ProHelp EPM System Administration Manual - Mattec · PDF file · 2007-05-295.1 Voice Alarms and Email Alarms ... Many MIUs have an optional PLC interface ... machines. Advanced Tip

ProHelp® EPM

Production & Process Monitoring System

System Administration Manual For ProHelp® EPM, Release 7.1.0

MANUAL #810-0014

Revision – C

May 19, 2007

ATTENTION You can obtain service support by visiting Mattec’s web site at http://www.mattec.com, by emailing the help desk at [email protected], or by telephone at (800) 966-1301. This manual is intended for advanced users only who have been properly trained how to configure the ProHelp® EPM system.

Copyright © 1983-2007 Mattec Corporation

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TABLE OF CONTENTS 1. Introduction To ProHelp® EPM........................................................................................ 1-3

1.1 Overview ........................................................................................................................ 1-3 1.2 The System Manager ...................................................................................................... 1-4 1.3 System Components ....................................................................................................... 1-5

1.3.1 Server Computer ...................................................................................................... 1-5 1.3.2 Machine Interface Unit (MIU)................................................................................. 1-5 1.3.3 RocketPort Serial Communication Board And Buffer Box..................................... 1-5 1.3.4 Client Computers ..................................................................................................... 1-6

1.4 Shut Down Procedure..................................................................................................... 1-6 2. Basic System Administration............................................................................................. 2-7

2.1 Shift Configuration ......................................................................................................... 2-8 2.2 Shift Exceptions............................................................................................................ 2-12 2.3 Department ................................................................................................................... 2-16 2.4 Channel......................................................................................................................... 2-18 2.5 System Configuration ................................................................................................... 2-23 2.6 Down Codes ................................................................................................................. 2-31 2.7 Scrap Codes .................................................................................................................. 2-37 2.8 Help Codes ................................................................................................................... 2-41 2.9 Machine Preventive Maintenance Codes ..................................................................... 2-44 2.10 Tool Preventive Maintenance Codes......................................................................... 2-46 2.11 Process Parameters.................................................................................................... 2-48 2.12 PCMIU (Cell Controller) Configuration ................................................................... 2-50 2.13 Operator IDs.............................................................................................................. 2-53 2.14 Material Characteristics............................................................................................. 2-56 2.15 Gauge Types.............................................................................................................. 2-58 2.16 Groups ....................................................................................................................... 2-60 2.17 Group Categories....................................................................................................... 2-62

3. Machine Configuration .................................................................................................... 3-63 3.1 Machine Configuration (General Tab) ......................................................................... 3-68 3.2 Machine Configuration (Miscellaneous Tab)............................................................... 3-70 3.3 Machine Configuration (Code Maps Tab).................................................................... 3-71 3.4 Machine Configuration (AIUs Tab) ............................................................................. 3-72 3.5 Machine Configuration (Process Parameters Tab)....................................................... 3-74 3.6 Machine Configuration (Tool Compatibility Tab) ....................................................... 3-77 3.7 Machine Configuration (PM History Tab) ................................................................... 3-77 3.8 Machine Calibration ..................................................................................................... 3-78

4. Real-Time Display Writer................................................................................................ 4-80 4.1 Standard Real-Time Display ........................................................................................ 4-82 4.2 Graphical Plant Floor Display ...................................................................................... 4-88 4.3 Operator Efficiency Display......................................................................................... 4-92 4.4 Cost Display ................................................................................................................. 4-95 4.5 Process Alarm Display ................................................................................................. 4-98

5. Advanced System Administration ................................................................................. 5-101


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5.1 Voice Alarms and Email Alarms................................................................................ 5-101 5.1.1 Acknowledging Alarms ....................................................................................... 5-103 5.1.2 Recording .WAV Files for Voice Alarms............................................................ 5-104 5.1.3 Creating Email Addresses for Email Alarms....................................................... 5-107 5.1.4 Voice and Email Maps......................................................................................... 5-109 5.1.5 Advanced Registry Settings................................................................................. 5-113 5.1.6 Advanced Email Settings (For Microsoft Exchange Server)............................... 5-114 5.1.7 Voice Administrator – Diagnostic Tool............................................................... 5-116

5.2 On-Demand Barcode Printing .................................................................................... 5-120 5.2.1 Print Servers......................................................................................................... 5-121 5.2.2 Printers ................................................................................................................. 5-123 5.2.3 Label Design ........................................................................................................ 5-124 5.2.4 Configuration ....................................................................................................... 5-126 5.2.5 Advanced Registry Settings................................................................................. 5-129

5.3 Automatic Barcode Printing ....................................................................................... 5-130 5.4 System Security .......................................................................................................... 5-133 5.5 Database Backup ........................................................................................................ 5-138 5.6 Purge........................................................................................................................... 5-141 5.7 Loading the Client Software....................................................................................... 5-143

5.7.1 ODBC Data Source.............................................................................................. 5-145 5.7.2 System Names Edit .............................................................................................. 5-147

6. ERP Integration.............................................................................................................. 6-149 6.1 DTR Data Export........................................................................................................ 6-149 6.2 CMS Software Integration.......................................................................................... 6-150 6.3 CMS Event Based (Map)............................................................................................ 6-150


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1. Introduction To ProHelp® EPM The following sections provide a brief introduction to the ProHelp® EPM Production and Process Monitoring System. 1.1 Overview Mattec Corporation's ProHelp® EPM Production and Process Monitoring System is specifically designed for real-time monitoring of all types of production equipment. It is used extensively in the plastics injection molding, extrusion, blow molding, blown film, metal stamping, die casting, printing, painting, and assembly industries. The basis behind the benefits from the ProHelp® EPM system is the rationale that plant managers and operational people will take corrective actions to solve problems on production equipment when they are aware of such problems. ProHelp® EPM is the device to alert employees to problems immediately when the problems occur. Therefore, tremendous savings can occur in increased productivity and decreased scrap parts. The ProHelp® EPM system combines computer hardware, computer software, and Machine Interface Units (MIUs) into an efficient system to provide real-time production and process monitoring, production reports, process alarms, job scheduling, preventive maintenance, and SPC/SQC process and part capability analysis. Floor personnel can make use of the machine-mounted terminals to signal different departments for help, to view production results at the machine site, and to enter downtime reasons or scrap reasons. Production, downtime, and scrap reports can be generated on a shift and daily basis, or the user can generate these reports for extended time periods by specifying a start and end date for the desired report. Job history data is continuously summarized and available for management's review. ProHelp® EPM utilizes the Microsoft Windows Server 2003 operating system and the Microsoft SQL Server 2005 database. Users can connect to the system from most Microsoft Windows operating systems. This manual describes the System Administration functions in ProHelp® EPM. These functions are used to configure ProHelp® EPM in an appropriate manner for your facility.


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1.2 The System Manager The System Manager is a person appointed to be the expert on the ProHelp® EPM system. This person is usually an employee of the Production Control Department, but may be an engineer or project leader. The responsibilities of the System Manager include:

1. Communicate any problems to Mattec’s Customer Service Department.

2. Install new software updates when sent by Mattec’s Customer Service Department.

3. Determine and initialize the installation variables for downtime names, scrap names, shift start and end times, machine numbers, etc.

4. Backup the system’s data to protect against accidents. Daily backup is recommended; weekly backup is mandatory.

5. Utilize the purge function of the system to keep things functioning properly.

6. Configure User IDs and Passwords to permit access to authorized personnel only.

7. Coordinate training for users of the system.

8. Contact the Mattec Customer Service Department to stay abreast of new software and hardware releases.

It is a good idea for the System Manager to visit Mattec once per year to receive additional training on the ProHelp® EPM system.


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1.3 System Components The following sections provide a brief overview of those components that comprise the ProHelp® EPM system. 1.3.1 Server Computer The main ProHelp® EPM computer is referred to as the “server”, “host”, or “monitoring node” computer. This is the only computer that is required to run the ProHelp® EPM system. This computer contains all of the configuration files, data files, and ProHelp® EPM software. The server computer runs Microsoft’s Windows Server 2003 operating system and Microsoft’s SQL Server 2005 database. All MIUs connect to the server computer. All data from MIUs is automatically recorded at the server and can be viewed from other computers in real-time. 1.3.2 Machine Interface Unit (MIU) The Machine Interface Unit (MIU) is an industrial-strength data collection device that has been designed and manufactured by Mattec. It is used to collect production and process information from the manufacturing machine and transmits that data in real-time to the server computer. There are a wide variety of MIUs. Most have a graphical interface that allows the machine operator to view data about the current job and input relevant information (e.g., scrap parts). Many MIUs have both analog and digital inputs. Many MIUs have an optional PLC interface that can be used to extract data directly from supported machine controllers. 1.3.3 RocketPort Serial Communication Board And Buffer Box MIUs are connected to the server computer via RS-485 cabling. Typically, up to 16 MIUs can be daisy-chained together on a single channel. Multiple channels can be used in order to reach the maximum 4,096 MIUs per system. The Buffer Box is a small device that has been designed and manufactured by Mattec. It is usually located within a few feet of the server computer. The Buffer Box converts the RS-485 signal to an RS-232 signal and “conditions” the signal. A channel of MIUs (RS-485) is wired into the Buffer Box on one side. On the other side, the Buffer Box outputs an RS-232 signal that is connected to a serial communication port on the server computer. In most applications, Mattec will have installed a RocketPort Serial Communication Board in the server computer. The RS-232 signal from the Buffer Box is connected to one of the channels on the RocketPort board. The RocketPort board contains multiple communication ports and is a “smart” device that improves the communication process.


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1.3.4 Client Computers Although the server computer is a fully functioning “client” system, most users will want to connect to the system from their own computer. To do so, they will need to have an approved Microsoft operating system loaded on their computer. The System Manager will load the ProHelp® EPM Client software on that computer and configure it to connect to the server computer. The user will be given permissions to access or modify data, as appropriate. These users with then be able to view data for the entire facility in real-time. 1.4 Shut Down Procedure ProHelp® EPM is intended to run 24 hours per day, every day. When it does become necessary to reboot the system, use this procedure. It will bring the system to an orderly shut down.

• Announce to all users that you will be taking the system down. Have all users exit the ProHelp® EPM software.

• Assure that no ProHelp® EPM job changes are under way.

• Assure that a shift change is not in progress.

• Login to the server computer as an authorized user.

• Using the mouse, click on the Microsoft Windows Start Menu and select Shut

Down. The Shut Down Windows dialog box will be displayed.

• Select Shut Down the computer? and press Ok.


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2. Basic System Administration In most cases, the Mattec Customer Service Department will work closely with your System Manager to configure your system properly. The following sections are intended as a reference for the System Manager when it becomes necessary to reconfigure your system.

Caution:

It is a good idea to contact the Mattec Customer Service Department for assistance when you need to modify an area of system configuration with which you are unfamiliar. Settings in the System Configuration application control the behavior of your ProHelp® EPM system, and modifying some settings can cause a permanent loss of data!


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2.1 Shift Configuration A shift is used to define the normal, day-to-day working shift schedule for one or more machines.

Advanced Tip #1

Exceptions to the shift configuration (e.g., holidays) are configured in the Shift Exception configuration screen. Reference Section 2.2 for additional information.

A department (Section 2.3) contains a default shift configuration that, by default, applies to all machines that are assigned to the department. However, individual machines (Section 3) can override the department default shift configuration and specify a machine-specific shift configuration. Each shift configuration has at least one (1) “shift change”, and no more than ten (10) shift changes, per day. The shift configuration is required to “repeat” at least every year (52 weeks). Each day in the shift configuration must account for 24 hours in a day. Each week in the shift configuration must account for 7 days in a week. The most common configuration is a shift configuration that repeats every single week (and is comprised of a single week in the configuration screen.) A maximum of 127 shift configurations can be configured in the system. The end of one shift and the beginning of the next shift may cross into the next day. For example, Monday’s third shift may end on Tuesday morning at 6:00 a.m.

Example #1

Imagine a facility where the machines are scheduled to work three (3) shifts per day, seven (7) days per week. The System Manager would define a shift configuration with 3 “shift changes” per day and a “repeat” pattern of 1 week. Thus, only a single week would be defined in the shift boundary configuration.

The precise working hours for each shift would be entered into the shift configuration. The shift configuration could then be assigned to a specific department and/or specific machines.

In this example, it doesn’t matter whether the machines are scheduled to work on Saturday and/or Sunday. The System Manager defines whether or not a shift is “active” using the shift configuration screen.


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To create a shift configuration, follow these steps:

• Start the System Configuration program. To do this, start the Main Menu and press the Launch System Configuration icon.

• Click the Site menu and select Shift Configuration. The Shift Configuration screen will be displayed.

Shift Configuration

You can view existing shift configurations, edit existing shift configurations, create new shift configurations, and delete existing shift configurations if you have been assigned appropriate security permissions by the System Manager. You can only delete a shift configuration if no machines or departments are using that shift configuration.

Advanced Tip #2

When editing a shift configuration, the current day is highlighted in YELLOW.


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The following fields are available in the Shift configuration screen:

Field Description Description A unique name for the shift configuration. This name will be

displayed in the Machine configuration and Department configuration programs.

# Shifts The number of shifts for the specified day of the week. Name A 2-character name for the shift. Start The start time for the shift for the specified day of the week. End The end time for the shift for the specified day of the week. Working If checked, the specified shift is a working shift. If not checked, the

specified shift is inactive (not working). You can step through the weeks in an existing shift configuration using the Up/Down arrow keys on the right-hand side of the display.

Example #2

Imagine a facility where employees are scheduled in “crews” numbered “A”, “B”, “C”, and “D”. Each crew works twelve hours per day for 3 days, then is off work for 4 days, then works for 4 days, then is off work for 3 days.

For example, crew “A” works the morning shift and crew “C” works the evening shift. Both crews work Sunday, Monday, and Tuesday, then are off Wednesday, Thursday, Friday, and Saturday, then work Sunday, Monday, Tuesday, and Wednesday, then are off Thursday, Friday, and Saturday. Crews “B” and “D” work the opposite of crews “A” and “C”.

In this example, a two-week repeat pattern will be required. The shifts will be named “A”, “B”, “C”, and “D”, as appropriate.

The precise working hours for each shift would be entered into the shift configuration. The shift configuration could then be assigned to a specific department and/or specific machines.

Care should be taken when creating multi-week shift configurations. These types of configurations are generally much more complicated than the simple configuration in example #1. It may be a good idea to contact the Mattec Customer Service Department for assistance when you plan to create a multi-week shift configuration.


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Advanced Tip #3

The Shift Time Utility serves two purposes:

• It can translate an internal “time_t” value into a human-readable date/time string.

• It can assist the user who is creating a multi-week shift boundary configuration by determining where the present week would fall within the multi-week configuration. This was needed in ProHelp® EPM, Release 6.0.0 and earlier.

The Shift Time Utility is no longer needed to determine where the present week would fall within a multi-week shift configuration, because the current day is highlighted in yellow in the shift configuration program.


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2.2 Shift Exceptions Shift exceptions are used to define exceptions to the normal, day-to-day working schedule (shift configuration) that was described in Section 2.1. There are several reasons why you would need to define an exception to the shift configuration, including:

• Holidays.

• Exceptions to the “working” flag for a shift configuration. For example, if you normally work on Saturdays, but will not work this Saturday, the System Manager might create a shift exception.

• Exceptions to the “not working” flag for a shift configuration. For example, if you normally do not work on Sundays, but will work this Sunday, the System Manager might create a shift exception.

The System Manager can create shift exceptions for specific departments and/or specific machines.

Example #1

Imagine that all machines in the department named “Injection Molding” normally work three shifts per day, Monday through Friday, and are off on Saturday and Sunday.

December 25th falls on a Tuesday and the plant will be shut down on that day. You could create a shift exception for December 25th that applies to all machines and all departments and that specifies that they are “not working”.

To configure a shift exception, follow these steps:


• Click the Site menu and select Shift Exception. The Shift Exception configuration screen will be displayed.


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Shift Exception Configuration

You can view existing shift exceptions, edit existing shift exceptions, create new shift exceptions, and delete existing shift exceptions if you have been assigned appropriate security permissions by the System Manager. A shift exception may be applied to the following:

• One department or all departments.

• One machine in the department or all machines in the department.

• A specific shift for the specified day or all shifts for the specified day. Additionally, a shift exception may specify that the machine(s) will be “active” (working) or will be “not active” (not working).


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The following fields are available in the shift exception screen:

Field Description Exception Type This field defines whether the exception applies to the entire plant,

an entire department, or one specific machine. Department When creating a Department Exception, the Department that the

exception applies to must be specified. Machine Number When creating a Machine Exception, the Machine that the

exception applies to must be specified. Date The date that the exception applies to. Entire Day When checked, the exception will apply to all shifts that will occur

on the specified date. When not checked, you must specify a specific shift.

Shift When the Entire Day field is not checked, you must specify a specify shift that the exception applies to.

Shift Exception This field specifies whether the shift exception means that the specified day/shift is going to be “working” or “not working”.

Advanced Tip #1

You are not required to create a shift exception when a machine runs during a shift when the machine would normally be turned off. If the machine is running and creating parts, the MIU will automatically monitor and collect this information.

However, if you run a machine during a shift when the machine is not scheduled to run, the MIU will not record downtime. This is one reason why you might want to create a shift exception.

Also, if you plan to run a machine during a shift when the machine is not scheduled to run, or you plan to turn off a machine during a shift when it should run, the Job Schedule will be slightly inaccurate because it won’t account for planned runtime for the shift. This is another reason to create a shift exception.

Advanced Tip #2

Shift exceptions are “cumulative”. This allows you to easily create exceptions within exceptions, as needed.

For example, imagine that the department named “Injection Department” is normally scheduled to run on Saturday. However, this Saturday, most of the department will shut down. You could create a shift exception that applies to all machines in the department that says the machines will be “not working”.


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However, Machine #1, which is part of the “Injection Department”, is running an important job and will run on Saturday. You could create a second shift exception that applies only to Machine #1 that says Machine #1 will be “working”. This machine exception, which will only apply to Machine #1, will override the department exception.

Advanced Tip #3

Plant Exceptions always apply to the entire day.

Machine Exceptions always apply to one and only one machine and can be applied to the entire day or to a specific shift.

In a typical system, all machines in a department will use the same shift configuration as the department’s shift configuration. However, this is not required, and a machine in a department can have a different shift configuration than the department has.

A Department Exception will apply to all machines in the department that use the same shift configuration that the department uses. If a machine uses a different shift configuration than it’s department, then a Department Exception will not apply to that machine.


