Black Box

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IPC SERVER: the corner stone

Figure 1- IPC Server

Figure 2 – Control centre of IPC Server

Figure 3: Machine Supervision

Figure 4 – diagram of control in real time of the temperature mould in a machine

Figure 5 – diagrams of control in real time about some quotas process

Figure 6 – statistical process control charts X, X-R

Figure 7- Normal Distribution and capability process on line

Figure 8 –point of supervision and access point for data in a plant (insert data by keyboard)

Reassumed

IPC Server is the heart of the system and allows the supervision, the collection data and the programming of the production I

The system makes the control of the plant and the supervision; it is able to produce advancement situations and work on the process shares.

The data are taken from the productive plant through the terminals connected to the machines, through remote I/O, or through manual insertions and/or direct links to the moulding machines using the protocol of communication of the builder.

It is possible to create screened custom-made graphics typical of the systems "SCADA".

The data can be picked up in the server database of the system, or exported in several formats.

The technology used for IPC Server guarantees a speed and a continuous flow of data without interruptions. The system is able to serve from few machines up to hundreds of machines through the given job.

DATABASE:

The database is necessary for the recording of the data for job order and the production programming.

In screened figure one of the BBData form which manages the resources of the system.

In many cases these data are already pre-existent on the managerial system.

The database is responsible for managing:

Articles

Cycles of manufacturing

Manufacturing centres

Moulds

Material mixtures

Colouring (master)

Raw materials

Inserts

Suppliers

Manufacturing phases

Operators

Moulding combinations

Customers

PROGRAMMING:

The programming of the production is made to two levels.

1. The basic level allows planning the job orders on the various machines in helped manual way.

The job orders arrive already prepared from IPC Tea or the managerial system: then job orders are sorted on the various moulding machineries.

The compatibility of the job order with the machine is increased the value either the mould or the cycle of work.

2. The second level of the programming allows calculating the theoretical times, and of scheduling the job orders: it is managed by Plan View (we send you again to the specific part).

The plan of the production is seen in figure.

The columns represent the moulding machines of the table, the single cells are the job orders planned on the machine, in chronological order by the high one towards the bass.

The job orders can be shown in several ways, for example by the job order code or through information of its characteristics.

Various symbols are used to show the physical state of available advancement and the resources.

The machines compatible with the same mould are shown on color green; in the lower panel there is detailed information of the selected job order.

The job orders can be manually moved, through the dragging with the mouse, or through a few keys.

The plan of the production is seen in figure: the job orders present the color of the article, which will go in production.

The most varied representations on the situation of the plan exist, through colours and graphic images.

In the submitting figure it is possible to notice the management of the zones of the mould.

The system is able to manage the moulds, which produce in a printed only one various articles; it calculates the possible combinations of several articles to solve molding of more committed on only mould simultaneously.

The tool, which allows doing all this, is called "Task affinity"

The plan of the programming can be shown in the form "dataset" that is database table.

The dataset allows the order of the data in the wished way.

The shown information is customizing and register able.

It is possible to use the dataset for the researches and for the graphic filters.

In submitting figure history of the mould is highlighted print; with a click on the selected job order you can see the history of the mould: you can see all the historical job orders with the same mould, and a statistics by machine of how many times the mould was historically mounted on that machine.

ANALYSIS:film about job order/machine

The registered data can be studied and represented through the module “Analysis”.

Analysis is not a compulsory module, as the system can put the data at disposal to others applicatory, so the company can analyse the data through other software.

However "Analysis" is a very powerful tool and already ready for use.

The "Analysis" application is divided into two childbirths: the first part is very any user can use simple; it concerns the representation of the data of job order and machine.

The second part is more articulate and allows making some complete studies on all the data.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Description of the figures

The figures from the number 1 to the number 6 represent some screened, referable to the "job order film".

Through several information, the "job order film" represents the data associated to the job order, picked up to balance sheet, and registered through software/device hardware of the system.

In figure 1 the data of header of the job order are identified, as the code, the customer, the order reference, dates it of beginning and end. The amounts moulded and packed are furthermore suitable.

The turns of the same job order are listed in the lower panel, with the most representative data as the machines detents, the discards, and the cycle average of the turn.

The realized total amount and the discards appear in figure 2 in form of designer to cake. In the second “cake” you can see the time taken for preparation, production and detent machine. Detent machine is due to inefficiencies as break plots, lack oil, operator lack.

The percents of defective pieces, happened during the production are represented in figure 3.

