declares the amount packed relative to the open job orders, and he possibly proceeds to the print of label in automatic.

The system offers the visibility of the job orders opened to the operator, and makes the advancement data available: for instance, the warehouseman is able to compare the amount made by the machine with the packed goods, and it’s more simple to know when it’s necessary closing the order.

In such a way, the system finds already loaded the goods, in its respective store (article store or shipment store).

In any cases, the labeling is made in the work center, before the arrival in the store; the bar code is affixed on the product. With the bar code, in phase of final packing, the pieces are directly loaded at store, using a suitable reader for bar code.

The solutions are always various, according to the business reality.

Plan View

Plan View manages the plant calendars and calendars machine in simple and innovative way. The situation of the plant real-time reflects, and it shows the present and future situation of the programming, through several screened.

It manages the production pauses in simplified way.

It prepares plans for equipping.

It produces the print of the jobs to be made, for the head of department.

It calculates the needs of the raw and auxiliary materials instant for instant.

It shows the times of equipping and starting.

Manages the period of equip and period of not equip.

It manages the block of the mold for maintenance.

It allows the simulation of the production.

It accesses the historical production data and the data of the origin order.

It incorporates the datasheet tool.

It completes personalization of the reports.

Plant calendar management.

Calendar holiday’s management.

Calendar management by single machine.

Period calendar management of not equips (ex. night hours).

Management of the pauses for maintenance.

Management of the pauses of not work.

Automatic calculation about period of change mold.

Automatic calculation about period of version change (for the mold).

Automatic calculation about period of changing color (color on molding machine).

Further information about changing mold and version planned.

Preview about defective pieces for change color.

Calculation of the real duration of the job order (without pause).

Management of the impossibility to change mold in determinate period (ex. by night).

Possibilities to fix duration specify for a job order.

Possibilities to fix the beginning of job order in specified moment.

Visualization of the color of the articles/job orders directly to display on the bars of the Gantt.

Visualization of the job orders late on the times of delivery, directly to display, using the bars of the Gantt.

Time visualization of equipping, starting and unrigging directly to display

Change event visualization mold, version and color directly on the Gantt.

Visualization turns holidays, pauses, and days directly on the Gantt.

Job order shifting directly on the Gantt.

Filter and researches about data directly shown on the Gantt.

Print specifies about planning jobs for workers, in every specific department.

Future engagement visualization for machine, customer, product.

Software version special for commercial office and technical office.

Control of the whole execution of an order.

Traceable of an order on estimate, work in progress, and stored data.

Theoretical times and relationship real times.

Continuous updating of the data.

Recalculation for times of execution about job order activates, thanks to real data registered and controlled by IPC Server in real-time.

Personalization of the prints.

Optimization of the work tails with dynamic algorithms of disposition of job orders on the tails in automatic, parameterized.

What IF.

Calculate of the raw and auxiliary material needs.

Analysis

Analysis is an open system for data analysis. Analysis shows all the information concerning the historical production without time limits.

The system furthermore offers a research laboratory, a graphic laboratory and a report laboratory.

Thanks to the various laboratories, it can create custom-made interrogations for data, showing the result through designers or reports, or exporting them in other applications.

The created objects (tables and designers) can be memorized in the repository of the program, to be reused as weekly or monthly research models, to produce, for instance, reports.

Efficiency report plant /machines

Film machine, job order film

Weekly/reports monthly

Complete traceable of the data

Statistical researches

Research laboratory

Graphic laboratory

Report laboratory

Analysis allows the most disparate researches: the number of equipping made in a month, the average times of inter-cicle for the operators, the causal of defective pieces, divided by machine……. or the produced amount, divided for month and compared in the many years….. etc.

After setting up the search criteria, it is possible to memorize the model in a general repository, and to recall it in another moment.

Analysis can make studies also on any database. For instance, Gruppo Q uses it to evaluate the reliability of the data, which the customer asks to import in the BlackBox system.

Pulsar

“Pulsar” is the tool for the sampling of the production and the statistical process control. Pulsar receives the measures charged by the operator through keyboard, or any electronic device with a PC, with its interfaces; measures concern the characteristics of the sampled articles (caliber, telecamera, balances..).

While IPC Server has the control of real-time process, Pulsar manages the samplings on the products off-line.

Normally, the article realized needs a stabilization period, before being checked. The taken samples will be subsequently measured, and placed under statistical control with several tools.

The aim of pulsar is to manage the specifications (articles) and the characteristics (weigh, height, and thickness…), the sampling plans and the studies.