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2.3 Department A department is used to group a set of machines together. Every machine must be assigned to one and only one department. Departments are a convenient way of organizing machines on the Real-Time Display, in reports, and elsewhere. A maximum of 99 departments can be defined in the system. A department must be defined before you can create machines. A machine is assigned to a department via the Machine configuration program. Reference Section 3 for additional information. To configure a department, follow these steps:


• Click the Site menu and select Department. The Department configuration screen will be displayed.

Department Configuration

You can view existing departments, edit existing departments, create new departments, and delete existing departments if you have been assigned appropriate security permissions by the System Manager. You can only delete a department if no machines are assigned to that


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department. The following fields are available in the Department configuration screen:

Field Description Name A unique name for the department. This name will be displayed on

the Real-Time Display, in reports, and elsewhere. Description A description for the department. The description will be displayed

on the Real-Time Display, in reports, and elsewhere. Shift Configuration

The default “Shift Configuration” for the machines that will be assigned to this department. This setting can be overridden on a machine-by-machine basis in the Machine configuration program. Reference Sections 2.1 and 3 for additional information

Sound File The name of the sound file (*.WAV) to use for voice alarms. This file is typically located in the “Voice\Names\Dept” directory. Reference Section 5.1 for additional information.


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2.4 Channel MIUs are typically connected to the server computer via RS-485 cabling. Typically, up to 16 MIUs can be daisy-chained together on a single channel. Multiple channels can be used in order to reach the maximum 4,096 MIUs per system. The Buffer Box is a small electronic device that has been designed and manufactured by Mattec. It is usually located with a few feet of the server computer. The Buffer Box converts the RS-485 signal to an RS-232 signal and “conditions” the signal.

ProHelp® EPM Communication Wiring A channel of MIUs (RS-485) is wired into the Buffer Box on one side. On the other side, the Buffer Box outputs an RS-232 signal that is connected to a serial communication port on the server computer. In most applications, Mattec will have installed a RocketPort Serial Communication Board in the server computer for this purpose. The RS-232 signal from the Buffer Box is connected to one of the channels on the RocketPort board. The RocketPort board contains multiple communication ports and is a “smart” device that improves the communication process. For smaller applications, it may be possible to use a communication port that is built-in to the server computer, instead of using a RocketPort board. However, the RocketPort board is used for most applications.

MIU Channel 4

Server

Rocketport Board

Cable P07

Phone Modem

Belden 8777 to MIU’s

Buffer Box

Cables P0, P1, P2, P3

MIU Channel 3

MIU Channel 2

MIU Channel 1

Up to 16 MIUs may be daisy-chained per channel


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A channel must be defined before you can create machines. A machine is assigned to a channel via the Machine configuration program. Reference Section 3 for additional information. A maximum of 255 channels can be defined in the system. Each channel will require an available serial communication port in the server computer. To configure a channel, follow these steps:


• Click the Site menu and select Channel. The Channel configuration screen will be displayed.

Channel Configuration

You can view existing channels, edit existing channels, create new channels, and delete existing channels if you have been assigned appropriate security permissions by the System Manager. You can only delete a channel if no machines are using that channel.


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The following fields are available in the Channel configuration screen:

Field Description Number An internal reference number, 1-255, for the channel. Description A description for the channel that will be seen in the Machine

configuration program. Type This value is always set to “Mattec 422”. Computer This value is the name of the server that the channel is physically

wired in to. This will always be the name of the ProHelp® EPM server computer.

Setup String This value contains initialization information, including the serial communication port that the channel is connected to.

In the example above, “Channel 1” is wired to “COMM1” on a computer named “PROHELP_EPM_SERVER”. Only the number of the serial communication port, not the word “COMM”, is included in the “Setup String”.

Advanced Tip #1

You must restart the “Mattec MIU Service” (e.g., reboot the server computer) after making changes to the channel configuration.

Advanced Tip #2

MIUs from different departments and different styles of MIUs may be configured on the same channel.

Advanced Tip #3

ProHelp® EPM supports only one (1) monitoring node. All MIUs in the system are wired into the same server computer.

Advanced Tip #4

The baud rate that is selected for a channel must correspond to the baud rate that has been selected at the MIUs that are wired in to the channel. If you change the baud rate for a channel without making a corresponding change at the MIUs, the MIUs will be unable to communicate with the server computer.


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Advanced Tip #5

The “Setup String” is used to specify the COMM port and baud rate for this channel. If a baud rate is not specified, a default baud rate of 4800 is used. The fields are entered in the “Setup String” field the form comm[:baud], where comm is the COMM port number and baud is the optional baud rate.

For example, to create a channel for COMM 3 at 4800 baud, you can enter 3 in the “Setup String” field. To create a channel for the same COMM port at 9600 baud, you would enter 3:9600 in the “Setup String” field.

The following baud rates are supported by ProHelp® EPM, provided that they are also supported by all of the MIUs on the channel: 1200 2400 4800 9600 14400 19200 38400 56000 57600 115200 128000 256000

RocketPort Serial Communication Board In most applications, Mattec will have installed a RocketPort Serial Communication Board in the server computer. This board increases the number of serial communication ports that are available for use. To determine the port number for a serial communication port on the RocketPort board (for use in the “Setup String” in the channel configuration screen), follow these steps:

• Click on the Microsoft Windows Start Menu.

• Click on the Programs menu, click on the Comtrol RocketPort RocketModem menu, and select RocketPort Setup.

• The Comtrol RocketPort/RocketModem Setup program will be displayed.


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Comtrol RocketPort/RocketModem Setup Program

The possible serial communication port numbers will be displayed. For example, the ports 11-18 exist, as shown in the above picture. These numbers, without the word “COM”, are used in the “Setup String” in the channel configuration screen.


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2.5 System Configuration The System Configuration screen in the System Configuration program is used to control a variety of settings for your ProHelp® EPM system. To configure the system, follow these steps:


• Click the Site menu and select System Configuration. The System Configuration screen will be displayed.

System Configuration

You can view the existing system configuration and edit the existing system configuration if you have been assigned appropriate security permissions by the System Manager. You can not delete the system configuration.


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The tabs on the display contain fields that control the behavior of different areas of the ProHelp® EPM system. The following fields are available in the System Configuration screen:

Tab Field Description Calculations Parts To Go Calculation This field modifies the value that is displayed in

“Part To Go” fields in reports, on the Real-Time Display, in the Job Schedule, and at MIUs. “Calculated Good” is the default setting. This will cause the system to calculate “Parts To Go” based on the job’s lot size minus good parts made and takes actual percent scrap into account. “Packed Production” will cause the system to calculate “Part To Go” as the job’s lot size minus packed parts. Percent scrap is not taken into account. Because packed parts are usually entered by machine operators and are often not entered in real-time, this setting will cause “Parts To Go” calculations to only be as accurate as the last packed parts entry.

Calculations Scrap Predictor Limit This field minimizes the impact of the actual scrap percent when calculating a job’s forecasted end date. For example, if a job has a standard scrap percent of 5%, and the Scrap Predictor Limit is set to 6, then 11% (5% + 6%) is the maximum actual scrap percent that will be used when calculating the job’s forecasted end date.

Calculations Cycle Time Predictor Limit This field minimizes the impact of fast or slow average cycle times when calculating a job’s forecasted end date. For example, imagine a job has a standard cycle time of 30 seconds and the Cycle Time Predictor Limit is set to 50. The minimum cycle time that would be used when predicting the job’s forecasted end date is 15 seconds (30 - (30 * 50%)) and the maximum cycle time for this calculation is 45 (30 + (30 * 50%)).

Calculations Overall Equipment Effectiveness (OEE) Calculation

This field allows the System Manager to modify the OEE calculation that is displayed in different areas of the system. Valid choices are “Includes Cycle Efficiency” and “Includes Yield Efficiency”. Overall Equipment Effectiveness is an optional feature.

Calculations Schedule From This field specifies whether jobs in the Job Schedule are schedule from the desired start date or the desired end date.


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Tab Field Description CMS Software

Event Based Host URL This field allows you to enter the URL for the CMS Event Based Host. This URL can then be launched from the PCMIU.

CMS Software

Facility Code This field allows you to specify the facility code if you are using CMS. This data will be used in the Event Based interface between ProHelp® EPM and CMS.

CMS Software

Idle Code This field allows you to specify the idle downtime code (e.g., “IDLEINACTV”) for use with the Event Based interface between ProHelp® EPM and CMS.

Field Length The fields on this display are used to modify the

maximum number of records that are displayed in various areas of the system.

MIU MIU Password This field is the universal MIU password that is used

in older MIUs to control access to certain areas of the MIU, including Machine Calibration. Newer MIUs allows user-specific passwords to be specified in the Operator Permissions configuration program if you have purchased the MIU Security option. Reference Section 2.13 for additional information.

MIU Active Cavity Edit Enabled This field controls whether the machine operator can modify the number of active cavities for a job. This field is almost always turned on.

MIU Packed Parts Entry Enabled This field controls whether the machine operator can enter packed parts from the MIU.

MIU Case Entry Enabled This field controls whether the machine operator can enter scrap production from the MIU in the form of parts and cases. When disabled, only scrap parts can be entered. When enabled, the machine operator can enter data as parts or cases. If “Packed Parts Entry Enabled” is enabled, this field also controls whether the machine operator can enter packed production from the MIU in the form of parts and cases. The number of parts per case (for scrap or packed production) is entered in the Part IDs screen in Edit Facilities.

MIU Keypad Enabled This field controls whether the keypad will work on some types of MIUs. This field is almost always turned on.

MIU Job Change Enabled This field controls whether a machine operator can perform “job control” at an MIU. This field is almost always turned on.


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Tab Field Description MIU Job Selection Enabled This field controls whether a machine operator can

select which job should be started when performing a job change at an MIU. This functionality requires a supported MIU. This field is almost always turned on. “Job Change Enabled” must be turned on for this field to be relevant.

MIU MIU EOJ Lot Size Check Enabled

When set, this field prevents users from changing jobs at the MIU unless the running job has reached its lot size.

MIU Automatically Log Out Operators At Shift Change

When set, this field causes all operators who have logged in at an MIU for “Operator Efficiency” or “Operator Tracking” to be automatically logged out at shift change.

MIU Security Timeout This field controls the amount of time after which supported MIUs will disable all operator functionality. This requires the MIU Security option.

MIU Not Down Label This field controls the text that is displayed at an MIU when the machine is running. The default value is “In Prod”.

MIU Downtime Unknown This fields controls which downtime reason is selected when a machine transitions from running to down. When downtime unknown is enabled, the machine will always default into the “Unknown” category of downtime. When downtime unknown is disabled, the machine will return to the last known downtime reason when it goes down. With this setting, the machine will only default into the “Unknown” category if the MIU has been rebooted since the last time a downtime reason was selected.

MIU Reset Elapsed Downtime On Reason Change

This field controls whether the “Time In Status” field on the Real-Time Display is reset to 0 when a machine is currently down and the machine operator selects a new downtime reason.

MIU Base Job This field controls where a “base job” (that is, an entire “family job” or a “bachelor job”) is placed in the machine schedule when a job change occurs and the base job is suspended.

MIU Component Job This field controls where a “component job” (i.e., a “son job”) is placed in the machine schedule when a “job change” occurs and the component job is suspended.


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Tab Field Description MIU Part Qualification Scrap Reason When set, if Part Qualification is enabled in a

Process Sheet and a part is rejected the part will be scrapped for the specified scrap reason.

MIU Kanban Quick Start, Job Number Style

Defines the type of job number that will be created when the user creates and starts a job from the TSMIU using the Kanban Quick Start feature.

Process Sheet Standard Percent Scrap This field controls the default value for “Standard

Percent Scrap” when you create a new Process Sheet in Edit Facilities.

Process Sheet Standard Percent Down This field controls the default value for “Standard Percent Down” when you create a new Process Sheet in Edit Facilities.

Process Sheet Standard Cycle Time This field controls the default value for “Standard Cycle Time” when you create a new Process Sheet in Edit Facilities.

Process Sheet Non-Production Limit This field controls the default value for “Non-Production Limit” when you create a new Process Sheet in Edit Facilities.

Prompt The fields on this display are used to configure the

text associated with various areas of the system. For example, you can change the prompt that is displayed next to the miscellaneous comment fields throughout the system.

ProStat SQC Entry Order This field controls the entry order for Variable SQC

data entry at the MIU. This field controls the default setting for the “Entry Order” flag in the ProStat® Sample Data Edit program. The user can override this value in that program as needed.

ProStat Warning If Out-Of-Specification This value controls the default setting for the “Warning if Out-Of-Specification” flag in the ProStat® Sample Data Edit program. The user can override this setting in that program as needed.

ProStat Require Double Read on GagePort Devices

This setting controls the behavior of the MIU when entering Variable SQC data using a GagePort device. When enabled, this field requires the GagePort device to have two (2) consecutive and identical readings before the reading will be accepted. When disabled, this field accepts any input from the GagePort device.

ProStat Variable SQC Decimal Places This field controls the number of decimal places that are used at the MIU for Variable SQC data entry.


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Tab Field Description ProStat Automatic SPC Interval This field specifies the default frequency for taking

Automatic SPC samples at the MIU. This is a default value only. The actual value that will be used must be specified in the Process Sheet.

ProStat Automatic SPC Subgroup Size This field specifies the default subgroup size for Automatic SPC samples that are taken at the MIU. This is a default value only. The actual value that will be used must be specified in the Process Sheet.

ProStat Samples per Run This field specifies the default number of SPC samples that comprise a “Run” (“Shift” or “Trend”). This is a default value only. The actual value that will be used must be specified in the Process Sheet.

Purge The fields on this display are used to configure the

maximum number of days of historical data to retain for the specified data types when the “Purge” stored procedure is executed. You must manually execute the “Purge” stored procedure or configure the stored procedure to execute automatically before data will be purged from the system. Reference Section 5.6 for additional information.

Real-Time Display

End Of Job Warning This field controls when the “Parts To Go” and “Hours To Go” fields on the Real-Time Display will turn YELLOW. This will alert personnel to a pending job change.

Real-Time Display

End Of Job Alert This field controls when the “Parts To Go” and “Hours To Go” fields on the Real-Time Display will turn RED. This will alert personnel to a pending job change.

Real-Time Display

Downtime Color Codes In the standard system, when a machine is down it is colored YELLOW on the Real-Time Display and the Graphical Plant Floor Display. However, both displays allow the user to select “Use downtime colors for machine fields” to allow the machine to be colored differently, depending on the type of down code that has been selected. This field allows you to associated colors with types of down codes. The Down Code configuration display allows you to associate a down code with a type. Reference Section 2.6 for additional information.

Reports First Line This field controls the first header line that appears

in all reports after the report title. It can be used to identify your facility.


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Tab Field Description Reports Second Line This field controls the second header line that

appears in all reports after the report title. It can be used to identify your facility.

Reports Reporting N/A String This field controls the text that is displayed in reports when something is “not applicable”.

Tool Compatibility

The fields on this display are used to configure the text (descriptions, units, and options) associated with Tool / Machine Compatibility. This data can be seen in the Tool IDs screen of Edit Facilities and the Machine configuration program in System Configuration.

Units Date Format This field controls the display format for date-related

fields in the MIU and most areas of ProHelp® EPM. Units Date Style This field controls the display format for date-related

fields in advanced applications. This setting only applies to some, not all, applications.

Units Date Delimiter This field controls the delimiter for date-related fields in most areas of ProHelp® EPM and should be modified, as appropriate, to match the “Date Format”. This setting does not affect the MIU.

Units Time Amount Format This field controls the display format for time-related fields in most areas of ProHelp® EPM. This setting does not affect the MIU.

Units Time Delimiter This field controls the delimiter for time-related fields in most areas of ProHelp® EPM and should be modified, as appropriate, to match the “Time Amount Format”. This setting does not affect the MIU.

Units Part Weight Units This field controls the display format for part weight data. This field affects the data that is displayed on the screen only. All weight-related data is stored in the database in “grams”.

Units Material Weight Units This field controls the display format for material weight data. This field affects the data that is displayed on the screen only. All weight-related data is stored in the database in “grams”.

Units Weight Per Part This field controls the display format for part weight data.

Units Currency Symbol This field controls the display of currency data. Units Currency Comma This field controls the display of currency data. Units Currency Decimal This field controls the display of currency data. Units Decimal Places This field controls the display of currency data.


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Advanced Tip #1

MIU Security, Overall Equipment Effectiveness (OEE), Preventive Maintenance, Kanban Quick Start, and ProStat® SPC/SQC are optional features. You may purchase these features at any time by contacting the Mattec Sales Department.

Advanced Tip #2

It is a good idea to restart the “Mattec MIU Service” (e.g., reboot the server computer) after making changes to the system configuration to ensure that your changes take effect.

Advanced Tip #3

Fields in the System Configuration screen will be disabled if they are associated with an optional feature and you have not purchased that feature.

Advanced Tip #4

If you have purchased the ProStat® SPC/SQC option, Automatic SPC sampling is enabled in the Process Sheet. Manual SPC, Variable SQC, and Attribute SQC sampling is enabled in the Sample Sheet.

Advanced Tip #5

System Configuration is not a good place for “trial and error”. If you are unfamiliar with a setting in System Configuration, contact the Mattec Customer Service Department before modifying the setting.


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2.6 Down Codes The System Manager can define up to 10,000 down codes for the entire system. Down codes are then assigned to a down map that can then be assigned to a specific machine. Each down map can contain up to 191 down codes, depending on the MIU type. To configure a down code, follow these steps:


• Click the Site menu, click on the Codes menu, and select Down. The Down Codes configuration screen will be displayed.

Down Codes Configuration

You can view existing down codes, edit existing down codes, create new down codes, and delete existing down codes if you have been assigned appropriate security permissions by the System Manager. You can not delete a down code if the down code is assigned to a down map. If you delete a down code, you will lose all production history that has been collected for that down code.


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The following fields are available in the Down Codes configuration screen:

Field Description Down Code A unique identifier for this down code. Description A description for the down code. Optional Color In the standard system, when a machine is down it is colored

YELLOW on the Real-Time Display and the Graphical Plant Floor Display. However, both displays allow the user to select “Use downtime colors for machine fields” to allow the machine to be colored differently, depending on the value of this field. The types of downtime and the associated colors are configured in the System Configuration display. Reference Section 2.5 for additional information.

Sound File If Voice Enabled is set, this is the name of the sound file (*.WAV) to use for voice alarms. This file is typically located in the “Voice\Names\Down” directory. Reference Section 5.1 for additional information.

Voice Enabled Set this value to enable the voice alarming for this specific downtime reason. Disable this value to disable voice alarming for this specific downtime reason. You must also configure the Voice Alarm option.

Email Enabled Set this value to enable email alarming for this specific downtime reason. Disable this value to disable voice alarming for this specific downtime reason. You must also configure the Email Alarm option.