In figure 4 the detent causes are represented plots.

The data of declarations from keyboard are represented in figure 5, in the various manufacturing phases.

The submitting figure represents the selector of a machine in a determinate period set up by the user.

From the designer it is possible to identify in precise way the changes of the physical state of the machine, as for instance from manual to automatic.

One deduces, for instance from the designer:

The machine begins in manual.

The machine comes in automatic and it remains there for a determinate period.

The machine comes in standby and in semiautomatic and then it becomes again undergone in standby.

In figure a few shares of the moulding process registered during a job order.

ANALYSIS: open studies

Analysis allows the interrogation of data in way opened and simplified.

From the figure to side it is possible to leave to explore the database, choosing what data to study.

In the submitting figure a query appears in BlackBox format.

This type of query allows questioning the database in very simple way: it was specifically realized by Q Group to get the highest power and simplicity.

In the example the number of job orders counts, with finished production, and you realize through the same mold.

The result appears in the following page.

The result obtained by the interrogation is taken back in the table and the figure under the table.

The data are represented in table and can be correspondents to:

Internal graphic laboratory

Internal report laboratory

Copy in the notes

Export in the common formats (Excel, CSV, RTF, Dbase, Paradox …).

Directly send via Email

Register as query model in the repository.

.

In the figure the data are represented in graphic form, thanks to the graphic internal analysis laboratory.

The graphic laboratory allows the complete management of several types of designers, and the personalization of all the graphic elements.

Analysis has the laboratory report in which completely customizing the reports is possible.

The reports can be automatically produced or through the "assistant report".

Exists an advanced management, associated to expert users, in which a language is available of programming of the report itself.

Analysis has the "Repository", a powerful tool where are registered the query, the designers and the reports disguised as models.

After producing a query, or a designer is possible register it as model; the model will be subsequently reused with other data, directly selecting it from the repository.

We suppose to have created an interrogation, which represents the trend of the defective pieces in a month: registering it in the repository and reusing it every month, to extract the data without having to recreate the research from zero will be possible.

In case of complex interrogations, the company directly presents to Gruppo Q the request specification: in many cases Gruppo Q is able to study it in office, and directly send the solution via email.

To the user of the company he stays only to insert the repository interrogation.

PLAN VIEW: the future

Plan View represents the production plan in the future.

Plan View, taken back in the superior figure, calculates and represents the information concerning the plan of the production on the basis of the theoretical times, times of change mould, time starting, time change colour and to the work calendars.

The Gantt designer represents for every line a machine.

The pauses or moments of do not work are represented by the bars blue.

The job orders are represented by the other bars, of different colour according to the state of job order or possible blocked resources. The detail about the selected job order appears on the left (on the Gantt see her like a red bar).

Sailing in the designer in wide freedom is possible.

The red square bar show a change mould, the crosses a color change.

The shown period can change from a thin day to several years.

In the second of side can notice a detail about the operations to be made between a job order and the next one.

In the figure a detail about the plan is seen for a 7 day period.

We highlight the beginning of the job orders and the times of equipping and starting, shown with some rhombuses.

In figure a zoom on a job order change.

The black rhombus shows the phase of dismantling, the rhombus grey light the change phase print and in grey more dark the starting phase.

The red cross which separates the two bars, (that red brick to left and green to right, two job orders), follows a job order which finishes in a period without property-man (night example); so the next job order is automatically planned in a period of equipping.

Through Plan View the production planning can be shown also for customer, as in figure.

In this case can see the job order load in the divided period for customer.

The plan is also show able for other parameters as mould, colour, mixes, articulate.

The system manages the phases of pre-moulding and post moulding.

Normally the system considers the phase of molding or of production on the machine as the most important, because this phase lends her to be real-time checked.

Other phases secondary are also calculated on the basis of the article.

In figure you can see the phases of the article "COP1-VE", from the phase of material preparation to the phase of finish and packing.

PLAN VIEW: Task Compiler

“Task compiler” is present in the most powerful versions of Plan View and Plan View server: it allows the scheduling of the job orders in automatic way.

Task compiler places the job orders according to automatic criteria, on the basis of the options provided to the compiler.

The produced plan can further be modified and applied, or simply pretended.

Task Compiler uses the method "Go Back To End" and implements a technology typical of the compilers of programming languages, with the management of a preprocessor, compiler and optimizer.

Processor

PLAN VIEW: Raw material needs

Plan View includes the calculation of needs of the raw materials, that united with the management of the store, can manage the escorts.

