Basic Tracking Solution - Contel · WIP Processing View of BOM components needed for unit assembly Unit / lot status bar View of serialized unit(s) in queue and available for processing

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900C

Basic Tracking Solution A FactoryTalk® ProductionCentre MES Solution

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Global Solutions Bringing You a World of Experience

Manage projects that span multiple geographies

Standard business & project processes

The right team for your project from our worldwide talent

Based on PMI ® PMBOK®

Certified project managers

Repeatable, measurable, auditable

Risk Management

Global Execution

Helping you exceed your business goals.

80 Countries I 20 Languages I 2800 + employees Single point of contact I Average 13+ Years Experience I

Project Management

Information | Process | Discrete Automation | Power & Motion | Sustainable Production | Technology Migration | Hardware Integration

Combining technology & application knowledge

All major industries

Best practices from multiple industries

Domain Expertise

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

A FactoryTalk® ProductionCentre Pre-engineered MES Solution Work order management

Download work orders or create work orders manually

Lot / unit identification & labeling

WIP tracking for unit / lot traceability

View BOMs / recipes

View work instructions & drawings

Route / process enforcement

Manual or automated data collection

Raw material consumption for genealogy

Material & container labeling

Unit history and order status pre-built reporting .


Pre-engineered with basic MES functions & features

Scalable material tracking MES functionality

Built on FactoryTalk® ProductionCentre as a COTS

(Commercial-Off-The-Shelf) solution

Pre-built & easy to use standard interface

Configurable as a MES solution starter implementation

Rapid implementation by configuration

Reduced risk in pre-engineered solution

Immediate benefit realization & faster payback

.

The Benefits


BTS Architecture Overview

FactoryTalk® ProductionCentre

Order Management

Foundation

Reusable Components Production

Management Reports

Dashboards

Integration Framework


ERP

The Basic Tracking Application Scenario

Finished

Goods

Manual or Automated Control

DO

WN

LO

AD

F

RO

M E

RP

Order

Management #1 WIP

Processing

#N WIP

Processing

UP

LO

AD

P

RO

DU

CT

ION

T

O E

RP

Planning Mtl. / Resource

Planning

Work Order

Manual / scanned WIP identification Automated WIP identification (BC read)

Manual form-based data collection Automated data collection (LiveData)

Process route enforcement Conveyed process enforcement

View orders & status

Create new orders

Release orders for production

Complete orders (fulfillment)

Process enforcement Work instructions

Material consumption BOM verification

Manual data collection Quality inspection

FG quantity produced

Material usage / consumed

Date/time started/ completed

What to make (part, item)

How much to make (quantity)

When promised (due date)

How to make (BOM, recipe)


A FactoryTalk® ProductionCentre Pre-engineered MES Solution

Route = Desktop

Modeled process steps (operations) on route

Start of route

End of route

LETS TAKE A LOOK

using this route


Pre-Built & Easy to Use Standard GUI

Button functions available within module

Expandable space for extending functions

Button modules allow navigation

Expandable space for adding modules

Grid area display Displayed content based upon module


Manage Work Orders

Button functions available within order management module

Active module highlighted

View of available work orders & status

Displayed order item(s) to produce

Displayed lots for order item(s)


Create Work Orders

Work order items

Work order lots

Download work orders from ERP or

manually create work orders


BOM / Recipe

View BOM / recipe anytime during production


Lot & Serialized Unit View & Status

Serialized unit view / status

Lot view / status

Unique serial number automatically generated

Serial numbers can be changed (must be unique)

Enter new SN for unit (comment optional)

.


Label Printing (Unit or Lot)

Label serialized units or identified lots

Printing unit or lot label

Basic label printed format .


WIP Processing

View of BOM components needed for unit assembly

Unit / lot status bar

View of serialized unit(s) in queue and available for processing at operation (assembly)

Note: highlighted unit (RA278) is started and in-process at operation

View of SOP’s, WI’s, Dwg’s, etc.

WIP functions

.


Material Consumption

View of BOM components needed for consumption

Unit based & lot based consumption BOM item verification Alternate BOM item consumption (substitution)

Scan/enter SN for component

Serialized (unit) component consumption

Scan/enter lot ID & quantity

Un-serialized (lot) component consumption .

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. (Confidential – For Internal Use Only) Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

Hold & Release

Place unit on hold

Unit state

Scan/enter hold reason (comment optional)

WIP functions enable & disable based on selected unit disposition

Scan/enter unit release reason (comment optional)

Unit state WIP functions enable & disable based upon changed unit disposition

.


Scrap

Scrap unit

Unit state

Scan/enter scrap reason (comment optional)

Unit state


Data Collection

Collect data automatically from Process Control PLC’s

OR ……

Collect data manually using form-based data collection

Selection of data collection Sets of parameters configured at operation

Data entry fields

Viewable upper/lower limits (configured for data parameter)

Manual data entry

.


Viewing Collected Data

View data collected against a unit / lot

Selection of data collection set parameters for viewing View of data collected for selected unit

(for selected data collection set)


(Confidential – For Internal Use Only) Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

Viewing Unit / Lot History

View selected unit / lot history

View of all unit / lot operations & associated transaction data

(start time complete time stamp, operator, etc.)


Configured Reports

Report module (pre-configured reports) Existing configured reports Reports are configured using SSRS

(SQL server reporting services) Additional reports are configured & added as additional reports (functions)


BTS – Basic Tracking Solution

ORDER

MGMT

10:PROCESS 1 20:PROCESS 2 nn:PROCESS N

PRODUCTION

MGMTManufacturing Process (Manual and/or Automated)

ERP Interface XML File ERP Interface XML FileOrders, BOMs, Parts

Production Data

Business Systems

- View Orders

- Create Order

- ERP Dwnload

- Start

- Complete

- Hold

- Order Status

- Create Unit/Lot

- Start

- Complete

- Hold

- Consume Material

- View SOPs

- View Queue

- Scan/Enter ID

- Start

- Complete

- Hold

- QA Inspect

- QA Test Result

- View Queue

- Scan/Enter ID

- Start

- Complete

- Hold

- Data Collection (A/M)

- View Traveler

- Prod. Status

- WIP Status

- ERP Upload

Unique SN

Barcode Label

Order Status

Unit/Lot History

OPERATIONAL FUNCTIONS

Control System Interface via FactoryTalk LiveData


Rapid Implementation

Requirements Gap Analysis Review functional specification Determine gap vs. customer Constraints to accommodate gap

Design & Configuration Update design specification (if gap) Customer specification customization Configuration (route, op’s, parts, ..) Application testing (internal)

Application Deployment Installation & checkout System acceptance testing Startup Go-live support

.


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Rev 5058-CO900C

Basic Tracking Solution A FactoryTalk® ProductionCentre MES Solution

Documents

Basic Tracking Solution - Contel · WIP Processing View of BOM components needed for unit assembly Unit / lot status bar View of serialized unit(s) in queue and available for processing