Reference Section 5.1 for additional information about the Voice Alarm option and the Email Alarm option. When a machine is down, the Job Number and Machine Number fields on the Real-Time Display will be colored YELLOW.

Advanced Tip #1

The down code where “Number” equals 1 is a special reason and can not be deleted. This code represents “downtime unknown” and is the down code that is selected automatically when the MIU first goes down, provided that the “downtime unknown” feature is turned on in System Configuration. Reference Section 2.5 for additional information.


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Down Map A down map is a subset of the system-wide down codes. A down map must be defined before you can create machines. A down map is assigned to a machine via the Machine configuration program. It is common for all machines in a department to specify the same down map, although this is not required. Reference Section 3 for additional information. A down map can optionally contain sub-categories that are defined in the “Advanced” area. The primary downtime reasons (on the main display) are used for older MIUs, those that are capable of using 10 or 20 down codes only. If sub-categories are defined, those are used for new MIUs, including those that are capable of using up to 191 down codes. If sub-categories are not defined, newer MIUs use the primary downtime reasons that are defined. To configure a down map, follow these steps:


• Click the Site menu, click on the Codes menu, and select Down Map. The Down Map configuration screen will be displayed.


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Down Map Configuration

You can view existing down maps, edit existing down maps, create new down maps, and delete existing down maps if you have been assigned appropriate security permissions by the System Manager. You can not delete a down map if the down map is assigned to a machine. You can change the down codes that are assigned to a down map without losing any data.

Advanced Tip #1

The down map allows you to select a subset of the system-wide down codes so these codes can be assigned to one or more machines. It is a good practice to have all of the machines in a department use the same down map, but this isn’t required.


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Advanced Tip #2

Check the “Force Down (NPC)” checkbox to make the down code a “force-down reason” (or “non-production count” reason). When the machine operator selects a force-down reason, the machine will be treated as if it were down, regardless of whether or not it is cycling. That is, run time and parts made will not be accumulated.

A common use of this feature is to allow the machine to be placed in “setup”, where the machine will periodically be cycled, but will not produce parts.

The machine operator must manually restart the machine by selecting the down reason “In Prod” after selecting a force-down reason.

Any machine cycles that occur when the machine is in a force-down reason will be counted in the “non-production cycles” field in the job descriptor, unless the force-down reason is Reason #10. In this case, the machine cycles will be counted in the “setup cycles” field in the job descriptor.

Advanced Tip #3

Select an “Automatic Scrap” reason to make the down code an automatic scrap reason. When the machine operator selects an automatic scrap reason, the machine will count parts made, runtime, and even downtime if appropriate, however all parts made will be scrapped.

A common use of this feature is to allow the machine to be placed in some type of “startup” mode, where the machine will cycle and run but the parts that are made aren’t appropriate for shipping. An example of this might be a color change.

Advanced Tip #4

“Force Down” and “Automatic Scrap” downtime reasons are mutually exclusive.

If a machine is forced down, it will not count parts made and runtime. If a machine is in automatic scrap mode, it will count parts and runtime, but scrap those parts that are made.

Advanced Tip #5

You may add sub-categories to any downtime reason by pressing the “Advanced” button. When you create a sub-category, you will be allowed to specify a category name and 10 additional downtime codes. Each sub-category must contain at least 1 down reason and may contain as many as 10 down reasons.


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Advanced Tip #6

If you have 10 or fewer down codes defined, the Downtime Selection display at the TSMIU will use large push buttons for the data entry. If you have between 11 and 20 down categories, the Downtime Selection display at the TSMIU will use small push buttons for the data entry.

Advanced Tip #7

If you are using Mattec’s PCMIU software, the Downtime Selection display will only work if the related MIU supports the “remote downtime selection” feature. If the MIU supports this feature, you will be able to select the same number of downtime reasons (10, 20, or 191) that the MIU supports.


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2.7 Scrap Codes The System Manager can define up to 10,000 scrap codes for the entire system. Scrap codes are then assigned to a scrap map that can then be assigned to a specific machine. To configure a scrap code, follow these steps:


• Click the Site menu, click on the Codes menu, and select Scrap. The Scrap Codes configuration screen will be displayed.

Scrap Codes Configuration

You can view existing scrap codes, edit existing scrap codes, create new scrap codes, and delete existing scrap codes if you have been assigned appropriate security permissions by the System Manager. You can not delete a scrap code if the scrap code is assigned to a scrap map. If you delete a scrap code, you will lose all production history that has been collected for that scrap code.


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The following fields are available in the Scrap Codes configuration screen:

Field Description Scrap Code A unique identifier for this scrap code. Description A description for the scrap code.

Scrap Map A scrap map is a subset of the system-wide scrap codes. A scrap map must be defined before you can create machines. A scrap map is assigned to a machine via the Machine configuration program. It is common for all machines in a department to specify the same scrap map, although this is not required. Reference Section 3 for additional information. A scrap map can optionally contain sub-categories that are defined in the “Advanced” area. The primary scrap reasons (on the main display) are used for older MIUs, those that are capable of using 10 or 20 scrap codes only. If sub-categories are defined, those are used for new MIUs, including those that are capable of using up to 200 scrap codes. If sub-categories are not defined, newer MIUs use the primary scrap reasons that are defined. To configure a scrap map, follow these steps:


• Click the Site menu, click on the Codes menu, and select Scrap Map. The Scrap Map configuration screen will be displayed.


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Scrap Map Configuration

You can view existing scrap maps, edit existing scrap maps, create new scrap maps, and delete existing scrap maps if you have been assigned appropriate security permissions by the System Manager. You can not delete a scrap map if the scrap map is assigned to a machine. You can change the scrap codes that are assigned to a scrap map without losing any data.

Advanced Tip #1

The scrap map allows you to select a subset of the system-wide scrap codes so these codes can be assigned to one or more machines. It is a good practice to have all of the machines in a department use the same scrap map, but this isn’t required.

Advanced Tip #2

ProHelp® EPM uses the system-wide scrap reasons as the names of Attribute SQC “defects”.

The first 10 primary scrap codes are used to define the Attribute SQC “defects” that are available for entry from an MIU (for MIUs that support this feature).


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Advanced Tip #3

You may add sub-categories to any scrap reason by pressing the “Advanced” button. When you create a sub-category, you will be allowed to specify a category name and 10 additional scrap codes. Each sub-category must contain at least 1 scrap reason and may contain as many as 10 scrap reasons.

Advanced Tip #4

If you have 10 or fewer scrap codes defined, the Scrap Entry display at the TSMIU will use large push buttons for the data entry. If you have between 11 and 20 scrap categories, the Scrap Entry display at the TSMIU will use small push buttons for the data entry.

Advanced Tip #5

If you are using Mattec’s PCMIU software, the Scrap Entry display will always allow you to enter up to 200 scrap reasons, even if the related MIU only supports 10 (or 20) scrap reasons.


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2.8 Help Codes The System Manager can define up to 10,000 help codes for the entire system. Help codes are then assigned to a help map that can then be assigned to a specific machine. To configure a help code, follow these steps:


• Click the Site menu, click on the Codes menu, and select Help. The Help Codes configuration screen will be displayed.

Help Codes Configuration

You can view existing help codes, edit existing help codes, create new help codes, and delete existing help codes if you have been assigned appropriate security permissions by the System Manager. You can not delete a help code if the help code is assigned to a help map. If you delete a help code, you will lose all log history that has been collected for that help code.


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The following fields are available in the Help Codes configuration screen:

Field Description Help Code A unique identifier for this help code. Description A description for the help code. Sound File If Voice Enabled is set, this is the name of the sound file (*.WAV)

to use for voice alarms. This file is typically located in the “Voice\Names\Help” directory. Reference Section 5.1 for additional information.

Voice Enabled Set this value to enable the voice alarming for this specific help reason. Disable this value to disable voice alarming for this specific help reason. You must also configure the Voice Alarm option.

Email Enabled Set this value to enable email alarming for this specific help reason. Disable this value to disable voice alarming for this specific help reason. You must also configure the Email Alarm option.

Reference Section 5.1 for additional information about the Voice Alarm option and the Email Alarm option.

Advanced Tip #1

The help code where “Number” equals 0 is a special reason and can not be deleted. This code represents “cancel help” and is the help code that the machine operator selects to cancel an active call for help.

Help Map A help map is a subset of the system-wide help codes. A help map must be defined before you can create machines. A help map is assigned to a machine via the Machine configuration program. It is common for all machines in a department to specify the same help map, although this is not required. Reference Section 3 for additional information. There is no such thing as an “Advanced Help Map”. Most MIUs are capable of using eight (8) help codes only, plus “Cancel Help”. To configure a help map, follow these steps:


• Click the Site menu, click on the Codes menu, and select Help Map. The Help Map configuration screen will be displayed.


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Help Map Configuration

You can view existing help maps, edit existing help maps, create new help maps, and delete existing help maps if you have been assigned appropriate security permissions by the System Manager. You can not delete a help map if the help map is assigned to a machine. You can change the help codes that are assigned to a help map without losing any data.

Advanced Tip #1

The help map allows you to select a subset of the system-wide help codes so these codes can be assigned to one or more machines. It is a good practice to have all of the machines in a department use the same help map, although this is not required.

Advanced Tip #2

The first help code in a help map is always “Cancel Help”. This is the help code that the machine operator selects to cancel an active call for help.


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2.9 Machine Preventive Maintenance Codes The System Manager can define up to 10,000 machine maintenance codes for preventive maintenance tracking and forecasting. The system will predict when each maintenance code will next be due provided that you perform maintenance (i.e., enter at least one history record) for the specific maintenance code for a specific machine first. Preventive Maintenance is an optional feature in the ProHelp® EPM system. To configure machine maintenance codes, follow these steps:


• Click the Site menu, click Codes, and select Machine Maintenance. The Machine Maintenance Codes configuration screen will be displayed.

Machine Maintenance Codes Configuration

You can view existing maintenance codes, edit existing maintenance codes, create new maintenance codes, and delete existing maintenance codes if you have been assigned appropriate


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security permissions by the System Manager. If you delete a maintenance code, you will lose all production history and log history that has been collected for that maintenance code.

Advanced Tip #1

Preventive Maintenance is an optional feature. You may purchase this feature at any time by contacting the Mattec Sales Department.

When you create machine maintenance codes, you can instruct the system to predict when the maintenance will next be due based on the following:

• Machine Run Time, • Calendar Time

• Machine Cycles.

You can modify the machine odometer in the Machine configuration program in System Configuration. This will affect maintenance predictions, so you should modify the odometer with care. Reference Section 3 for additional information.

Advanced Tip #2

The system will predict when each maintenance code will next be due provided that you perform maintenance (i.e., enter at least one history record) for the specific maintenance code for a specific machine first. Thus, even though machine maintenance codes are configured system-wide, they will only apply to those machines where you have specifically entered history.

Advanced Tip #3

Most MIUs are only capable of displaying 100 preventive maintenance codes. If more than 100 codes are defined for a machine, only the first 100 where history has been entered will be displayed at the machine.

Advanced Tip #4

You can override the default time/cycle settings for one or more machines by pressing the “Overrides” tab.


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2.10 Tool Preventive Maintenance Codes The System Manager can define up to 10,000 tool maintenance codes for preventive maintenance tracking and forecasting. The system will predict when each maintenance code will next be due provided that you perform maintenance (i.e., enter at least one history record) for the specific maintenance code for a specific tool first. Preventive Maintenance is an optional feature in the ProHelp® EPM system. To configure tool maintenance codes, follow these steps:


• Click the Site menu, click Codes, and select Tool Maintenance. The Tool Maintenance Codes configuration screen will be displayed.

Tool Maintenance Codes Configuration

You can view existing maintenance codes, edit existing maintenance codes, create new maintenance codes, and delete existing maintenance codes if you have been assigned appropriate


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security permissions by the System Manager. If you delete a maintenance code, you will lose all production history and log history that has been collected for that maintenance code.

Advanced Tip #1


When you create tool maintenance codes, you can instruct the system to predict when the maintenance will next be due based on the following:

• Tool Run Time, • Calendar Time,

• Cycles Against the Tool.

You can modify the tool odometer in Edit Facilities. This will affect maintenance predictions, so you should modify the odometer with care.

Advanced Tip #2

The system will predict when each maintenance code will next be due provided that you perform maintenance (i.e., enter at least one history record) for the specific maintenance code for a specific tool. Thus, even though tool maintenance codes are configured system-wide, they will only apply to those tools where you have specifically entered history.

Advanced Tip #3

Most MIUs are only capable of displaying 100 preventive maintenance codes. If more than 100 codes are defined for a tool, only the first 100 where history has been entered will be displayed at the machine.

Advanced Tip #4

You can override the default time/cycle settings for one or more tools by pressing the “Overrides” tab.


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2.11 Process Parameters The System Manager can define up to 10,000 process parameters for the entire system. A subset of these Process Parameters are assigned to specific machines, as appropriate. To configure a process parameter, follow these steps:


• Click the Site menu and select Parameter. The Parameter configuration screen will be displayed.

Parameter Configuration

You can view existing parameters, edit existing parameters, create new parameters, and delete existing parameters if you have been assigned appropriate security permissions by the System Manager. You can not delete a parameter if the parameter is assigned to a machine. You can delete an existing parameter without consequence.


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The following fields are available in the Process Parameters configuration screen:

Field Description Name A unique identifier for this process parameter. Description A description for the process parameter. Sound File Leave this field blank, even if “Voice Enabled” is checked. Voice Enabled Set this value to enable the voice alarming for this specific process

parameter. Disable this value to disable voice alarming for this specific process parameter. You must also configure the Voice Alarm option.

Email Enabled Set this value to enable email alarming for this specific process parameter. Disable this value to disable voice alarming for this specific process parameter. You must also configure the Email Alarm option.

Advanced Tip #1

When using the Voice Alarm option or the Email Alarm for out-of-specification alarming, it is a good idea to enable all process parameters and to not enable some process parameters while disabling other process parameters. It is a good idea to leave the “Sound File” blank.

If some process parameters are enabled for Voice or Email Alarms, while other process parameters are disabled for Voice or Email Alarms, the following will occur:

• If the machine goes out-of-specification for a process parameter that is enabled for alarming, then a Voice or Email Alarm will be sent. If the machine stays out of specification but for a different reason, including a reason that is disabled for alarming, the Voice or Email Alarm will continue to be sent for the original reason.

• If the machine goes out-of-specification for a process parameter that is disabled for alarm, then a Voice or Email Alarm will not be sent. If the machine stays out of specification but for a different reason, including a reason that is enabled for alarming, the Voice or Email Alarm will not be sent.

• If the machine goes out-of-specification for multiple process parameters, if any of those process parameters is enabled for alarm, a “generic” Voice or Email alarm will be sent. If the machine stays out of specification for any reason, a “generic” Voice or Email Alarm will continue to be sent.

Reference Section 5.1 for additional information about the Voice Alarm option and the Email Alarm option.


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2.12 PCMIU (Cell Controller) Configuration The PCMIU, also referred to as the Cell Controller, is a software-only program that provides a user interface for the machine operator. This interface is similar to the TSMIU interface. The PCMIU software runs on Microsoft Windows, uses standard Ethernet or wireless connections, and can be used with a touch-screen PC or with a standard desktop PC. To create the configuration for a PCMIU, follow these steps:


• Click the Miscellaneous menu and select PCMIU Cell Configuration. The PCMIU Cell Configuration program will be displayed.

PCMIU Cell Configuration

You can view existing PCMIU configurations, edit existing PCMIU configurations, create new PCMIU configurations, and delete existing PCMIU configurations if you have been assigned appropriate security permissions by the System Manager. You can delete an existing PCMIU without consequence.


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If one and only one machine exists in the PCMIU Cell Configuration, then the “Machine Selection Button” will not be displayed at the PCMIU. If two or more machines exist in the PCMIU Cell Configuration, this configuration is often referred to as a “Cell Controller”, and the “Machine Selection Button” will be displayed at the PCMIU.

PCMIU Machine Selection Display

Advanced Tip #1

An MIU/AIU may appear in multiple PCMIU configurations.


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Advanced Tip #2

Some features of the PCMIU will only work if the MIU/AIU being displayed supports the related feature. For example, you can only select a downtime reason at the PCMIU if the related MIU/AIU supports the “remote downtime selection” feature.

Advanced Tip #3

A PCMIU will always allow you to select up to 200 scrap reasons (Advanced Scrap Map) and 19 help call reasons (plus Cancel Help), even if the related MIU/AIU being displayed only supports 10 scrap reasons and 8 help call reasons.


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2.13 Operator IDs The Operator IDs program allows the System Manager to create Machine Operator IDs and Passwords that control access to MIU functions. To configure Operator ID settings, follow these steps:


• Click the Miscellaneous menu and select Operator Permissions. The Operator IDs program will be displayed.

Operator IDs You can view existing Operators, edit existing Operator permissions, create new Operators, and delete existing Operators if you have been assigned appropriate security permissions by the System Manager. You can delete an Operator ID without losing any other data, including


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Operator login history and Operator efficiency data.

Advanced Tip #1

MIU Security is an optional feature that requires a supported MIU, such as the TSMIU. This feature does not work with the PCMIU (Cell Controller). You may purchase this feature any time by contacting the Mattec Sales Department. If you have this feature, the MIU user will always be required to enter a User ID and Password before using any MIU functions.

TSMIU Operator Login Display

Operator IDs and Passwords must be at least 4 alphanumeric characters. You are always required to enter a Password, even if you don’t have the MIU Security option and are just using this program to associate an Operator ID (number) with a Name.


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The following table describes the fields on the Operator Permissions display:

Field Description Name A descriptive name for the machine operator. Work Location The work location, department, or other description for the

machine operator. Account Is Disabled This field allows you to temporarily disable an Operator ID

without deleting the record. This may be necessary, for example, when an authorized user takes a temporary leave-of-absence from your company.

Security Permissions These fields control access to the related MIU functions. For example, a user with “Scrap” permission is permitted to enter scrap parts at an MIU, whereas a user who does not have “Scrap” permission can view the MIU’s Scrap Display but can enter scrap parts.

Advanced Tip #2

Operator permissions at an MIU are automatically revoked after a certain amount of time of inactivity at the MIU. The amount of time is configured in the “Security Timeout” field in the System Configuration screen. Reference Section 2.5 for additional information.

Advanced Tip #3

You may optionally use the Operator Permissions display to create Operator IDs even if you have not purchased the MIU Security option. This data can then be viewed on the “Operator Login Report” and the “Operator Efficiency Report” in System Reports and the Operator Efficiency Real-Time Display.

You will be required to enter a password for each user that is created, even though you have not purchased the MIU Security option.


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2.14 Material Characteristics The Material Characteristics program allows the System Manager to define characteristics that will apply to all Material IDs. To configure Material Characteristics, follow these steps:


• Click the Miscellaneous menu and select Material Characteristics. The Material Characteristics program will be displayed.

