Transcript Wonderware Presentation Template 2007

Using Application Server for
Warehousing and Batching
Barry Clemence
DC Industrial Scanning
Introduction
► Working as a system integrator.
► Have worked with InTouch for many years
InTouch 5.6 on Windows 3.11
InTouch 6.0b on Windows NT4.0.
► Specialise in the MES and Track and Trace projects.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Schaeffler
Schaeffler –
3 Brands Working Together
Total sales: approx. € 8.9 Bn. approx. 66,000 Employees
Automotive
Industrial
Aerospace
Schaeffler –
Automotive Components
Variable
valve timing
Finger follower w.
hydraulic pivot element
Hydraulic
tappet
Clutch
release system
Dual Mass
Flywheel
CVT Components
• Engine and Transmission
Components
SAC
• Clutch and
Transmission
components
Timing chain
drive
Shifting system
Overrunning
alternator pulley
Drawn
needle bearing
• Wheel-Modules
• Transmission
bearings
Strut bearing
Sensor - wheel bearing
Dual Clutch System
dry/wet
Torque Converter
Schaeffler –
Locations in South Africa
►Port Elizabeth (503 employees)
Automotive Headquarters
Luk Manufacturing Plant
INA/FAG Automotive Sales and Warehouse
Automotive Aftermarket Warehouse
Schaeffler SA Central support functions - F&C,HR,IT
►Johannesburg (61 Employees)
Industry operational Headquarters
Industry Warehouse
Automotive Aftermarket Headquarters
►Regional sales representatives (5 Employees)
Cape Town, Durban, Bloemfontein
Schaeffler –
Port Elizabeth
Schaeffler –
Port Elizabeth
Founded: 1963
LuK Purchased: 1987 \ 1992
Production Area: 15,404 m²
Warehouse Area:
Site Area:
3,680 m²
35,806 m²
Employees:
450
R&D:
15
Toolroom:
27
Annual Turnover: Eur 40 mil
Production - 2007:
Facings
2.5 million
Clutch sets 1.1 million
(OE 34%, AM 66%)
Export 51%
Schaeffler –
Port Elizabeth
Disc Assembly
Cover Assembly
Capacity : 1.7 Million
Customer Requirement
► Warehousing application.
► Batch mixing system.
► Automated system.
► Tracking system.
► Reporting system.
Customer Environment –
Not Clean
► Simple and robust operator interface required.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Why Wonderware?
► Previous system:
Wonderware InTouch 6.0
InTrack 3.0
Windows NT4.0 platform
Interfaced to a Siemens S5 PLC.
Running since 1997
► The customer used the same system integrator as before.
► Only problem was that the software and hardware was
now obsolete.
► For us, it was a natural decision to continue using
products from the Wonderware stable.
Topology
Client’s Oracle
Database Server
Application Server
Galaxy Repository
Information Server with
Microsoft Reporting
Services
Application Client
(Receiving PC)
Existing Clients
(Web based reports)
Confidential so cannot show.
Application Client
(Trolley PC)
Stand Alone InTouch
(Laboratory PC)
Datalogic Skorpio
Distributed application with objects running on each client
Client Requirement –
Screen Navigation
► Client required a cost effective soloution
that withstood the dirty environment.
► Easy navigation
► Create a industrial strength button object.
Object –
Button Interface
► We used standard electrical buttons with
separate replaceable contact blocks.
► This was interfaced with a standard
computer serial port.
► A .net object was written inside ArchestrA
to do the interfacing.
Object –
Button Usage
► Operator navigates between the functions.
► Navigates between the required screens.
► Progress to the next step.
► The mouse and keyboard is only used for
administrator functions.
► Demo
Client Requirement –
Interact With Database
► Client required a way to display the data in
a list.
► Operator need to select from the list.
► Achieved using Wonderware SQL Objects.
Object –
SQL Grid
►Demo
Object –
SQL Object
Client Requirement –
Interact With Scanner
► Client required a way to guide the operator.
► Allow operator movement ( i.e. wireless)
► Capture user input (i.e. barcode or keyboard)
► The solution was a wireless hand held
computer with barcode reader.