The needs of the raw materials are very exact: it can be calculated with the precision of the time.

The calculation algorithm is very powerful because it is able to bring the needs up to date with the amount produced in the precise instant.

So the needs correspond to the reality, not to an estimate or a simulation.

With Plan View can see the load of resources as in the figure taken back; for instance you see that the mould"Coperchio1" is planned for 140 total days.

Plan View presents the necessary property-men number, now for the moment.

IPC TEA: Orders and store

IPC Tea manages the customers' produced orders finished and the store.

In many cases this operation is made by the managerial system in the factory, and this type of module is not necessary for the input of the data.

It can still be useful also in the case mentioned, because it allows an instantaneous vision to 360 degrees of the situation of the advancement of the order.

EASY LABEL: Simple labels

With EasyLabel is possible printing labels in the productive department, in a simplified way. For the operator is sufficient positioning it on the machine, and pressing a key.

The program is simplified to the maximum, so as to allow the use to the every factory operator.

IPC LABEL: Advanced labels

IPC Label is divided into two childbirths, an administrative part and a simplified part for the operator in production.

With IPC Label are possible managing labels, which change seconds the customer or the code articulate.

It furthermore manages the labels, in which the customer asks to affix his specific code: for the same article manages the relative codes bound to the single customer, included the code draw.

In figure a preview of a label.

The operator can directly produce the label in the moulding department or the packing department, easily.

Is possible affixing a code to bars in productive line, and then the warehouseman makes the load of the goods in stock, with an only reading of the code, through the reader.

The label plan, associates at every article, for the specific customer, a label model detailed and set up, or a generic model.

In such a way it is possible to associate the customer's code and the pieces at an article for lot, normally required by such a customer.

In the plant it is possible to use a form as the suitable one in figure: the operator selects the machine, on which the article is in production, to create the label.

In such a way, a drastic fall of the labelling mistakes is guaranteed.

IPC Mould: Advanced management

The system already foresees a management of the molds.

This form adds further possibilities:

Gantt of the moulds (Plan View is necessary)

Management of the mould cards and the productive way for molds, created by the company for a customer

Management of the maintenances in workshop department.

IPC EnterPoint: manufacturing phases

Pulsar: statistical quality control

“Pulsar” is defined as a SPC type tool: it is a program created to keep the process productive under statistical control, or show, if someone asks it to you, that your process is under statistical control.

Classification of the characteristics

Pulsar arranges archives for the insertion of the characteristics general, offering the possibility of dividing them for groups (dimensional, weigh… ).

Classification of the specifications

Specific and relative cards characteristic of specification.

Pulsar offers the possibility of the duplication of the specification and the insertion to groups of the characteristics.

A specification corresponds, to big lines, to an article class: for every specification is necessary defining the characteristics (es weigh), and set up the properties, the tolerances and the means of sampling

Insertion of the measures

The insertion of the measures is foreseen both through devices as serial (as the caliber connected to the computer) and from keyboard.

The insertion can be made on all the characteristics of the specification, a group of characteristics or a characteristic only one.

The insertion of the measures involves the reference of the samples to the production lot, simply showing the set of data registered by IPC BlackBox.

Studies

The studies can be made on the whole set of data or narrower sets.

The single job orders are studied for the conformity of the product (ready for the shipment); studies are furthermore made on set of wide data for the statistical process control.

The studies can be made for all the characteristics or for a selected group

The studies are registered in the database to be subsequently started again.

The studies understand control charts for variables and attributes, the normal distribution, the histogram of the frequencies, the process capability indexes, the film of the production.

Control charts

The study allows using the x, r and x, s control charts, managed the mistakes, the references to the production and the minutes of not conformity.

There are also control charts for attributes.

Normal distribution, histogram, film of the production

The study shows the normal theoretical and real distribution, and the histogram of the frequencies, in graphic format and tabular format.

Process index calculation

The study allows to calculate the indexes capability Cp and Cpk which show the goodness of the process.

Conformity declaration

The study can be sent to the print of the conformity declaration.

Pulsar is used both the person in charge Check Quality, and the commercial office/shipment.

In this last case, when the document of transport is drawn up, you can print the conformity declaration, without wasting time.

IPC Server is included in BlackBox supervision, in gathered BlackBox data and BlackBox programming. The functionalities at disposal depend on the acquired licence.

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BBE Screen

2006-02-22T11:16:27