Material Characteristics

You can view existing Material Characteristics, edit existing Material Characteristics, create new Material Characteristics, and delete existing Material Characteristics if you have been assigned appropriate security permissions by the System Manager. If you delete an existing material characteristic, any related data that has been entered in a Material ID(s) will also be deleted.


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Advanced Tip #1

Material Characteristics are an optional feature that requires you to have the Material Manager option. You may purchase this feature any time by contacting the Mattec Sales Department.

All Material Characteristics apply to all Material IDs. A user using Edit Facilities and editing a Material ID may then enter a “Value” and “Notes” for each characteristic that has been defined:

Edit Facilities – Material ID


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2.15 Gauge Types The Gauge Types program allows the System Manager to define the types of gauges that exist in your facility. To configure Gauge Types, follow these steps:


• Click the Miscellaneous menu and select Gauge Types. The Gauge Types program will be displayed.

Gauge Types

You can view existing Gauge Types, edit existing Gauge Types, create new Gauge Types, and delete existing Gauge Types if you have been assigned appropriate security permissions by the System Manager. You can not delete a Gauge Type if the Gauge Type is being used by a Gauge.


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Advanced Tip #1

Gauge Types are an optional feature that requires you to have the Gauge Manager option. You may purchase this feature any time by contacting the Mattec Sales Department.

A user using Edit Facilities and editing a Gauge may select the Gauge Type from the list of types that have been defined:

Edit Facilities – Gauge Configuration


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2.16 Groups The Groups program allows the System Manager to define the items that appear in the Group picklists throughout the system. To configure Groups, follow these steps:


• Click the Miscellaneous menu and select Groups. The Groups program will be displayed.

Groups

You can view existing Groups, edit existing Groups, create new Groups, and delete existing Groups if you have been assigned appropriate security permissions by the System Manager.


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There are several Group Categories that are displayed throughout the ProHelp® EPM system, including:

• A Part IDs group. • A Tool IDs group. • A Material IDs group. • Four Machine groups. • Four Material Order groups. • A Material Supplier ID group.

When you create a new Group, you must specify the Group Category that it belongs to in the “Type” picklist.

Advanced Tip #1

The four Machine groups can be used as filters on the Real-Time Display.

Advanced Tip #2

You can use the groups to group data on a custom report. For example, you can create a custom Daily Production Report that groups data together based on the Part ID group.


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2.17 Group Categories The Group Categories program allows the System Manager to change the names of the Group picklists that appear throughout the system. To configure Group Categories, follow these steps:


• Click the Miscellaneous menu and select Group Categories. The Group Categories program will be displayed.

Group Categories

The Group Categories in the system are pre-defined. You can view existing Group Categories and edit the name of existing Group Categories, but you can not create new Group Categories nor delete existing Group Categories.


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3. Machine Configuration The Machine Interface Unit (MIU) is an industrial-strength data collection device that has been designed and manufactured by Mattec. It is used to collect production and process information from the manufacturing machine and transmits that data in real-time to the server computer. There are a wide variety of MIUs. Most have a graphical interface that allows the machine operator to view data about the current job and input relevant information (e.g., scrap parts). Many MIUs have both analog and digital inputs. Many MIUs have an optional “PLC interface” that can be used to extract data directly from supported machine controllers. Machines (MIUs) are grouped together in departments. MIUs are wired to the server computer in channels. Each machine can have its own shift schedule, scrap map (scrap reasons), down map (down reasons), help map (help call reasons), voice and email map, CMS Event Based map, barcode print server and barcode printer, machine preventive maintenance reasons, and process parameters. However, for conformity and ease-of-use, it is common for all machines in a department to be configured in a similar manner. The Machine configuration program is unique because it must correspond to the physical hardware and wiring in your system. It is used to perform the following:

• Identify the physical MIU hardware that will be used to collect data from the manufacturing machine, including analog inputs, digital inputs, PLC inputs, and reduction methods. This configuration must correspond to the actual MIU hardware that will be used.

• Identify the type of production data that will be monitored (e.g., cycle time, cycles per

hour, cycles per minute, or meters per minute).

• Identify configuration for the MIU, including shift schedule, scrap map (scrap reasons), down map (down reasons), help map (help call reasons), voice and email map, CMS Event Based map, barcode print server and barcode printer, and process parameters.

Caution:

It is a good idea to contact the Mattec Customer Service Department for assistance when you need to modify an existing Machine configuration or need to add a new machine to your system. Changes that are made to this configuration can cause permanent loss of data! For example, if you delete an existing machine, all data that is associated with that machine will also be deleted, including all process sheets, jobs, and job and shift history that are associated with the machine.


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To configure a machine, follow these steps:


• Click the Site menu and select Machine Configuration. The Machine Configuration program will be displayed.

Machine Configuration

You can view existing machines, edit existing machines, create new machines, and delete existing machines if you have been assigned appropriate security permissions by the System Manager. You can not delete a machine if that machine has a running job(s) or has a job scheduled. If you delete a machine, you will lose all data that is associated with that machine, including all job and shift production history for any jobs that ran on that machine. Instead of deleting a machine, you can set the “MIU Level” to “None (Disabled)”. The machine will continue to exist and will be available for reporting purposes, but it will not appear on the Real-Time Display, will not appear in the Job Schedule, and will not count as a machine for licensing purposes.


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If you make significant changes to an existing machine, you can cause the system to permanently lose data.

Advanced Tip #1

Changes to the Machine configuration program should be made with care.

Advanced Tip #2

You must restart the “Mattec MIU Service” after making changes to the Machine configuration. It is also a good idea to reboot the affected MIU.

There are several tabs on the Machine configuration screen that are used to configure different areas of the MIU, including:

Field Description General This tab is used to configure general information for the MIU,

including the machine number (name), department that the machine is assigned to, physical cabling information (channel and address), and the type of MIU (MIU Type and MIU Level).

Miscellaneous This tab is used to configure miscellaneous information, including the four machine groups, barcode printing information, and the URL for the web-based setup sheet.

Code Maps This tab is used to select an existing down map, scrap map, help map, voice and email map, and CMS event based map that will apply to this MIU.

AIUs This tab is used to configure the AIU hardware that comprises the physical MIU. When referred to in this context, an AIU is a collection of analog and digital inputs that are part of the MIU. Modern MIUs, including the TSMIU, have two (2) built-in AIUs. Older MIUs, including the “black box” MIU, have one (1) built-in AIU. If the MIU has an optional PLC interface, the PLC interface is specified here. If you are using TSMIUs, you must also select the PLC interface at the MIU’s Service Display screen.


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Field Description Parameters This tab is used to configure physical analog and digital inputs that

are associated with the MIU and configure process parameters. This is the actual data that will be collected from the machine (analog inputs, digital inputs, and/or PLC inputs) and that will be stored for jobs. A process parameter is selected from the list of configured process parameters (see Section 2.11). Each process parameter is associated with one input. However, multiple process parameters can be associated with the same input. This tab allows you to define the reduction method that will be used to convert the physical input into useful information. If you specified that the MIU has an optional PLC interface (on the AIU tab), then the inputs on this tab can optionally be configured as “PLC Source”. When this is done, additional information is required to configure the PLC input, and that configuration is entered on this display. Inputs are automatically added or deleted as you add or delete AIUs.

Tool Compatibility

The compatibility tab allows you to specify Tool / Machine Compatibility information that can be used to manually compare with the Tool ID. This tab does not affect the MIU’s data collection.

PM History This tab shows the preventive maintenance history that has been performed for the machine.

Advanced Tip #3

If you delete an existing machine, all data that is associated with that machine will also be deleted. For example, all process sheets, jobs, and job and shift history that are associated with the machine will be deleted.

Advanced Tip #4

If you delete an AIU from an existing machine, all parameters that are associated with that AIU will also be deleted. All historical information that is associated with those parameters will also be deleted, including Automatic SPC history.


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Advanced Tip #5

If you delete a parameter from an existing machine, all historical information that is associated with that parameter will also be deleted, including Automatic SPC history.

If you have purchased the ProStat® SPC/SQC option, Automatic SPC sampling and Parameter Recording can be enabled or disabled in a Process Sheet. Process Exception logging can be enabled on the General tab.

Advanced Tip #6

ProStat® SPC/SQC, Cavity Pressure Transfer, Voice Alarms, Email Alarms, PLC interfaces, Stage Detection, Web-based Setup Sheets, On-Demand Barcode Printing, and Preventive Maintenance are optional features. You may purchase these features at any time by contacting the Mattec Sales Department.

The System Manager selects appropriate machine filter groups in the “Grouping” section of the “Miscellaneous” tab in the Machine configuration program. These groups may be used as filter conditions on the Real-Time Display. Reference Sections 2.16 and 2.17 for additional information.

Advanced Tip #7

Unlike older ProHelp® systems, ProHelp® EPM supports only one (1) monitoring node. All MIUs in the system are wired into the same server computer.

Advanced Tip #8

MIUs are daisy-chained together on a channel. The channel is connected to a buffer box which, in turn, is connected to the server computer. Different types of MIUs can be wired together on the same channel provided that they are all configured to communicate at the same baud rate.


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3.1 Machine Configuration (General Tab) The following fields are available on the “General” tab of the Machine configuration program:

Field Description Machine Number A unique identifier for the machine. Description A description for the machine. This field appears next to the

Machine Number in many areas of the system. Comment 1 A comment field. Comment 2 A comment field. Machine Icon The icon that is used for this machine on the graphical plant

floor status display (graphical Real-Time Display) and the PCMIU’s Machine Selection Display.

Cavity Transfer The analog channel that is used to transfer the machine from the injection phase to hold pressure. The pressure value that causes the transfer is configured in the Process Sheet.

Down Cost A cost value associated with machine downtime. This value, as with all cost values, can only be viewed or modified by users with appropriate security permissions.

MIU Type This value is always set to “MATTEC MIU”. MIU Level This value corresponds to the type of MIU that will be

configured. MIU Speed Units This value defines the type of production data that will be

monitored and is typically set to cycle time (seconds per cycle), cycles per hour, cycles per minute, or meters per minute.

Linear Rate Multiplier This value is used to convert “machine cycles” into a length of part produced when the MIU Speed Units is set to a unit similar to “meters per minute”.

Department The department that the machine is assigned to. Reference Section 2.3 for additional information.

Channel The physical RS-485 channel that the MIU will be wired in to. Reference Section 2.4 for additional information.

Address The physical address, typically 0-15, that the MIU will be configured at. It is very important to ensure that each MIU has a unique Channel/Address setting.

Shift Configuration The Shift Configuration that will be used for the machine. To use the Shift Configuration that has been assigned to the department, select “Department Default”. Reference Section 2.1 for additional information.

Process Exception Logging

When set, every machine cycle that is out-of-specification will be logged.


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Field Description Remote Scrap (Pushbutton)

When this value is enabled, any time that digital contact #2 in the MIU fires, a scrap part will be entered for the running job for the first scrap reason that is defined in the scrap map. If a family job is running, one machine cycle (not one part) will be scrapped. This feature requires a supported MIU.

The Process Exception Log will record any machine cycles that result in a violation of specification limits, control limits, and/or part qualification limits for any monitored process parameter. This log can be enabled for a machine by placing a checkmark in the “Process Exception Log” field on the “General” tab in the Machine configuration program. The data that is collected in this log can be viewed using ProStat®.

WARNING:

The Process Exception Log has the potential to grow very rapidly and should only be turned on if the data collected will be used. The Process Exception Log is intended to be a short-term debugging tool and should not be used in place of statistical analysis of data.

Advanced Tip #1

The Mattec Customer Service Department can help you create custom Machine Speed Units configurations by adding records in the dbo.MachineSpeedUnits database table.

ProHelp® Millennium was only aware of cycle time, cycles per hour, cycles per minute, and meters per minute. As a result, most MIU types are also only aware of those units.

However, the PCMIU and all host software programs allow for user-defined machine speed units where all time values (“seconds” in cycle time, “per hour” in cycles per hour, “per minute” in cycles per minute, and “per minute” in meters per minute) can be variable. For example, it’s possible to create a custom machine speed unit that allows you to view/enter cycle time values in “minutes per cycle” instead of “seconds per cycle”.

Similarly, programs allow for user-defined machine speed units where all lengths (i.e., meters per minute) can be variable. For example, it’s possible to create a custom machine speed unit that allows you to view/enter linear rate values in “feet per minute” or “meters per hour”.


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3.2 Machine Configuration (Miscellaneous Tab) The following fields are available on the “Miscellaneous” tab of the Machine configuration program:

Field Description Grouping 1-4 A machine can be assigned to four different groups. These

groups can be used as filters on the Real-Time Display or in custom reports. Reference Sections 2.16 and 2.17 for additional information.

Barcode Printer The barcode printer that will be used, by default, when a barcode label is printed for a job that is running on this machine when using the On-Demand Barcode Printing option. Reference Section 5.2.2 for additional information. Reference Section 5.2.5 for information how to override this setting for a specific computer.

Print Server The print server that will be used, by default, when a barcode label is printed for a job that is running on this machine when using the On-Demand Barcode Printing Option. Reference Section 5.2.1 for additional information. Reference Section 5.2.5 for information how to override this setting for a specific computer.

Setup Document A URL for the web-based setup sheet for this machine that can be viewed in the PCMIU or the Document Control Center.

Advanced Tip #1

Web-based Setup Sheets and On-Demand Barcode Printing are optional features. You may purchase these features at any time by contacting the Mattec Sales Department.


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3.3 Machine Configuration (Code Maps Tab) The following fields are available on the “Code Maps” tab of the Machine configuration program:

Field Description Help Code Map The Help Code Map that defines which help codes are

available for this machine. Reference Section 2.8 for additional information.

Scrap Code Map The Scrap Code Map that defines which scrap codes are available for this machine. Reference Section 2.7 for additional information.

Down Code Map The Down Code Map that defines which down codes are available for this machine. Reference Section 2.6 for additional information.

Voice/Email Alarm Map The Voice/Email Alarm Map that defines the behavior of the Voice Alarm option and the Email Alarm Option for this machine. Reference Section 5.1.4 for additional information.

Sound File The name of the sound file (*.WAV) to use for voice alarms. This file is typically located in the “Voice\Names\Mach” directory. Reference Section 5.1 for additional information.

CMS Event Based Map The CMS Event Based Map that defines the events that this machine will automatically send to your CMS ERP system. Reference Section 6.3 for additional information.

Advanced Tip #1

The Voice Alarm Option and Email Alarm Option are optional features. You may purchase these features at any time by contacting the Mattec Sales Department.

Advanced Tip #2

Modern MIUs, including the TSMIU, allow you to configure 200 scrap reasons and 191 downtime reasons for the machine. Older MIUs only allow you to configure 10 or 20 scrap reasons and 10 or 20 downtime reasons for the machine.


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3.4 Machine Configuration (AIUs Tab) When referred to in this context, an AIU is a collection of analog and digital inputs that are part of the MIU. Modern MIUs, including the TSMIU, have two (2) built-in AIUs. Older MIUs, including the “black box” MIU, have one (1) built-in AIU. You can view existing AIUs that have been created, edit existing AIUs, add new AIUs, and delete existing AIUs if you have been assigned appropriate security permissions by the System Manager.

Advanced Tip #1

If you delete an AIU from an existing machine, all parameters that are associated with that AIU will also be deleted. All historical information that is associated with those parameters will also be deleted, including Automatic SPC history.

The following fields are available on the “AIUs” tab of the Machine configuration program:

Field Description AIU The number for this AIU. Typically, most MIUs have one or

two AIUs. Stage Detect The stage detection feature is a software algorithm that

allows a supported MIU to derive up to three discrete stages of operation (injection pressure, hold pressure, and back pressure) from a single analog input (Analog 6). The derived pressures for the three stages are inserted into the Analog 6, Analog 7, and Analog 8 parameters. In order for the stage detection algorithm to be able to derive the three stages of injection, the Analog 6 pressure transducer should be calibrated to use at least half of its dynamic range.

Stage Auto Insert When stage detection is enabled, enabling this field will cause the derived times for each of the three stages to be inserted into the Pulse 2, Pulse 3, and Pulse 4 parameters. When disabled, these fields revert to their normal operation.

Stage Tolerance When stage detection is enabled, this field is used by the stage detection algorithm to determine when a change between two stages has occurred. The stage tolerance level must be greater than any noise that may be present in the analog signal, but must be less than the actual difference between any two stages.


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Field Description PLC The name of the PLC interface for collecting process

parameter information. If you change this value, you must make a corresponding change (or EPROM change) at the MIU. Failure to do so can cause the MIU to stop communicating.

PLC Configure Some PLCs require additional configuration information for the overall PLC (in addition to configuration information for each individual PLC parameter). If the selected PLC requires this additional information, it will be entered here. Contact the Mattec Customer Service Department for additional information.

Advanced Tip #2

Stage Detection and PLC interfaces are optional features. Both require a supported MIU. You may purchase these features at any time by contacting the Mattec Sales Department.


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3.5 Machine Configuration (Process Parameters Tab) The Process Parameter tab of the Machine configuration program is used to configure physical analog and digital inputs that are associated with the MIU and configure process parameters. This is the actual data that will be collected from the machine (analog inputs, digital inputs, and/or PLC inputs) and that will be stored for jobs. A process parameter is selected from the list of configured process parameters (see Section 2.11). Each process parameter is associated with one input. However, multiple process parameters can be associated with the same input. This tab allows you to define the reduction method that will be used to convert the physical input into useful information.

Machine Configuration – Process Parameters Tab

If you specified that the MIU has an optional PLC interface (on the AIU tab), then the inputs on this tab can optionally be configured as “PLC Source”. When this is done, additional information is required to configure the PLC input, and that configuration is entered on this display. Inputs are automatically added or deleted to this tab as you add or delete AIUs on the AIUs tab. Reference Section 3.4 for additional information.


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The following fields are available on the “Process Parameters” tab of the Machine configuration program:

Field Description Input An input is associated with the physical hardware in the MIU.

Inputs are automatically added or deleted from the machine when AIUs are added or deleted.

Parameter The process parameter name to be associated with the input. If a parameter is not specified, data will not be collected for this input. Reference Section 2.11 for additional information.

Current Value The last value for this parameter that was sent from the MIU to the host computer. Click on the “Current Value” header to cause the program to reread this data.

Units This field is descriptive text for the parameter and can be seen in a variety of places in the system.

Type This field allows you to modify the input. For digital inputs that can be modified, the type can be “Digital” (raw data is read from the MIU hardware) or “PLC Source” (processed data is read from the machine’s PLC). For analog inputs, the type can be one of several sensor types (raw data is read from the MIU hardware using the specified sensor type) or “PLC Source” (processed data is read from the machine’s PLC).