Object –
Scanner interface
► Connection status
► Heading
► 3 instruction lines
► Scanner enable/disable
► Real time interaction
► Demo
Process Layout –
Receiving
Customer’s System
•Given a unique bar
code per pallet
Scan Bar Code
•Retrieve data for
scanned bar code.
•Operator enters
supplier batch no and
manufacture date
•System calculates
material expiry.
Laboratory
•Sample passed or
failed
Serialize Material
•Each bag given
unique serial number.
•Barcode printed for
each bag
Scan Rack
•Destination rack
scanned.
•System validates
Move Pallet
•Pallet placed in rack
Process Layout –
Make Pre Mix
Select Recipe
•Operator selects recipe.
•System checks
quantities.
Weigh Container
•Empty container
weight verified
against database
weight.
Not Enough Material?
•System decides what
material based on expiry.
•Operator guided by
scanner.
•Bag scanned and moved
Weigh Material:
•Premix into
container
•Weighed against
limits.
Weigh Material
•Weight based on recipe
Move To Temp. Area:
•Containers moved to a
temporary storage area
•Placed on hold.
Mix Material:
•Mixed for x
minutes.
Scan Container
•Each container
has unique bar
code
•Empty container
weight retrieved
from database.
Inspect Material:
•Premix material is
passed or failed.
Move To Rack:
•New rack
scanned.
Process Layout –
Silo Refill
Need a Refill?:
•System decides
what material
based on expiry
date.
•Operator is guided
by the scanner.
Scan A Bag:
•The operator
scans a bag OR
Premix container.
Which Silo:
•The scanner
informs the
operator which silo
to go to.
•Operator moves to
the required silo.
Scan Silo:
•Silo is scanned
•System validates
Process Layout –
Making A Batch
Select Recipe
•Operator selects
recipe.
• System checks
for sufficient stock
level in silo’s.
Verify Mix Bin
•Certain recipes
certain mix bins.
•Mix bin scanned
•System validates.
Trolley Move
•Trolley has PC,
scale and operator.
•Moves to required
silo.
Zero the scale
•System validates
that the scale is
zero.
Weigh Material
•Material between
tolerances.
Weigh Routine –
Process Confidential
► The materials and quantities used is confidential
► As a result, we have censored some screen shots.
► Screens are kept as simple as possible.
► Interfacing is done using just 3 buttons.
Process Layout – Receiving
Weigh Routine –
Cycle Start
Weigh Routine –
Select Recipe
Weigh Routine –
Selected Recipe With Silo Stock
Weigh Routine –
Scan The Required Mix Bin
Weigh RoutineDisplay The Current Recipe
Weigh RoutineInterface To PLC AND Trolley Move
Weigh Routine –
Zero The Scale
Weigh Routine –
Weigh The Material
Weigh Routine –
Weigh The Material
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Benefits / Goals Achieved
► Automatic system
Greatly reduces operator error.
The system guides the operator.
► Warehouse management system
Provides instant current stock levels.
Know where each bag is and how much is left.
Less material loss due to material expiry.
► Easier operation
Wireless scanner prompts.
Screen prompts.
Button interface.
Benefits / Goals Achieved
► Mixing Benefits:
Prevent wrong material being added.
Prevent incorrect amounts being added.
Reduce scrap.
► Traceability:
The ability to trace from supplier raw
material batch to end product.
The ability to trace from end product back to
supplier raw material batch.
► Technology:
Replaced obsolete technology.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Lessons Learned –
Specifications
► We spent plenty of time on the specification.
It is worth the effort.
► We met with IT, Production and Process.
We should have spoken more to “Joe”
Lessons Learned –
Structure
Lessons Learned –
Knowledge / Tools
► We did not deliver the project on time.
► The training was received about 3 years
before the project. It was forgotten.
► There was a version change.
► The .net SQL functions were difficult to use.
► The Wonderware SQL objects were
released months after the project started.
Lessons Learned –
Summary
► Specifications.
► Programmer to meet with Joe if possible.
► Have the tools and the knowledge to do the
project.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Summary
► Re engineered an old application to current
technology.
► Based on ArchestrA technology.
► Created customised objects for the clients
requirements.
► Used ArchestrA SQL objects extensively.
End
► Thank you for attending.
► Any questions or comments?