Production Award

SHOP FLOR MANAGEMENT FactoryFramework™

PHASE I: Machine Data Collection, Visualization, and Reporting

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SYSTEM BRIEF

• TRANSPARENCY; Every machine states is recognazible

• Visualization of Production System Status

• Root Cause Analysis (Faults, Downtimes, ...)

• Web-based Interface Anywhere / Anytime Access

• Accurate machine data – greater visibility

• Wastes analysis for continuous improvement

• Better data: where are the operators working

• Real-time analysis instead of reactive

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Shop Floor Management Realtime deviation analysis for EVERY work place

ACTUAL TARGET

Office Shop Floor Office Shop Floor

?

? Realtime / Online ACTUAL-TARGET

Comparison

ManualTime-delayed

Shift Shift

Realtime / Online ACTUAL-TARGET

Comparison

Realtime / Online ACTUAL-TARGET

Comparison

ANDON Visualisation

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Project overview

There are downselected machines that represent group of machines(type of

PLC/hardware):MACHINE PLC TYPE TECHNICTUR Manual machine WAGOTZC 80N Sinumerik 810D IBH LINKHyundai-KIA SKT-V5

Fanuc 21i-TB FOCAS

CTX 410 Sinumerik 840D 31A IBH LINKMazak megaturn900M

Mazarrol Matrix nexus NC Model FCA730PY-N31

MT-Connect

DMC Sinumerik 840D SL RPCMakino Fanuc FS31iB5 FOCAS

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System architecture

NOT in Ph I

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SFM Reporting, Analysis & Visualization

Machine Data Collection (MDC) with Heterogeneous Adapters

Machine Data Collection (MDC) for Heterogeneous Controls/PLCs

Ethernet (Works LAN)

PluginModbus over

TCP/IP

PluginOPC / OPC-UA

Client

PluginSiemens

RFC 1006

PluginSiemens

TCP/IP native…

FANUCOmron

OKUMA

Mitsubishi

Siemens840D / TI

PLC S5/S7

Plugin

MTConnect™

Factory Framework connects to and acquires real-time data from various machine controls using a variety of readily-available protocols.

Heidenhein

MAZAK

Makino

Fieldbus Controllers for Legacy Controls

(B&R / Elau / G&L / Koyo / Other)

…

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PLC vs. hardware

Siemens S5/S7- IBH Link FANUC- Focas Wago

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Machine-Shop Visualisation

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Machine-Shop Visualisation (3D)

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Single machines visualization/monitoring

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Reporting – Status Gantt Diagram

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Reporting – Status Log

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Reporting: Shift Book

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Reporting : Operational Status Reports

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Reporting: Maintenance HIT list

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Rollout

No. Line Machine-ID SAP No Machine Text Name of Machine PLC Type Techinic

1 SW2 446004 MAZAK Tokarka CNC Mazatrol 640T Nexus  Mtconnect(do sprawdzenia)2 SW2 445004 84915002 TZC Tokarka uchwyt. wielonoz. SN Siemens Wago3 STUDER Szlifierka do walków ‐ Wago4 OFA-1 Frezarka obwiedniowa OFA-16A ‐ Wago5 GLEASON Dlutownica do uzębień CNC Sinumerik TYP??6 BUAJ- Szlifierka do walków CNC Fanuc 0‐GC Wago7 BUA-2 Szlifierka klowa Kavalir K‐51 Wago8 MORI Tokarka CNC MSX‐850 III Wago9 MORI Tokarka CNC MSX‐850 III Wago

10 SOJ-1 Szlifierka do otworów ‐ Wago11 MAZAK Tokarskie centrum obróbcze - MAZAK Mazatrol matrix 2   Mtconnect(do sprawdzenia)12 KAPP Szlifierka do uzeb. KAPP CNC Optronic AG CNC D 150/OP 500 Wago13 OKUMA Tokarka CNC- OKUMA LB35 II Okuma OSP‐U100L Wago/ Okuma plug‐in it think protocol14 - Tokarka CNC- NEF600 Sinumerik 810D NCU 571.5 Wago15 TUR Tokarka uniwersalna - TUR-630M ‐ Wago16 EUR Tokarka pociagowa ‐ Wago17 TZC Tokarka uchwyt.wielonoz. Sinumerik 810 D CCU 3.4 IBH‐Link S7 (jeżeli MPI connector jest dos18 TZC Tokarka uchwyt.wielonoz.SN Sinumerik 810 GA3 IBH‐Link S7 (jeżeli MPI connector jest dos19 AXA Frezarka pionowa SN Heidenhain LE426M Wago20 TZC Tokarka uchwyt.wielonoz.SN Sinumerik 828D SL IPS7LNK on X 130 Network Connector IP‐S21 MAZ Tokarka klowa wielonoz SN Mazatrol Fusion 640  Mtconnect(do sprawdzenia)22 TZC Tokarka uchwyt.wielonoz.SN Sinumerik 802D SL Wago23 BOS Frezarka pionowa NC Bostomatic Wago24 ID Szlifierka do otworów ‐ Wago25 TSCHU Szlifierka do walków CNC Ge Fanuc Series 18‐T Wago26 125 Szlifierka do otworów AEROTECH ‐ Wago27 STU Szlifierka uniwersalna ‐ Wago28 DMC 125 FD duoblock Centrum obróbcze DMC Sinumerik 840D SL IBH‐Link S7 / MCIS RPC29 UCP-800 Frezarka MIKRON Heidenhain iTNC53030 Mazak Integrex e-500H II Centrum Frezarsko-Tokarskie Mazatrol matrix 2   Mtconnect(do sprawdzenia)31 NH4000DCG Frezarka CNC MORI SEIKI Fanuc Series 31i Model  A02B‐0307‐B822 Focas 232 Roboform 550 Elektrodrążarka Fanuc Series 180I‐MB Model  A02B‐0283‐B801 sprawdzić Focas 2

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Project Steering Committee

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Pratt & Whitney (Kalisz, Poland)

● Phase 1 SFM for Machine data collection, visualization, and reporting.

● Phase 2 includes SAP ERP integration and dynamic scheduling. Our contact persons that are running the project area:

● Zbigniew Gralka, P&W Production Director

● Robert Choja, P&W Production Manager

● Tomasz Koczorowski, P&W IT/Business Process Optimization Officer