Reduction Method This field allows you to take the raw analog data that is read from the input (including inputs that are cross-coupled) and convert that data into the desired parameter value. For example, Analog 6 may have an Injection Pressure sensor wired into the analog and the Reduction Method may be configured to capture the “Maximum Value” that was read during the course of a machine cycle. If Type has been set to “PLC Source”, then the Reduction Method does not apply.

Cross-Coupling If the Type field is set to anything other than “PLC Source”, then the Cross-Coupling field allows the input to derive its data from another input. For example, a digital input could be configured to derive data from an analog input. This is useful if you want to measure multiple values (i.e., use multiple reduction methods) on one analog signal.

Decimal Places The number of decimal places for the parameter. Gain Gain is a multiplier to the raw data value that is read by the MIU.

Reference Section 3.8 for additional information.


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Field Description Offset Offset is added to the raw data value that is read by the MIU.

Reference Section 3.8 for additional information. PLC If Type has been set to “PLC Source”, then this field allows you to

specify additional information to define which field should be read from the PLC. Contact the Mattec Customer Service Department or your PLC Supplier for additional information.

Advanced Tip #1

PLC interfaces are an optional feature that require a supported MIU. You may purchase this feature at any time by contacting the Mattec Sales Department.

Advanced Tip #2

You should only set the Cycle Time parameter to have more than 2 decimal places if this is a high-speed machine. When this parameter is set to have 3 decimal places, the Cycle Time value that is displayed in the system will be the calculated average of the last 10 machine cycles. When this parameter is set to have 4 decimal places, the Cycle Time value that is displayed in the system will be the calculated average of the last 100 machine cycles.

Advanced Tip #3

If a parameter is configured to be type “Linear Analog (Tool)”, then the related machine calibration data is stored with the tool/machine. This is useful if you have cavity pressure sensors installed in a tool (which will be removed from the machine and periodically rerun). You still must calibrate the sensor once for each machine that the tool is run in. However, after the sensor has been calibrated once, the correct calibration information will be retrieved any time that tool is run in the machine.


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3.6 Machine Configuration (Tool Compatibility Tab) The Tool Compatibility tab of the Machine configuration program allows you to specify Tool / Machine Compatibility information that can be used to manually compare with the Tool ID. This tab does not affect the MIU’s data collection. Similar information (for “Machine Compatibility”) can be defined in the Tool ID in the Edit Facilities program. The compatibility values that are displayed are configured by the System Manager. Reference Section 2.5 for additional information.

Advanced Tip #1

The fields on this display do not prevent you from scheduling a job (tool) to a machine that doesn’t meet the compatibility requirements. These values are for informational purposes only.

3.7 Machine Configuration (PM History Tab) The PM History tab of the Machine configuration program shows the preventive maintenance history that has been performed for the machine. The number of history records that will be displayed can be limited by the System Manager. Reference Section 2.5 for additional information.

Advanced Tip #1



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3.8 Machine Calibration The Machine Calibration program allows users to enter known calibration information, including “gain” and “offset”, for the analog signals that are configured for MIUs. To enter calibration settings for a machine, follow these steps:


• Click the Site menu and select Machine Calibration. The Machine Calibration program will be displayed.

Machine Calibration

You can view or edit existing Machine Calibrations if you have been assigned appropriate security permissions by the System Manager. You can not create nor delete a Machine Calibration. If you edit an existing Machine Calibration, this will change the values that are read


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by the MIU and transmitted to the host computer. Make changes with care. The following fields are available in the Machine Calibration screen:

Field Description Input The name of a physical input that is associated with the MIU

hardware. Description The description of the physical input. Units The units for the physical input that was entered by the user in the

Machine configuration program. Gain Gain is a multiplier to the raw data value that is read by the MIU. Offset Offset is added to the raw data value that is read by the MIU.

When a gain or offset is applied, an “adjusted raw value” is created: Adjusted Raw Value = (Raw Value * Gain) + Offset.

Advanced Tip #1

Mattec teaches a “Maintenance, Calibration, and Troubleshooting” class that instructs attendees in the proper calibration techniques for MIUs. This class is intended for maintenance technicians who are responsible for calibrating MIUs.

Advanced Tip #2

If a parameter is configured to be type “Linear Analog (Tool)”, then the related machine calibration data is stored with the tool/machine. This is useful if you have cavity pressure sensors installed in a tool (which will be removed from the machine and periodically rerun). You still must calibrate the sensor once for each machine that the tool is run in. However, after the sensor has been calibrated once, the correct calibration information will be retrieved any time that tool is run in the machine.


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4. Real-Time Display Writer Users can create their own custom Real-Time Displays and graphical Plant Floor Status Displays for use with the Real-Time Display program. This powerful, yet easy-to-use, feature gives you a great deal of flexibility to control the information that is available in real-time to users of the system. There are five (5) types of Real-Time Display, including:

• Standard Real-Time Display

• Operator Efficiency Display

• Cost Display

• Process Alarm Tab

• Graphical Plant Floor Display

Advanced Tip #1

Graphical Plant Floor Displays are created using the Plant Floor Display Writer. The other four (4) types of display are created using the Real-Time Display Writer. A display type is assigned to the custom Real-Time Display when the display is created and can not be modified.

Advanced Tip #2

Your ProHelp® EPM system shipped with several built-in Real-Time Displays. Mattec created these displays using the Real-Time Display Writer. You can modify or delete these displays, if desired.


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To start the Real-Time Display Writer, follow these steps:


• Click the Site menu and select Real-Time Display Writer. The Real-Time Display Writer screen will be displayed.

Real-Time Display Writer

The Real-Time Display Writer is used to create, modify, or delete any of the four supported display types. Displays that are created will be available to all users of the ProHelp® EPM system. Each display type is described further in the following sections.


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4.1 Standard Real-Time Display The Real-Time Display is one of the most powerful features in the ProHelp® EPM system. This display allows users throughout your facility to view the status of all jobs and machines in the plant in real-time. Fields are color-coded to make identifying problems easy. To view a Standard Real-Time Display, follow these steps:

• Start the Real-Time Display program. To do this, start the Main Menu and press the Launch Real-Time Display icon. The Standard Real-Time Display screen will be displayed.

Standard Real-Time Display

The fields on the Standard Real-Time Display screen are configurable by the System Manager in the Real-Time Display Writer screen. More than 500 fields are available for display, including the following:

• Job Standards

• Part Standards

• Tool Standards

• Current process parameter values


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• Shift Production History

• Job Production History

• Next Job Data

• Machine PM History and PM Due

• Tool PM History and PM Due To start the Real-Time Display Writer, follow these steps:


• Click the Miscellaneous menu and select Real-Time Display Writer. The Real-Time Display Writer screen will be displayed.

Sample Standard Real-Time Display

The Real-Time Display Writer will show a list of all existing displays for the supported display types. All standard Real-Time Displays displays will identify their “Type” as “Standard Real-


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Time Display”. To add a new field to the display, press the Add button. A list of available fields will be displayed. You can manually modify the “Column Header” and “Width” for the field or you can accept the default values. You can reorder the fields in the display. To do this, hightlight a field and use one of the four arrow keys on the right-hand side of the display to move the field up or down. To delete a field from the display, highlight the field and press the Delete button. There are so many fields that are available for display that the fields are broken down into “Categories”. The following table describes of the various categories of data that are available for Standard Real-Time Displays:

Category Description Basic Data Contains various fields related to the Machine or Job

Descriptor, including the Machine Number, Job Number, Department information, and internal fields that are useful to the Mattec Customer Service Department.

Custom Data This category requires special software. Father Job Data Contains fields related to Father Job Descriptor standards.

These fields will be blank for “bachelor” jobs. Job Data Contains fields related to Job Descriptor standards. Job Digital Counters Contains fields related to the overall job digital counter data

that is being accumulated in real-time for running jobs. Job Production Data Contains fields related to the overall job production history

data that is being accumulated in real-time for running jobs. Machine Configuration Data

Contains fields related to the machine configuration.

Machine PM Due Contains fields related to the next Machine Preventive Maintenance activity that is due, provided that the due date falls within the “PM Due Warning” or “PM Due Alert” that is specified in System Configuration. Reference Section 2.5 for additional information.

Machine PM History Contains fields related to the last Machine Preventive Maintenance activity that was performed, provided that the date the activity was performed falls within the “Hours of PM History to Display” that is specified in System Configuration. Reference Section 2.5 for additional information.

Material List Contains fields related to the Material List that is specified in the Part ID for the running jobs.

Material Lot Data Contains fields related to the current material lot(s) for the running jobs.


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Category Description Next Job Data Contains fields related to Job Descriptor standards for the

next scheduled job. Next Job Material List Contains fields related to the Material List that is specified in

the Part ID for the next scheduled job. Next Job Primary Material

Contains fields related to the Primary Material that is specified in the Material List in the Part ID for the next schedule job.

Part Data Contains fields related to Part ID standards. Primary Material Contains fields related to the Primary Material that is

specified in the Material List in the Part ID for running jobs. Primary Material Used Contains fields related to material used for the Primary

Material for the running jobs. Process Parameter (Preferred)

Contains fields related to process parameters. This category is preferred over the “Process Parameter Indicators” and “Process Parameter Values” because it lets you specify the numbers 1 through 32 to represent the process parameters that are configured for a machine. Fields in this category can dramatically impact system performance. Each process parameter that is added to the display will require one additional read from the database for every machine that is displayed.

Process Parameter Calculations

Contains fields that are calculated based on the value of certain process parameters.

Process Parameter Indicators

Contains fields related to process parameters. Rather than display the process parameter value, fields in this category will display a color-coded “indicator”, where “1” is used for the first parameter, “2” is used for the second parameter, etc. Fields in this category can dramatically impact system performance. Each process parameter that is added to the display will require one additional read from the database for every machine that is displayed.

Process Parameter Values

Contains fields related to process parameters. The fields in this category will display a color-coded value for each parameter that is selected. Fields in this category can dramatically impact system performance. Each process parameter that is added to the display will require one additional read from the database for every machine that is displayed.

Process Sheet Data Contains fields related to Process Sheet standards.


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Category Description Shift Digital Counters Contains fields related to the shift digital counter data that is

being accumulated in real-time for the running jobs. Shift Production Data Contains fields related to the shift production history data

that is being accumulated in real-time for the running jobs. Tool Data Contains fields related to Tool ID standards. Tool PM Due Contains fields related to the next Tool Preventive

Maintenance activity that is due, provided that the due date falls within the “PM Due Warning” or “PM Due Alert” that is specified in System Configuration. Reference Section 2.5 for additional information.

Tool PM History Contains fields related to the last Tool Preventive Maintenance activity that was performed, provided that the date the activity was performed falls within the “Hours of PM History to Display” that is specified in System Configuration. Reference Section 2.5 for additional information.

Advanced Tip #1

When you add new fields to the display, a name and description are shown in the “Field” picklist. Generally, only Mattec Service Personnel will be interested in viewing fields that contain the description “Internal”.

For example, the field labelled “MachNo – Internal MachNo” is not the same as the field that is labelled “Mach Number – Machine Number”. Both fields can be found in the “Basic Data” category.

Advanced Tip #2

When you add a field to the display, you may be permitted to modify the “SubField”, depending on which field you have just added. For example, if you add any process parameter to the display from the “Process Parameters (Preferred)” category, then the “SubField” controls the process parameter number 1-32 that is displayed.

The text in the “SubField Description” describes the purpose of the “SubField” for the current field.

Advanced Tip #3

Unlike the other types of Real-Time Display, you must consider speed and performance issues when you create a Standard Real-Time Display.


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When you add a field from a new “Category” of data to the display, the Real-Time Display will require one additional read from the database for every machine that is displayed. For example, if your Real-Time Display has one field from each of three (3) categories, then three (3) database reads will be required for every machine that is displayed. Conversely, if your Real-Time Display has three (3) fields from a “typical” category (e.g., Basic Data), only one database read will be required for every machine that is displayed.

You should be very careful when using fields from the “Process Parameter (Preferred)”, “Process Parameter Indicators”, and “Process Parameter Values” categories. Fields in these categories can dramatically impact system performance. Each field that is added to the display from one of these categories will require one additional read from the database for every machine that is displayed.

For example, if your Real-Time Display has thirteen (13) different process parameter values on the display (from the “Process Parameter Values” category), the display will require thirteen (13) reads from the database for every machine that is displayed.

Contact the Mattec Customer Service Department for additional information.


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4.2 Graphical Plant Floor Display The Plant Floor Real-Time Display is a graphical version of the standard Real-Time Display. This display allows users throughout your facility to view the status of all jobs and machines in the plant in real-time. You can create your own background image and add up to four lines of text for each machine. Machine icons are color-coded to make identifying problems easy. To view a graphical Plant Floor Display, follow these steps:

• Start the Real-Time Display program. To do this, start the Main Menu and press the Launch Real-Time Display icon. Press the Plant Floor tab. The Plant Floor Display screen will be displayed.

Graphical Plant Floor Status Display


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The same fields that are available in the Standard Real-Time Display Writer (Section 4.1) are available in the graphical Plant Floor Display Writer. To start the graphical Plant Floor Display Writer, follow these steps:


• Click the Miscellaneous menu and select Plant Floor Display Writer. The Plant Floor Display Writer screen will be displayed.

Sample Plant Floor Display

The Plant Floor Display Writer will show a list of all existing displays. You may add up to four lines of text for each display. Each line of text may contain up to 2 variable fields. The same text will be displayed for all machines that are added to the display. To add a new line to the display, press the Add Line button. A list of available categories/fields will be displayed. You can manually modify the “Text Format” to add static text, but you must be careful to preserve the insert characters (anything that starts with a “%”, such as “%s”).


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Add Line Dialog

To modify an existing line of text, highlight the line and press the Modify Line button. To delete an existing line of text, highlight the line and press the Delete Line button. Unlike a standard Real-Time Display, you must manually add machines to the graphical Plant Floor Display and assign each machine X/Y coordinates. The upper left-hand corner of the display is point (0,0) and the lower right-hand corner of the display is point (800, 600).


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You can create your own background image for each display using any off-the-shelf tool, such as Microsoft Paint. The only requirement is that the image file must be a BMP file and must be located in ProHelp’s “sys\images” directory.

Advanced Tip #1

Image files (for the Background image) are stored in ProHelp’s “sys\images” directory, such as C:\Program Files\Mattec\ProHelp\Sys\Images on the server computer. All image backgrounds should be valid BMP files.

Machine icons can vary for each machine and are assigned by the System Manager in the Machine configuration program. Reference Section 3.1 for additional information.

Advanced Tip #2

Users can not create their own machine icons. Icons are pre-defined by Mattec and are available in a picklist in the Machine configuration program.


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4.3 Operator Efficiency Display This feature allows machine operators to log in at supported MIUs for operator efficiency recording. The system will then automatically record performance information for the machine operator, including parts made, percent down, percent scrap, percent of machine cycles that are out-of-specification, yield efficiency, and much, much more. The information that is collected for the machine operator is available in the Operator Efficiency Report and can be seen in real-time on the Operator Efficiency Real-Time Display. To view an Operator Efficiency Real-Time Display, follow these steps:

• Start the Real-Time Display program. To do this, start the Main Menu and press the Launch Real-Time Display icon.

• Press the Operator Efficiency Display icon. The Operator Efficiency Real-Time Display screen will be displayed.

Operator Efficiency Real-Time Display

The fields on the Operator Efficiency Real-Time Display screen are configurable by the System Manager in the Real-Time Display Writer screen.


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Sample Operator Efficiency Real-Time Display

Advanced Tip #1

Operator Efficiency is an optional feature. You may purchase this at any time by contacting the Mattec Sales Department.

The Real-Time Display Writer will show a list of all existing displays for the supported display types. All Operator Efficiency displays will identify their “Type” as “Operator Efficiency Display”. To add a new field to the display, press the Add button. A list of available fields will be displayed. You can manually modify the “Column Header” and “Width” for the field or you can


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accept the default values. You can reorder the fields in the display. To do this, hightlight a field and use one of the four arrow keys on the right-hand side of the display to move the field up or down. To delete a field from the display, highlight the field and press the Delete button.

Advanced Tip #2

There are no speed concerns regarding Operator Efficiency Real-Time Displays. You can add any of the available operator efficiency-related fields to the display without a noticeable impact on system performance.


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4.4 Cost Display This feature allows users to associate costs with different types of data (e.g., material costs, part costs, etc.). The system will then provide basic costing information. The cost of scrap and downtime for running jobs is available in real-time on the Cost Real-Time Display. To view a Cost Real-Time Display, follow these steps:


• Press the Cost Display icon. The Cost Real-Time Display screen will be displayed.

Cost Real-Time Display

Advanced Tip #1

Cost Manager is an optional feature. You may purchase this at any time by contacting the Mattec Sales Department.

The fields on the Cost Real-Time Display screen are configurable by the System Manager in the Real-Time Display Writer screen.


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Sample Cost Real-Time Display

The Real-Time Display Writer will show a list of all existing displays for the supported display types. All Cost Efficiency displays will identify their “Type” as “Cost Display”. To add a new field to the display, press the Add button. A list of available fields will be displayed. You can manually modify the “Column Header” and “Width” for the field or you can accept the default values. You can reorder the fields in the display. To do this, hightlight a field and use one of the four arrow keys on the right-hand side of the display to move the field up or down. To delete a field from the display, highlight the field and press the Delete button.


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Advanced Tip #2

There are no speed concerns regarding Cost Real-Time Displays. You can add any of the available cost-related fields to the display without a noticeable impact on system performance.


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4.5 Process Alarm Display The Process Alarm Real-Time Display doesn’t look like a Real-Time Display at all. However, the fields on this display are configurable just like the other types of Real-Time Displays. To view a Process Alarm Display, follow these steps:

• Start the Real-Time Display program. To do this, start the Main Menu and press the Launch Real-Time Display icon. The Standard Real-Time Display screen will be displayed.

• Double-click on any machine number or job number. The Machine Status screen

will be displayed. Press the Process Alarm tab. The Process Alarm screen will be displayed.

Process Alarm Tab

The fields on the Process Alarm screen are configurable by the System Manager in the Real-Time Display Writer screen.


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Sample Process Alarm Display

The Real-Time Display Writer will show a list of all existing displays for the supported display types. All Process Alarm displays will identify their “Type” as “Process Alarm Tab”. To add a new field to the display, press the Add button. A list of available fields will be displayed. You can manually modify the “Column Header” and “Width” for the field or you can accept the default values. You can reorder the fields in the display. To do this, hightlight a field and use one of the four arrow keys on the right-hand side of the display to move the field up or down. To delete a field from the display, highlight the field and press the Delete button.