Two are the studies' aims.

The first aim is to check the quality of the product through the control charts, the process indexes, the distributions and the relative designers thank to the statistical theory.

The second aim, not least important, is to certify the lot through a conformity declaration. This declaration normally follows the document of transport of the goods, or it is sent by fax or e-mail.

Other features:

Complete statistical control with production of Charts X, X-R, X-S, Charts for attributes. Normal distribution and histogram of the frequencies.

Calculation of the process capability Cp, Cpk.

Conformity declaration also prints multilingual.

Declaration conformity through sending email.

Studies' recording.

Developed studied especially for certified companies and the motor, medical ant technical sector.

IPC Label

IPC Easy Label

We offer various solutions for the labeling.

The labeling can be made in line, or in the molding department or during the packing phase. In all the cases, the management of the label proposed by the central system, with the relative data, proposes itself like a simple and direct operation by the operator, reducing the human mistakes.

The label can being interns (for internal use), or external (live to the customer): the module uses the technology of the bar code. The system manages the label simple, identical for all the products, or variable labels, according to the article and/or the customer.

We manage the customer's article codes and the pieces for lot, specifically article and customer. The label models are directly modifiable from the user, through a publisher report.

With Easylabel you will be able to manage identical labels for all the products. With IPC Label will be able to manage models of labels that are different, according to the customer to who is sent the goods, or according to the type of article.

IPC TEA

Ipc Tea manages the customers' orders, the advancement state and the creation of the job orders to production (MRP).

The system uses a particular method ("Task Affinity") to direct several job orders on same particular mold (special mold is a mold with several zones, with several versions or a “taken-mold”).

The order management is connected to the real-time production.

Normally the orders are managed by the managerial system in use in the business reality. However in a few cases this form is required to have a real-time vision of the advancement situation, since the form obviously integrates inside the BlackBox system.

IPC Clean

IPC Clean keeps the database clean, keeping the system fast and efficient.

It furthermore manages the creation of off-line consultable historical archives.

For instance, through this tool, you can keep only the last period of data, while the historian is instead preserved of course, far from indiscreet eyes.

Other application is the creation of an archive off-line, consulting externally from the company (for instance on a notebook computer).

Plan MP

Plan MP is a specific Plan View for the raw material management.

It is positioned in raw material preparation department, and it checks the operating plan of the raw materials that must be prepared real-time.

It allows the recording of the data for the prepared mixtures, directly associating them to the work/job order with the immediate unloading from the store.

It manages the mixtures.

Other features:

Gantt of the production programming.

Gantt of the raw materials just used.

Work planning for operators.

Unloading of the raw materials with imputation directed to the job order.

Return of the mixtures.

Loading/unloading of the store raw materials, with association to the directed job order/fight.

Automatic traceable of the raw material lot for job order/product.

IPC MOLD

Ipc Mold is a complete management of the mold.

IPC DATA

IPC Data is the structure of the base of data used by BlackBox; can be independent, or bound to the existing managerial system in the business reality.

The database is very articulate, but generally we succeed in installation phase to automate the importation, and the characteristics on the existing databases.

Management raw materials, mixtures, suppliers

Color, color video representation, suppliers

Part inserts

Molds, exclusive multi-zone molds management.

Work-zones, work-cycles, work-zone-resources

Products and parts

Lifecycle phase management

Bill of material.

Legacy compatibility

Code-tree micro-fields technology

Workers management (operators, workers for equipping…).

Regulation parameter management machine.

Customer management, customer's articles, customer's mold, labels of the customer.

Exclusive complex cycle management for multi-zone molds.

Management of the phases of manufacturing and of cycle of work

Management of the calendars.

Management of the calendars for the calculation of the efficiency.

Link directed with the database of the managerial system.

The database is very wide and covers several possibilities.

BB USER ADMIN

BB User Admin sets up the users of the system, the passwords and rights of every user.

IPC Configurator

This form is normally used by the administrator or by supervisor of the system. It allows setting up the system, the drivers and the base tables.

For instance, on a machine very various park, it can be the necessity of inserting a bitbus (ex. serie Sandretto Mega), one register on parallel door (A1010 microset), one serial 485 (serie Sandretto 7), one serial 485 (BB56) and other devices. This way, using all the doors of the computer is easy. With the driver to given technology, the devices can be connected on others PC remote.

BlackBox System, General Concepts --- page 1 of 18

BBE Analysis

2006-02-22T11:13:22