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Advanced Tip #1

There are no significant speed concerns regarding Process Alarm Real-Time Displays. All data for each line of the Process Alarm display is read with two or fewer reads of the database. This data is viewed one machine at a time. You can add any of the available process alarm-related fields to the display without a significant impact on system performance.


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5. Advanced System Administration The following sections describe advanced system administration functionality. 5.1 Voice Alarms and Email Alarms The Voice Alarm option allows alarm conditions to be announced through a voice board which can be connected to a PA system. Alarms will repeat periodically until the alarm condition is resolved or until the alarm is “Acknowledged” at the MIU or the Real-Time Display. The Email Alarm option allows the same alarm conditions to be sent to users via email. Instead of repeating periodically, email alerts can be sent to additional users (i.e., the alarm is escalated) until the alarm condition is resolved or until the alarm is “Acknowledged” at the MIU or the Real-Time Display. The following alarm conditions are available for the Voice Alarm and Email Alarm options:

• Calls For Help initiated at the MIU or the PCMIU. Alarms may be enabled for any or all help calls.

• Machine Downtime. Alarms may be enabled for any or all downtime reasons. • Machine Out-Of-Specification. Ideally, alarms must be enabled for all process

parameters for a machine.

Advanced Tip #1

Voice Alarms are an optional feature. Email Alarms are a similar, but different, optional feature. Both features work with any MIU type, although older MIUs may not allow the Machine Operator to “Acknowledge” an alarm. You may purchase these features any time by contacting the Mattec Sales Department.

To configure the voice alarm option, you must do the following:

1. Install a sound card and the appropriate drivers in the ProHelp® EPM server computer. At this point, it is easiest to connect a simple pair of speakers to the sound card instead of connecting the sound card to your PA system.

2. Record sound files, copy them to the appropriate directory on the server

computer, and enter the file names in the Department program, Machine configuration program, Help Codes program, Down Codes program, and Process Parameters program. Reference Section 5.1.2 for additional information.

3. Create a Voice and Email Map and assign the map to one or more machines.


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Reference Section 5.1.4 for additional information.

4. Restart the “Mattec MIU Service”.

5. Test your configuration. If problems exist, the Voice Administrator (Section 5.1.7) can be a helpful diagnostic tool.

6. Connect the sound card to your PA system.

To configure the Email Alarm option, you must do the following:

1. Log in to the ProHelp® EPM server computer as the Microsoft Windows “Administrator” and configure Outlook Express to send emails.

2. Define email addresses in ProHelp® EPM. Reference Section 5.1.3 for additional

information.

3. Create a Voice and Email Map and assign the map to one or more machines. Reference Section 5.1.4 for additional information.

4. Restart the “Mattec MIU Service”.

5. Test your configuration. If problems exist, try using the Advanced Email Settings

described in Section 5.1.5. The Voice Administrator (Section 5.1.7) can be a helpful diagnostic tool.


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5.1.1 Acknowledging Alarms The Voice Alarm option allows alarm conditions to be announced through a voice board which can be connected to a PA system. Alarms will repeat periodically until the alarm condition is resolved or until the alarm is “Acknowledged” at the MIU or the Real-Time Display. The Email Alarm option allows the same alarm conditions to be sent to users via email. Instead of repeating periodically, email alerts can be sent to additional users (i.e., the alarm is escalated) until the alarm condition is resolved or until the alarm is “Acknowledged” at the MIU or the Real-Time Display. To acknowledge a voice or email alarm from a computer, follow these steps:


• Double-click on the appropriate machine (or machine icon). The Machine Status display will be displayed.

• Press the Voice/Email button. The Acknowledge Voice/Email Alarms display

will be displayed. Select the type(s) of alarm(s) to acknowledge and press Acknowledge.

Acknowledge Voice/Email Alarm Display

To acknowledge a voice or email alarm from an MIU, go to the related area of the MIU and press the Acknowledge Voice button. For example, to acknowledge Help alarms, go to the Call For Help display and press the Acknowledge Voice button. To acknowledge Downtime alarms, go to the Downtime selection display and press the Acknowledge Voice button. To acknowledge Out-of-specification alarms, go to the Status/Alarm display and press the Acknowledge Voice button.


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5.1.2 Recording .WAV Files for Voice Alarms Before enabling the Voice Alarm option, you must create the necessary sound files. All sound files that are used by ProHelp® EPM are typically recorded by the customer and are always stored in .WAV files. It is a good idea to use a third-party tool to record and edit sound files.

Advanced Tip #1

Goldwave™ is a good third-party sound recorder. When using Goldwave™, save the sound files as .WAV files in the format “PCM signed 16 bit, Mono, 44100Hz”. This will provide a good quality sound for most PA systems.

Sound files are read by the monitoring engine from a pre-defined location (C:\Program Files\Mattec\ProHelp\Voice) on the server computer. Files of different types are stored in different subdirectories. For example, the names of machines are stored in the “..\Names\Mach” subdirectory (C:\Program Files\Mattec\ProHelp\Voice\Names\Mach). Each machine (e.g., “01”) will have its own sound file (e.g., “01.wav”) that simply says the name of the machine (e.g., “Machine One”).

Advanced Tip #2

Before creating hundreds of sound files, you may want to use the default sound files that Mattec provides to enable the Voice Alarm option for one Help Call reason. This will allow you to test your configuration and to listen to some of Mattec’s sample files.

The following table describes the types of sound files that you will need to create and their default location:

Type Subdirectory Description Machine Names ..\Voice\Names\Mach The names of each machine. The name

of each file (e.g., “01.WAV”) will be entered into the Machine configuration program. Reference Section 3 for additional information.

Department Names ..\Voice\Names\Dept The names of each department. The name of each file will be entered into the Department Configuration program. Reference Section 2.3 for additional information.


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Type Subdirectory Description Help Call Reasons ..\Voice\Help The names of each help call reason.

The name of each file will be entered into the Help Codes Configuration program. Reference Section 2.8 for additional information.

Downtime Reasons ..\Voice\Down The names of each downtime reason. The name of each file will be entered into the Down Codes Configuration program. Reference Section 2.6 for additional information.

Parameter Names ..\Voice\Parm The name of each process parameter. The name of each file will be entered into the Process Parameters Configuration program. Reference Section 2.11 for additional information.

You may not need to record all sound files. For example, if you are not going to perform alarming for calls for help, then you do not need to record the Help Call Reasons. If you are not going to perform alarming when a machine is down, then you do not need to record the Downtime Reasons. If you are not going to perform alarming on process parameter out-of-specification conditions, then you do not need to record the Parameter Names. If a sound file is needed, but is missing, it will simply be skipped. There are a handful of special sound files that don’t exist in the above directories. The following table describes these special files that you will need to create and their default location:

File Name Subdirectory Description bell.wav ..\Voice\Names This file contains the bell sound that can

optionally be played at the start of a voice announcement.

down.wav ..\Voice\Names This file, which typically contains the phrase “…down for…”, is played during a downtime announcement.

help.wav ..\Voice\Names This file, which typically contains the phrase “…needs assistance…” is played during a help call announcement.

signal.wav ..\Voice\Names This file, which typically contains the phrase “…limits violation…” is played during an out-of-specification announcement.


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File Name Subdirectory Description unknown.wav ..\Voice\Names This file, which typically contains the

phrase “Unknown”, is played whenever a needed voice file can not be located.

Advanced Tip #3

A good sound recording will be loud, without any distortion. You may want to practice recording and playing back the sound and adjust your distance to the microphone, as appropriate.

Instead of simply recording the needed text, try saying the full voice announcement, then edit out the unnecessary text. For example, imagine that you have a Help Call named “Supervisor”. You want the full voice announcement to say “Machine One needs a supervisor”. Instead of simply recording the text “needs a supervisor”, try recording the full announcement “Machine One needs a supervisor” then edit out the text “Machine One”. This may result in a more natural-sounding announcement.

After placing the sound files in the appropriate directories on the server computer, ensure that you modify the appropriate areas of the software to list the names of the files. For example, each Machine configuration should be modified to list the name of the relevant sound file for the machine. Repeat this for all Machines, Departments, Help Codes, Down Codes, and Process Parameters.


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5.1.3 Creating Email Addresses for Email Alarms Before enabling the Email Alarm option, you must create the necessary email address configurations. To configure an email address, follow these steps:


• Click the Miscellaneous menu and select Email Address. The Email Address screen will be displayed.

Email Address Configuration

You can view existing email addresses, edit existing email addresses, create new email addresses, and delete existing email addresses if you have been assigned appropriate security


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permissions by the System Manager. You can not delete an email address if the address is assigned to a Voice/Email Map. The following fields are available in the Email Address Configuration screen:

Field Description Email Address The email address (or alias) that email alarms will be sent to. Description A description for this configuration. If a user needs multiple

configurations, simply use the same Email Address and a different Description.

Account Disabled

Allows you to temporarily disable this Email Address, such as when a user is on vacation.

Days of Week Check the days of the week when this user should receive email alerts.

Times Check “All Times” to send email alerts to this user all day long for the enabled day(s) or specify a start time and end time for sending alerts.

The Email Address Configuration program allows you to define the hours of the day (or “All Times”) and the days of the week when a specific email address should receive email alerts. For example, some users may only receive email alerts during their normal working day, whereas other users may only receive email alerts after hours.

Advanced Tip #1

Some users may want multiple email configurations. For example, the Plant Manager may want to receive emails for downtime events after a machine has been down for 30 minutes, provided that he/she is currently in the office. However, he/she may want to be notified immediately if a machine goes down after hours.

To accomplish this, simply create two Email Address configurations for the user, each with the same “Email Address” but each with a different “Description”. One address will receive emails during certain days/times while the second address will receive emails during different days/times. (The Voice/Email Map will allow you to send email alerts to the first account after a machine has been down for 30 minutes and to the second account as soon as a machine goes down.)

Advanced Tip #2

If a user wants to receive email alerts from 8-12 and from 1-5, but not receive email alerts during lunch, simply create two email accounts for this user as described above.


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5.1.4 Voice and Email Maps The Voice Alarm option and the Email Alarm Option are two distinctly-separate options, but they share some things in common. For example, if you acknowledge an alarm, it is acknowledge both for voice alarms and email alarms. Similarly, both options are configured in the same “map”. To configure a Voice and Email Map, follow these steps:


• Click the Miscellaneous menu and select Voice and Email Maps. The Voice and Email Maps screen will be displayed.

Voice and Email Map Configuration – Help Voice Tab


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Voice and Email Map Configuration – Help Email Tab

You can view existing maps, edit existing maps, create new maps, and delete existing maps if you have been assigned appropriate security permissions by the System Manager. You can not delete a map if the map is assigned to a Machine. A Voice and Email Map is used to enable/disable the following:

• Voice alarms for calls for help. • Email alarms for calls for help. • Voice alarms for machines that are down. • Email alarms for machines that are down. • Voice alarms for machines that are out-of-specification. • Email alarms for machines that are out-of-specification.


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Advanced Tip #1

When using either alarm option for calls for help, the specific help codes must be individually enabled. Reference Section 2.8 for additional information.

When using either alarm option for machines that are down, the specific down codes must be individually enabled. Reference Section 2.6 for additional information.

Advanced Tip #2

When using either alarm option for out-of-specification alarming, it is a good idea to enable all process parameters and to not enable some process parameters while disabling other process parameters. Leave the “Sound File” blank for all process parameters. Reference Section 2.11 for additional information.

The following fields are available in the Voice and Email Map Configuration screen:

Field Description Map Name The unique name for the Map. This value will be displayed in the

Machine configuration program. Description A description for the map. Base File Location The file location, from the perspective of the server computer,

where voice files/directories are located. Voice Enabled Enables voice alarms for this tab (Help, Down, or Parameter). Play Bell If enabled, a bell sound will be played at the start of the voice

announcement. Play Department If enabled, the department name will be played before the machine

number is played. Play Type If enabled, the alarm type (e.g., “Needs Assistance”) will be

played before the specific reason (e.g., “Supervisor”) is played. This field is disabled for Parameter (out-of-specification) announcements so that a phrase similar to “limits violation” is always played.

Skip First Announcement

If enabled, the first voice announcement is skipped. The first audible announcement will be heard after “Repeat Minutes” have elapsed.


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Field Description Number of Plays This field defines the number of times the voice announcement is

repeated each time that it is read. Typically, this value is set to 1 or 2. This field does not affect how many times a voice announcement is repeated. An announcement will continue to repeat every “Repeat Minutes” until the alarm is acknowledged or cancelled. Reference Section 5.1.1 for additional information.

Repeat Minutes This field appears on the appropriate “Voice” tab, but it applies to both the Voice Alarm and the Email Alarm. When referring to Voice Alarms, this field defines how frequently the Voice Alarm will repeat. If “Skip First Announcement” is enabled, the first Voice Alarm will occur in “Repeat Minutes” after the alarm condition occurs, then will repeat every “Repeat Minutes”. When referring to Email Alarms, this field defines how frequently the Email Alarm will be sent to the next user. For example, if Repeat Minutes is set to 5, and a user has the Send On value set to 3, then the user will receive an email if the alarm condition still exists after 15 minutes (5 * 3 = 15).

Send On This field, combined with the field “Repeat Minutes”, defines when an email will be sent to the specified Email Address.

Message This field specifies the type of email message that will be sent to the user, either “Short” (which is appropriate for cell phones and other devices with small displays) or “Standard” (which includes more information than the “Short” message).

Advanced Tip #3

The field “Repeat Minutes” appears on the appropriate “Voice” tab (Help, Down, or Parameter), but it applies to both the Voice Alarm and the Email Alarm.

Advanced Tip #4

The field “Play Type” is disabled for Parameter (out-of-specification) announcements so that a phrase similar to “limits violation” is always played. If multiple process parameters are out-of-specification at the time the alarm condition occurs, no process parameter names will be announced.


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5.1.5 Advanced Registry Settings After you have configured the Voice Alarm option or the Email Alarm option, you may temporarily disable these options by modifying a registry setting and then restarting the “Mattec MIU Service”.

Advanced Tip #1

ProHelp® EPM’s advanced settings are stored in the Windows registry. Do not attempt to edit the registry unless you have experience doing so. Contact the Mattec Customer Service Department if you need additional assistance.

The settings to enable/disable the Voice Alarm option or the Email Alarm option are configured in the Windows registry in the directory HKEY_LOCAL_MACHINE\Software\Mattec\Moller. These values all have reasonable default settings.

Registry Key Description EmailEnabled You can set this value to 0 (disabled), then restart the

“Mattec MIU Service”, in order to temporarily disable all email alarms without needing to change any system configuration. The default value for this setting is 1 (enabled).

VoiceEnabled You can set this value to 0 (disabled), then restart the “Mattec MIU Service”, in order to temporarily disable all voice alarms without needing to change any system configuration. The default value for this setting is 1 (enabled).

VoiceSleep This value, which is specified in milliseconds, is the amount of time that the monitoring engine will pause after process all outstanding requests to play a voice alarm. This pause dramatically lessens the impact that voice alarming has on the overall system performance. The default value for this setting, if it is not specified in the system registry, is 10000 (10 seconds).

VoiceSleepAfterPlay This value, which is specified in milliseconds, is the amount of time that the monitoring engine will pause after processing one voice alarm request before processing the next voice alarm request. The default value for this setting, if it is not specified in the system registry, is 2000 (2 seconds).


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5.1.6 Advanced Email Settings (For Microsoft Exchange Server) In many cases, you will be able to configure the Email Alarm option simply by logging into the ProHelp® EPM server computer as the Microsoft Windows “Administrator”, then by configuring Microsoft Outlook Express to be able to send emails (presumably using a new email address that your IT Department will create for you). However, in some configurations, including when your email server is Microsoft Exchange Server, you will need to configure additional registry settings that ProHelp® EPM will use when sending emails.

Advanced Tip #2

Before trying the advanced settings described in this section, log in to the ProHelp® EPM server computer as the Microsoft Windows “Administrator”, then configure Microsoft Outlook Express to be able to send emails.

If the ProHelp® EPM system is able to send emails, no additional action is required. If ProHelp® EPM is unable to send emails, try using the settings that are described in this section.

All advanced email settings are configured in the Windows registry in the directory HKEY_LOCAL_MACHINE\Software\Mattec\Email. Many values are not configured by default. Those are the values that this section will describe how to configure.

Registry Key Description FromEmailAddress Advanced Setting. Set this value to the (reply) email

address that will be used by ProHelp® EPM. SendEmailAddress Advanced Setting. Set this value to the (send) email

address that will be used by ProHelp® EPM. SendPassword Advanced Setting. This is the password for the email

account that will be used by ProHelp® EPM. SendUserName Advanced Setting. This is the user id for the email

account that will be used by ProHelp® EPM. SendUserReplyEmailAddress Advanced Setting. Set this value to the (reply) email

address that is specified in FromEmailAddress.


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Registry Key Description SendUsingMethod Advanced Setting. Typically, this value should be set

to 2. This is the default setting for POP3 email servers. Set this value to 1 if you are using an SMTP Pickup Directory. This is rarely used. Set this value to 2 if you are using SMTP Over Network (e.g., sending over port). This is very common.

SMTPAccountName Advanced Setting. The email account name. SMTPAuthenticate Advanced Setting. Set this value to 0 if your SMTP

server does not require authentication. Set this value to 1 if your SMTP server requires authentication and you will “Use same settings as my incoming mail server”. Set this value to 2 if your SMTP server requires authentication and you will “Log on using an account name and password”.

SMTPConnectionTimeout Advanced Setting. This value is specified in seconds and is the amount of time the mail program will wait before timing out. A value of 60 is common.

SMTPServer Advanced Setting. This is the name of your outgoing mail (SMTP) server. This name can be specified in the form mailserver.company.com or a TCP/IP address.

SMTPServerPort Advanced Setting. This is the port number that your outgoing mail (SMTP) server requires. This value is typically 25 if your SMTP server does not use SSL and 465 if your SMTP server requires SSL.

SMTPUseSSL Advanced Setting. Set this value to 0 if your outgoing mail (SMTP) server does not require SLL. Set this value to 1 if your outgoing mail server requires a secure connection (SSL).

UseDefaultAccount This value is set to 1 by default. You must change this value to 0 and restart the “Mattec MIU Service” to cause ProHelp® EPM to use the advanced email settings in the registry. When this value is set to 1, ProHelp® EPM will use the default settings that have been set in Outlook Express.

After modifying the registry, you must restart the “Mattec MIU Service” to cause ProHelp® EPM to use the advanced email settings.


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5.1.7 Voice Administrator – Diagnostic Tool The Voice Administrator is a diagnostic tool. It exists to help you troubleshoot problems with the Voice Alarm option or the Email Alarm option. You must manually launch the Voice Administrator. To do this, follow these steps:

• Navigate to the directory C:\Program Files\Mattec\ProHelp\Bin and double-click on the file VoiceAdmin.exe. The Voice Administrator will be displayed:

Voice Administrator

The “Acknowledge” tab of the Voice Administrator will show you all pending voice (and email) alarms for the selected Department(s), Machine(s), and the Request Type (Help, Down, and/or Parameter).


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Advanced Tip #1

If an alarm should be pending, but is not displayed, then the alarm is probably not configured properly. For example, if you have called for Help (Reason #2) from Machine #1, but an alarm is not displayed, check the following:

1. Ensure that Help Reason #2 has been enabled for voice alarms (and has a “Voice File” specified) or has been enabled for email alarms.

2. Ensure that Machine #1 has a Voice and Email Map specified.

3. Ensure that the Voice and Email Map has voice alarms for help call or email alarms for help calls enabled.

You can press the sound icon to test a pending voice request. The request will be played immediately using the configuration in the Voice and Email Map. You can press the email icon to test a pending email request. You will be prompted to select a valid email address (such as your own) and the system will send you the email alarm using the configuration in the Voice and Email Map.


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The “Diagnostics” tab of the Voice Administrator allows you to quickly see which sound files have been properly configured and which have not. To see which sound files have been configured and which have not, follow these steps:

• Start the Voice Administrator program. To do this, navigate to the directory C:\Program Files\Mattec\ProHelp\Bin and double-click on the file VoiceAdmin.exe.

• Press the Diagnostics tab.

• Select the appropriate categories of data that should be configured and press the

Start button. The program will analyze the system configuration and display the voice files that are configured and those that are missing.

Voice Administrator - Diagnostics


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The “Configuration” tab of the Voice Administrator allows you to quickly see the value of registry settings that affect the Voice Alarm option and the Email Alarm option. To see the registry settings for the Voice Alarm option and the Email Alarm option, follow these steps:

• Start the Voice Administrator program. To do this, navigate to the directory C:\Program Files\Mattec\ProHelp\Bin and double-click on the file VoiceAdmin.exe.

• Press the Configuration tab. The relevant registry settings will be displayed.

Voice Administrator – Configuration

Advanced Email Alarm registry settings are described in Section 5.1.5.


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5.2 On-Demand Barcode Printing Mattec’s On-Demand Barcode Printing option is a low-cost, but highly-flexible way of implementing barcode printing within your facility. This option gives you a great deal of control over the label design, supports a large number of printers, and is even capable of generating RFID tags.

Advanced Tip #1

On-Demand Barcode Printing is an optional feature. You may purchase this feature any time by contacting the Mattec Sales Department.

To configure the On-Demand Barcode Printing option, you must do the following:

1. Purchase and install at least one copy of Ultra Label Gold. Many customers will find that they can load this software on the ProHelp® EPM server computer.

2. Design one or more barcode labels.

3. Define a Print Server in the ProHelp® EPM software and configure the Print

Server to scan for print requests. Reference Section 5.2.1 for additional information.

4. Create one or more Printers in Microsoft Windows and define them in the

ProHelp® EPM software. Reference Section 5.2.2 for additional information.

5. Assign a Print Server and a Printer to each Machine in the Machine configuration program.

6. Enable On-Demand Barcode Printing in a Part ID.

Labels can be printed by pressing the “Print Label” button in the PCMIU or by launching the Document Control Center from the Real-Time Display.

Advanced Tip #2

On-Demand Barcode Printing requires you to purchase at least one copy of Ultra Label Gold from General Software (www.general-data.com). Ultra Label Gold will be used to design barcode labels and will be used by the ProHelp® EPM software to print the labels. Any printer that is supported by Ultra Label Gold can be used, including RFID printers.


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5.2.1 Print Servers When you install the Ultra Label Gold software on a computer (e.g., the ProHelp® EPM server computer), this computer will be referred to as a “Print Server”. You must define at least one Print Server within ProHelp® EPM and configure the Print Server to scan for print requests. To define a Print Server, follow these steps:

• Load the Ultra Label Gold software on the Print Server computer. • Start the System Configuration program. To do this, start the Main Menu and press

the Launch System Configuration icon.

• Click the Miscellaneous menu and select Barcode Print Servers. The Barcode Printer Server configuration screen will be displayed.

Barcode Print Server Configuration

You can view existing Print Servers, edit existing Print Servers, create new Print Servers, and delete existing Print Servers if you have been assigned appropriate security permissions by the System Manager. You can not delete a Print Server if the Print Server is assigned to a machine. The “Command File Directory” must be a directory on the Print Server computer that is shared


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so that all computers that will print barcode labels are able to write print request files to the directory. The example above presumes that the directory “C:\Commands” has been shared and that users will have Read/Write access to that directory.

Advanced Tip #1

Each system needs at least one Barcode Print Server. You can create additional Print Servers to increase the throughput of the system. Simply load additional copies of Ultra Label Gold on additional computers, define the Barcode Print Servers in the ProHelp® EPM software, and redirect some machines to send their print requests to the additional Print Servers.

After defining a Print Server, you must run the Ultra Label Gold software to tell it to look for print requests in the appropriate directory. To do this, follow these steps:

• Start the Ultra Label Gold software on the Print Server computer. • Click the Options menu, click the Configuration menu, and select Command File.

• Enter the name of the “Command File Directory” that was specified above, such as

C:\ Commands. In order to print labels, you must manually start the Command File Monitor in the Ultra Label Gold software. To do this, follow these steps:

• Start the Ultra Label Gold software on the Print Server computer. • Click the Server menu and select Command File. The Command File Monitor will

be started.

Advanced Tip #2

Barcode labels will not be printed unless the Ultra Label Gold Command File Monitor is running. This program must be started manually every time the Print Server computer is rebooted.


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5.2.2 Printers The Ultra Label Gold software supports a large number of printers. Any printer that is supported by Ultra Label Gold can be used with the On-Demand Barcode Printing option, including RFID printers. To define a Printer, follow these steps:

• Log in to the Print Server computer. Using the Microsoft Windows Control Panel, define a new barcode printer. The printer can be a networked printer, a printer that is connected directly to the Print Server, or a printer that is connected directly to a different computer and shared for use by the Print Server. However, you must be able to define (and access) the printer from the Print Server computer.

• Start the System Configuration program. To do this, start the Main Menu and press

the Launch System Configuration icon.

• Click the Miscellaneous menu and select Barcode Printers. The Barcode Printer configuration screen will be displayed.

Barcode Printer Configuration

You can view existing printers, edit existing printers, create new printers, and delete existing printers if you have been assigned appropriate security permissions by the System Manager. You can not delete a printer if the printer is assigned to a machine. The “Printer Name” is the long name for the printer that is displayed in the Control Panel.


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Advanced Tip #1

The Printer Name is the long name for the printer that is displayed in the Microsoft Windows Control Panel (Printers and Faxes). Enter this name carefully, as it is case-sensitive.

5.2.3 Label Design Barcode labels should be designed using the Ultra Label Gold software. Label formats should then be copied to a common directory, such as C:\Labels. When you print a barcode label using the ProHelp® EPM software, you will probably want to include “variable” information, such as the current Job Number or the current Part Number. To do this, follow these steps:

• Start the Ultra Label Gold software and create a barcode label. • Right-click on the label and select Add then select Text.

• Press the Text tab. Change the value for Data Source to When Printed, as shown

below:

Configuring Variable Fields in Ultra Label Gold


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• Press the Options tab. Specify the variable in the Field Name box.

Specifying the variable “MATTECJob”

The following variable fields are available for use in the standard software:

Variable Field Description MattecJob The Job Number. MattecPart The Part Number. MattecPartsPerCase The parts per case for the Part ID. MattecBoxCount The packed production divided by the parts per case. MattecOperator The primary machine operator. MattecDate The date. MattecTime The time.

Advanced Tip #1

If you need additional variable fields, Mattec can create custom software for you to accomplish this. Please contact the Mattec Customer Service Department for additional information.


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5.2.4 Configuration After you have created a Print Server, barcode printers, and designed labels, you need to configure the ProHelp® EPM system. When a label is printed (at the PCMIU or via the Document Control Center), it is sent to a default Print Server. The Print Server will accept the print request, generate a barcode label that includes any variable fields, and send the formatted label to the default printer. The default Print Server and default printer may vary for each machine. To assign default Print Server and a default printer to a machine, follow these steps:


• Click the Site menu and select Machine Configuration. The Machine Configuration program will be displayed. Press the Miscellaneous tab.



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You can select a Print Server and a barcode printer from the items that have been previously created. Reference Section 5.2.1 and Section 5.2.2 for additional information.

Advanced Tip #1

You can override the default Print Server and barcode printer for a computer using the Advanced Settings described in Section 5.2.5. For example, you might want to do this if you have a computer where a lot of barcode labels will be printed.

To enable On-Demand Barcode Printing for a job, follow these steps:

• Start the Edit Facility program. To do this, start the Main Menu and press the Launch Edit Facilities icon.

• Click the Part ID icon and select the Part ID to edit. Press the Barcode Printing tab.

Part ID – On-Demand Barcode Printing Configuration

You can view existing configurations, edit existing configurations, add new label configurations, and delete existing label configurations if you have been assigned appropriate security


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permissions by the System Manager. The “Label Name” that is specified must be the fully-qualified file name that the Print Server requires, from the perspective of the Print Server. As such, this name can include a local path such as C:\Labels\labelname.lbl. It’s a good idea to place all labels in the same directory on the Print Server, such as C:\Labels. Users can then print labels by pressing the “Print Label” button at the PCMIU or by launching the Document Control Center. Details about the barcode label, printer, and Print Server are largely hidden from the end user.

PCMIU – On-Demand Barcode Printing


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5.2.5 Advanced Registry Settings The previous sections describe how to configure the On-Demand Barcode printing option. For most users, this will be sufficient. However, Mattec has created the ability to override the default settings, such as the printer and Command File Directory (Print Server) that are configured in the Machine configuration, on a computer-by-computer basis. For example, you might want to do this if you have a computer that will print a large volume of labels. You could configure this computer to be a Print Server with a locally-defined printer and cause all labels that are printed from the computer to be sent to the local Print Server and the local barcode printer. All advanced On-Demand Barcode Print settings are configured in the Windows registry in the directory HKEY_LOCAL_MACHINE\Software\Mattec\Pcmiu. These settings apply to both the PCMIU and the Document Control Center.

Advanced Tip #2

ProHelp® EPM’s advanced On-Demand Barcode Print settings are stored in the Windows registry. Do not attempt to edit the registry unless you have experience doing so. Contact the Mattec Customer Service Department if you need additional assistance.

Registry Key Description Label This registry setting is rarely used. It allows you to

force the PCMIU and/or the Document Control Center to always print the specified barcode label, regardless of what is defined in the Part ID.

Printer This registry setting allows you to override the name of the printer that is defined in the Printer Configuration and selected in the Machine configuration. For example, you might specify the name of a printer that is connected directly to this computer.

Copies This registry setting allows you to override the Default Number of Copies that will be printed. The user may still change this setting in the PCMIU or the Document Control Center.

FileLocation This registry setting allows you to override the location of the Command File directory for the Print Server. For example, you might specify a local directory named C:\Commands if you intend to configure this computer to be a Print Server.


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5.3 Automatic Barcode Printing Mattec’s Automatic Barcode Printing option is very powerful, yet surprisingly simple application. This optional feature allows the MIU to print a custom, serialized barcode label and to permanently record the serial number and related job information. Variable data, such as the Job Number and the Serial Number may be included on the barcode label. Because labels are generated and printed by the MIU, system throughput (the number of labels that the system is capable of printing) is very high. To configure an MIU for Automatic Barcode printing, follow these steps:

• Design a barcode label using a label design package (e.g., EasyLabel) that can “Print To File” in the Zebra ZPL2 format. You can use symbols to represent variables, such as %%S for the Serial Number.

• Name the file LABx.DAT, where x is the number 1-9. • Manually copy the LABx.DAT file to the MIU’s hard drive. Repeat this step for

every MIU that will print this barcode label. • Manually enable the label in the system by adding an appropriate entry in the

database table dbo.Label. • Enable Automatic Barcode Printing in the Part ID via Edit Facilities.

Advanced Tip #1

Automatic Barcode Printing is an optional feature that requires a TSMIU or a supported AIU. You may purchase this feature at any time by contacting the Mattec Sales Department.

Implementing Automatic Barcode Printing in a facility is surely a very expensive project. If you are looking for a low-cost barcode printing solution, Mattec’s On-Demand Barcode Printing option may be more appropriate. Reference Section 5.2 for additional information.

The following variable symbols are available:

Symbol Description %%S The Serial Number. %%T1 The Machine Number. %%T2 The Job Number for the running job. %%T3 The Part Number for the running job. %%T4 The Tool Number for the running job.

If you need additional variable data to be printed on the barcode label, custom programming will be required.


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Advanced Tip #2

To use the Automatic Barcode Printing feature, you must connect a Zebra barcode printer that supports the ZPL2 programming language via a serial interface to a COMM Port on the TSMIU. Since all COMM Ports on the TSMIU are already assigned, a small amount of custom programming is required.

Advanced Tip #3

Mattec designs labels for the Automatic Barcode Printing feature by using EasyLabel from Tharo Systems Inc. (www.easylabel.com). This is an easy-to-use label design package that allows you to “Print To File” for a Zebra printer that supports the ZPL2 programming language.

The “Mattec Standard Serial Number” is a 24-character serial number that has the following format: JJJJJJJJJJSSSSSSSSSCCCCC Where “JJJJJJJJJJ” is the internal JobSeq that uniquely identifies a Job Number, “SSSSSSSSS” is the internal ShiftSeq when the barcode was printed (a ShiftSeq uniquely identifies a date and shift) and CCCCC is the machine cycle count within the specified shift.

Advanced Tip #4

The Automatic Barcode Printing feature is not capable of recording 100% of the serial numbers that are generated. However, the default serial number includes data that would allow a knowledgeable user to derive the Machine Number, Job Number, and approximate Date/Time that the label was printed.

In a normal ProHelp® EPM system, the Automatic Barcode Printing feature will only record the serial number data for 95% to 98% of labels that are printed. If the MIU is unable to communicate with the host computer (such as when the host computer is turned off), this feature will record 0% of the related data.

Advanced Tip #5

If you wish to print an RFID tag, such as Mattec demonstrated at the NPE Show in 2006, custom programming is required. Specifically, most RFID tags are capable of holding only a tiny amount of information and your system will require a custom serial number as a result.


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Edit Facilities has a “Serial Number Locator” that allows you to type in a Serial Number. The program will return the Machine Number, Job Number, Shift, Date, and Time that the label was printed. If a Serial Number can not be found, you should manually look for similar numbers in the database table dbo.SerialNumbers to identify the relevant job data and approximate date/time that the label was printed. If Parameter Recording or Process Exception Logging were enabled when the serial number was printed, and if the Serial Number Locator finds the serial number in the database, the system will also display any related Parameter Recording data, Process Exception Log data, or the related Last 10,000 Chart data, if this data is still online.

Advanced Tip #6

When automatic barcode printing is enabled for a job, the system will store the serial number that is generated in the database table dbo.SerialNumbers.

Additionally, if Parameter Recording is enabled for the job, the serial number will be stored with that data in the database table dbo.ParameterRecording. If Exception Logging is enabled for the job, the serial number will be stored with that data in the database table dbo.ExceptionLog. Finally, the serial number will be recorded with the Last 10,000 Chart data in the database table dbo.ParmDat.


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5.4 System Security ProHelp® EPM relies heavily on the user/group security that is built into Microsoft Windows Server 2003 to permit/limit access to areas of the ProHelp® EPM software. To add a new user to the ProHelp® EPM system, follow these steps:

• Create a new Windows Server 2003 user using Microsoft Windows Computer Management utility.

• Make the user a member of the SQL Users group.

• Make the user a member of MATTEC groups, as appropriate.

Advanced Tip #1

If you are using Microsoft’s “domain security”, you can follow the above steps on the domain controller, provided that Mattec’s security-related scripts were run on the domain controller. Contact the Mattec Customer Service Department for additional information.

The security within ProHelp® EPM is extremely flexible, and it is common for customers to customize the security to meet their needs. Security to specific areas of ProHelp® EPM is based on the user’s rights to the security files in the C:\Program Files\Mattec\ProHelp\Sys\Security directory. Three types of permissions exist, including:

• None – The user can not view, edit, create, nor delete records in this area of ProHelp® EPM.

• Read+Execute – The user can view records in this area of ProHelp® EPM, but can not edit, create, or delete records.

• Create – The user can view, edit, create, or delete records in this area of ProHelp® EPM.

For example, the file “Schedule” in the above directory permits/denies access to the Job Schedule in ProHelp® EPM. A user who has no rights to the “Schedule” file will be unable to view or modify the Job Schedule. A user who has “Read+Execute” rights to the “Schedule” file will be able to view the Job Schedule, but will be unable to modify the Job Schedule. A user who has “Create” rights to the “Schedule” file will be able to view, edit, create, or delete records in the Job Schedule. You can grant access to areas of the ProHelp® EPM system by assigning users to the MATTEC-


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related groups. The following table lists the Windows 2000 groups that are created by the installation program and the area of the system that they permit access to:

Windows 2000 Group Description MATTEC Basic User The “MATTEC Basic User” has read access to most areas of the

ProHelp® EPM system and has full access to the following areas:

• Cavity Entry • Remote Downtime Selection • Real-Time Display Writer • Material Lot Edit • Packed Parts Entry • Scrap Parts Entry

MATTEC Maintenance User The “MATTEC Maintenance User” has read access to most areas of the


• Cavity Entry • Remote Downtime Selection • Real-Time Display Writer • Help Acknowledge • Machine Calibration • Machine Maintenance Logs • Tool Maintenance Logs

MATTEC SPC User The “MATTEC SPC User” has read access to most areas of the


• Cavity Entry • Real-Time Display Writer • GagePort Configuration • Process Sheets • Sample Sheets • Setup Sheets • Packed Parts Entry • Scrap Parts Entry • ProStat® SPC/SQC • ProStat® Sample Data Edit

MATTEC Job Manager The “MATTEC Job Manager” has full access to most areas of the system

except for some System Configuration-related areas. The “MATTEC Job Manager” is able to view and modify cost-related fields.

MATTEC System Administrator

The “MATTEC System Administrator” has full access to all areas of the ProHelp® EPM system.


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Advanced Tip #2

If a user is a member of two groups that have access to ProHelp® EPM security files, the most-restrictive group settings take effect if you are using NTFS security.

Advanced Tip #3

By default, the Windows Server 2003 group “Administrators” will have full access to all areas of the system.

Advanced Tip #4

The Mattec security groups are a simple method for providing access to the relevant security files in the security directory. Knowledgeable users can create their own groups or can modify the permissions on the relevant security files directly in order to permit/deny access to the system, as appropriate.

The following table lists the security files that are installed in the security directory and the area of the system that they control access to:

Security File Description Automatic SPC Controls access to the Automatic SPC sample edit feature in Edit

Facilities. Calculate Limits Controls access to the calculate limits feature in the Real-Time Display

and ProStat. Cavity Entry Controls access to the cavity entry feature in the Real-Time Display. CMS Event Based Controls access to the CMS Event Based Map configuration in System

Configuration. Cost Manager Controls access to the Cost Display in the Real-Time Display. Data Exchange Controls access to the Data Import/Export program. Departments Controls access to the Department configuration in System

Configuration. Display Writer Controls access to the Real-Time Display Writer in System

Configuration. Down Codes Controls access to the Down Codes and Down Map configuration in

System Configuration. Down Select Controls access to the remote downtime selection feature in the Real-

Time Display. Down Time Cost Restriction Controls access to the down cost fields in the system. Downtime Edit Controls access to the Downtime Edit program in Edit Facilities. Email Address Controls access to the Email configuration in System Configuration. Gage Configuration Controls access to the GagePort configuration in the ProStat® Sample

Data Edit program. Gauge Controls access to the Gauge Type configuration in System

Configuration.


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Security File Description Help Ack Controls access to the help acknowledge feature in the Real-Time

Display. Help Codes Controls access to the Help Codes and Help Map configuration in

System Configuration. Job Descriptor Controls access to the Job Descriptor in Edit Facilities. Job Setups Controls access to Job Setup Notes in Edit Facilities. JobControl Controls access to Job Control. KanbanScan Controls access to the Kanban Scanner program. Machine Calibration Controls access to the Machine Calibration in System Configuration. Machine Configuration Controls access to the Machine Configuration in System Configuration. Machine Maintenance Codes Controls access to the Machine Maintenance Codes in System

Configuration. Machine Maintenance Logs Controls access to the Machine Maintenance Logs in Edit Facilities. Manual SPC Controls access to the Manual SPC sample edit feature in Sample Data

Edit. Material Characteristic Controls access to the Material Characteristic configuration in System

Configuration. Material IDs Controls access to the Material IDs in Edit Facilities. Material Inventory Controls access to the Material Inventory in Edit Facilities. Material Lots Controls access to the Material Lots in Edit Facilities. Material Order Controls access to the Material Purchase Order in Edit Facilities and the

Job Schedule. Material Supplier Controls access to the Material Supplier in Edit Facilities. Operator Efficiency Controls access to the Operator Efficiency Display in the Real-Time

Display. Operator ID Controls access to the Operator Permissions program in System

Configuration. Packed Entry Controls access to the packed parts entry feature in the Real-Time

Display. Parameter Choices Controls access to the Parameter configuration in System Configuration. Part Cost Restriction Controls access to the part cost fields in the system. Part IDs Controls access to Part IDs in Edit Facilities. PCMIU Cells Controls access to the PCMIU Cell configuration in System

Configuration. PCMIU User Controls access to the PCMIU (Cell Controller) program and provides

access to nearly all features of the PCMIU. Percent Regrind Controls access to the percent regrind feature in the Real-Time Display. Printers Controls access to the barcode printer configuration in System

Configuration. Process Sheets Controls access to Process Sheets in Edit Facilities. Production Edit Controls access to the Production History Edit program in Edit Facilities. ProStat Controls access to the ProStat® SPC/SQC data analysis program. RealTimeDisplay Controls access to the Real-Time Display program. Sample Data Controls access to the ProStat® Sample Data Edit program in Edit

Facilities. Sample Sheets Controls access to the ProStat® Sample Sheets in Edit Facilities. Schedule Controls access to the Job Schedule. Scrap and Packed Parts Controls access to the scrap and packed parts entry program in Edit

Facilities. Scrap Codes Controls access to the Scrap Codes and Scrap Map configuration in

System Configuration.


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Security File Description Scrap Entry Controls access to the scrap entry feature in the Real-Time Display. Setup Sheets Controls access to the Document Control Center. Shift Configuration Controls access to the Shift Boundaries configuration in System

Configuration. Shift Exceptions Controls access to the Shift Exception configuration in System

Configuration. SPC Causes Controls access to the SPC Cause configuration in Edit Facilities. Supplier IDs Controls access to the Supplier IDs in Edit Facilities. System Configuration Controls access to the System Configuration option in System

Configuration. System Reports Controls access to the System Reports program. Tool IDs Controls access to the Tool IDs in Edit Facilities. Tool Maintenance Codes Controls access to the Tool Maintenance Codes in System Configuration. Tool Maintenance Logs Controls access to the Tool Maintenance Logs in Edit Facilities. VOICE ACK Controls access to the voice and email acknowledge feature in the Real-

Time Display. Voice And Email Controls access to the Voice and Email Map configuration in System

Configuration.

Advanced Tip #5

It is possible to manually modify security access to the system within SQL Server. This is not recommended. By default, the “SQL Users” group has been created to give users read/write access to SQL Server. Any user who will have access to ProHelp® EPM will need to be a member of this group.


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5.5 Database Backup It is important to backup the system’s data to protect against accidents. Daily backup is recommended; weekly backup is mandatory.

Advanced Tip #1

If the hard drive in your ProHelp® EPM server “crashes”, the system will be rebuilt using a database backup. If you don’t have a database backup that is physically separate from the server (e.g., located on a tape), then you may lose all data from your system!

Advanced Tip #2

The most important job that the System Manager has is to properly backup the ProHelp® EPM database in a timely manner and to copy the database to an appropriate storage device (including tape, a CD, a DVD, or another computer’s hard drive).

This job will likely go unnoticed unless/until your system’s hard drive “crashes”. At that point, all eyes will be focused on the System Manager.

Backing up the database is a function of SQL Server. That is, ProHelp® EPM does not provide any tools for performing a database backup. To backup the database, follow these steps:

• Start the SQL Server Enterprise Manager. To do this, click on the Microsoft Windows Start Menu. Click on the Programs menu, click on the Microsoft SQL Server menu, and select Enterprise Manager.

• Locate the MATTEC_PROHELP database.

• Right-click on the MATTEC_PROHELP database, click on All Tasks, and select Backup Database. The SQL Server Backup screen will be displayed.

• Ensure that Database – complete is selected.

• Ensure that in the Backup To area that Disk is selected. This will backup the database to a disk file.

• You can press the Add button to specify a Destination name for the database backup. If you have already run this utility, a Destination name will already be present. If you will copy the file to a removable device, then it is OK to reuse the


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Destination name. If you are copying the file to another computer’s hard drive, then it would be a good idea to Remove the existing Destination name and Add a unique Destination name.

• Press OK to start the database backup.

• Repeat this process on the master database.

SQL Server Backup Screen

Advanced Tip #3

If you are copying the database backup to a removable device (e.g., a tape), then it is OK to use the same “Destination” name over and over.

If you are copying the database backup to another computer’s hard drive (e.g., a network drive), then you should probably “Remove” the existing “Destination” name and “Add” a unique “Destination” name every time you make a database backup.


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Advanced Tip #4

The Mattec Customer Service Department can automate the database backup procedure for you. Then, the only job for the System Manager is to ensure that the database backup ran successfully and was copied to an appropriate storage device (including tape, a CD, a DVD, or another computer’s hard drive).


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5.6 Purge The System Manager is responsible for “purging” old data from the system after this data has been properly backed up. It is necessary to periodically purge data from the system in order to limit the amount of data that is kept on-line in order to maintain an acceptable level of system speed.

Advanced Tip #1

It is a good idea to backup your database and to store that backup in a secure location before purging data from the system. This will potentially allow you to view that data in the future.

“Purge” is a stored procedure that must be executed manually in order to delete old data from the system. The maximum number of days of historical data to retain is specified on the “Purge” tab of the System Configuration screen in System Configuration (Section 2.5). All data that is older than the specified dates will be deleted from the system when the purge stored procedure is executed. The data is not physically purged from the system unless/until you execute the purge stored procedure.

Purge Tab – System Configuration


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Advanced Tip #2

The maximum number of days of historical data to retain is specified on the “Purge” tab of the System Configuration screen in System Configuration (Section 2.5). However, the data is not physically purged from the system until you execute the purge stored procedure.

Advanced Tip #3

The Mattec Customer Service Department can automate the purge stored procedure for you.


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5.7 Loading the Client Software The System Manager is responsible for loading the ProHelp® EPM client software on computer workstations throughout your facility. This will need to be done periodically for the following reasons:

• When a new employee is hired, his/her computer will need to be configured to access ProHelp® EPM.

• When you receive a software update from Mattec Corporation, all existing client computers will need to be updated with the new software.

There are two types of client installations, including:

• Typical – This installation leaves most application files on the ProHelp® EPM server and does not copy files to the client computer. This type of installation can slow down the system slightly but can eliminate the need to update client computers when minor enhancements or patches are loaded on the system.

• Local – This installation copies all the necessary application files to the client

computer. This type of installation provides the greatest system performance but makes it necessary to update all client computers when a new release of software is loaded on the system.

To load the ProHelp® EPM client software on a client computer, follow these steps:

• Ensure that the client computer is running an approved Microsoft operating system.

• Ensure that the user of the client computer has the appropriate login permissions on the ProHelp® EPM server computer.

• Ensure that the user of the client computer has the appropriate ProHelp® EPM security permissions on the ProHelp® EPM server computer. Reference Section 5.2 for additional information.

• If this is a new client computer installation, create an ODBC DSN on the client computer that connects to the ProHelp® EPM server’s MATTEC_PROHELP database. The name of the ODBC DSN must be the same name as the database on the ProHelp® EPM server for historical reasons. Reference Section 5.7.1 for additional information.

• Install the ProHelp® EPM client software. This software can be found on the ProHelp® EPM Installation CD that came with your system in a sub-directory named Client. Follow the on-screen prompts as appropriate.


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• When prompted, reboot the computer and ensure that the installation finishes without

any errors.

• If this is a new client computer installation, and you have performed a “Local” installation, run the System Names Edit program and configure it as appropriate. Reference Section 5.7.2 for additional information.

• Resolve any errors immediately with the Mattec Customer Service Department.

Advanced Tip #1

You should resolve any installation errors immediately with the Mattec Customer Service Department.

Advanced Tip #2

When you upgrade the client software in the future (such as when you receive a new release of ProHelp® EPM), you will not be prompted to enter any data. If you wish to change the installation directory or any other options, you must first uninstall the existing installation.


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5.7.1 ODBC Data Source An ODBC Data Source (ODBC DSN) is the mechanism that is used by the ProHelp® EPM Software to read data from the server computer. Before loading the ProHelp® EPM software on a client computer, you must create an ODBC DSN to connect to the ProHelp® EPM system. This step only needs to be performed once. You do not need to perform this step when upgrading an existing client computer with a new release of software. To create an ODBC DSN, follow these steps:

• Start the ODBC Data Source Administrator on the client computer. To do this, click on the Microsoft Windows Start Menu, click on the Settings menu, and select Control Panel. In the Control Panel window, double-click on the Data Sources (ODBC) icon. The ODBC Data Source Administrator window will be displayed.

• In the ODBC Data Source Administrator window, select the System DSN tab. Press the Add button.

• When prompted to Select a drive for which you want to set up a data source, select SQL Server. Press Finish.

ODBC DSN Creation Display

• When prompted, specify MATTEC_PROHELP as the Data Source Name, where


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MATTEC_PROHELP is the data source name that was used on the server. Enter the name of the ProHelp® EPM server in the Server field. Press Next.

• Press Finish.

• Select Test Data Source. Do not continue until the data source test completes successfully.

Advanced Tip #1

The steps for starting the ODBC Data Administrator vary slightly depending on the version of Microsoft Windows that is loaded on the client computer. Reference the Microsoft documentation that came with the client computer for additional information.

Advanced Tip #2

The name of the ODBC DSN does not need to be the same name as the physical database on the ProHelp® EPM server.

Older ProHelp® EPM systems required the ODBC DSN to have the same name as the physical database. This is no longer required.

Advanced Tip #3

It is recommended that you select TCP/IP on the Client Configuration screen.

Older ProHelp® EPM systems required this value to be set to Named Pipes. This is no longer required.


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5.7.2 System Names Edit After loading the ProHelp® EPM software on a client computer, the computer must be configured to connect to the ProHelp® EPM system. The System Names Edit program is used to perform this configuration. This step only needs to be performed once. You do not need to perform this step when upgrading an existing client computer with a new release of software. To run the System Names Edit program, follow these steps:

• Click on the Microsoft Windows Start Menu.

• Click on the Programs menu, click on the Mattec menu, click on the Utilities menu, and select System Names Edit.

• The System Names Edit program will be displayed.

System Names Edit Program


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The following fields are available in the System Names Edit screen:

Field Description System Number The number for the system, corresponding to the number that is

configured on the server (in the registry and in the System Names Edit program). For most installations, this number will be “1”.

System Description

A description for the system. This description will appear in the title bar of some applications.

Server Name The name of the ProHelp® EPM server. This value should be entered without a leading “\\”.

Database / ODBC DSN

The name of the ODBC DSN that is capable of connecting to the database on the ProHelp® EPM server.

‘Sys’ Directory The location of the Sys directory on the server computer. Typically, the C:\Program Files\Mattec\ProHelp directory on the server computer will be shared under the name “ProHelp”.

Contact the Mattec Customer Service Department if you need assistance determining the values for any of the above configuration parameters.

Advanced Tip #1

A single client computer can be configured to connect to as many as 99 different ProHelp® EPM systems, provided that all of the systems are running the same version of software. If a client computer is configured to connect to two (2) or more systems, the user will be prompted to select which system he/she is connecting to whenever he/she starts an application. The System Names Edit program is used to perform this configuration.

Advanced Tip #2

When you start the System Names Edit program, you will be prompted to enter a password. This password is not a closely guarded secret and exists simply to prevent novice users from deleting their client computer configuration.

If you do not know the password to the System Names Edit program but have a need to know the password, contact the Mattec Customer Service Department.


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6. ERP Integration The Data Import / Export option allows ProHelp® EPM to be easily connected with third-party ERP systems like SAP, BAAN, Oracle, Microsoft, JD Edwards, PeopleSoft, DTR (Made2Manage), and others. Job and Machine Schedule information can be extracted from external systems, written into an ASCII text file in a Mattec-defined format, and imported into ProHelp® EPM. Data can also be exported from ProHelp® EPM into an ASCII text file and then read into external systems.

Advanced Tip #1

Data Import / Export is an optional feature. You may purchase this feature at any time by contacting the Mattec Sales Department.

Advanced users may utilize the database stored procedures and database views that are used by the Data Import / Export program to create a highly-customized, highly-integrated interface between ProHelp® EPM and your ERP System. This process is described in great detail in Mattec’s Data Exchange Manual, #810-0002.

Advanced Tip #2

Reference the Data Exchange Manual, #810-0002, for additional information on Mattec’s Data Import/Export feature.

6.1 DTR Data Export The DTR Data Export option for ProHelp® EPM allows the ProHelp® EPM system to be easily integrated with Made2Manage’s The Manufacturing Manager™ (TMM) software. It allows ProHelp® EPM shift history data to be exported using the TMM Standard format (revised February 3, 1999). Users will still need to purchase the Data Import / Export option if they need to import data into ProHelp® EPM or to export Production History, SPC History, Job History, Process Sheets, Part IDs, or Tool IDs.

Advanced Tip #1

DTR Data Export is an optional feature. You may purchase this feature at any time by contacting the Mattec Sales Department.


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6.2 CMS Software Integration In 2006, Mattec Corporation merged with CMS Software of Toronto, Canada. CMS is a leading provider of ERP software, manufacturing software, and supply chain management software solutions to manufacturers and distributors operating in supply-chain-intensive environments.

Advanced Tip #1

While Mattec remains committed to helping our customers integrate ProHelp® EPM with any ERP solution that the customer chooses, CMS’s IBM-based (i5) and Microsoft-based (m5) ERP solutions can be tightly integrated with ProHelp® EPM using standard tools provided by Mattec and CMS.

Data such as Part IDs, Tool IDs, Process Sheets, Material IDs, Material Lists, Job Descriptors, and Machine Schedules can be sent from CMS i5/m5 directly into the ProHelp® EPM database. The mechanisms for performing these transfers are configured within the CMS i5/m5 software. Data such as Production History information can be sent from ProHelp® EPM to CMS i5 or CMS m5 through one of two mechanisms:

• Batch Interface

• Event Based Interface Despite it’s name, the Batch Interface can be schedule to run many times throughout the day and can transfer Production History data from ProHelp® EPM to CMS i5/m5 in real-time. The mechanisms for performing these transfers are configured within the CMS i5/m5 software. The Event Based Interface between ProHelp® EPM and CMS i5/m5 is described in the following section. 6.3 CMS Event Based (Map) The CMS Event Based interface is available for CMS i5 and CMS m5. It is a mechanism that CMS created to allow users to enter data into the CMS ERP system in real-time. For example, CMS has created barcode-scanning applications that allow the user to scan a job number (work order number) and enter production, run time, downtime, scrap parts, etc. ProHelp® EPM takes advantage of this interface to allow the monitoring engine to enter shop-floor events, as they occur in real-time and without user interaction, into the CMS ERP system. You have total control over which machines will send data to CMS using the Event Based interface and even have control over which CMS Events will be used. You can even use Event Based entry for some machines and use the Batch Interface for other machines.


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To configure a CMS Event Based Map within ProHelp® EPM, follow these steps:


• Click the Site menu and select CMS Event Based Maps. The CMS Event Based Maps screen will be displayed.

CMS Event Based Map Configuration

You can view existing Event Based Maps, edit existing Event Based Maps, create new Event Based Maps, and delete existing Event Based Maps if you have been assigned appropriate security permissions by the System Manager. You can not delete an Event Based Maps if the map is assigned to a machine.


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Once you have created a CMS Event Based Map, you must assign it to one or more machines. To assign a CMS Event Based Map to a machine, follow these steps:


• Click the Site menu and select Machine Configuration. The Machine Configuration screen will be displayed. Press the Code Maps tab.


Specify a CMS Event Based Map, as appropriate. You must configure the CMS Event Based web interfaces on the ProHelp® EPM server, as appropriate. Contact the Mattec Customer Service Department for additional information. Finally, you must restart the “Mattec MIU Service” to ensure that your changes take effect.

Documents

ProHelp EPM System Administration Manual - Mattec · PDF file · 2007-05-295.1 Voice Alarms and Email Alarms ... Many MIUs have an optional PLC interface ... machines. Advanced Tip