CNC monitoring system
Discrete Process Automation
www.x-tensive.ru/dpa
© 2015 X-tensive
Shop flor management problems
Production process information, obtained from shop floor staff ,
doesn't always reflect reality. In fact, there is no actual/real time
production process information.
The main cause of this problem, is the fact that no one even has such
information, or tends to conceal it.
Up to date, actual information is essential for the equipment
performance forecasting and production planning.
Expensive equipment should be used in accordance with its purpose.
Solution – real time CNC monitoring
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Market analysis
Existing machine data collection systems doesn’t meet your requirements?
• Very expensive
• Require additional PLC modifications
• long implementation terms
• Gathered data, is too basic (machine on\off, production)
• Require interaction with electrical cabinet schemes
• Require additional equipment, such as panels, controllers, converters
There is a reasonably-priced system which is able to
collect maximum amount of data from your CNC and
has a project startup time of 4 weeks only!
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Data collection methods
OPC Server solution
Converter
Machine
Hardware solution
PLC
Machine
SOFTWARE SOLUTION BASED ON CNC DRIVER
does not require additional hardware, –
Siemens, Fanuc, Heidenhain, Okuma, Mazak, Galil, Alien-Bradley
OUR
SOLUTION!!!
Driver SW
Machine
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Network architecture
Driver
Profinet
Driver
Server DPA
Driver
Collected data is being transferred through industrial
Ethernet network.
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Network architecture
DPA server accumulates data and makes it available for everyone.
Shopflor
DPA Server
Data collected from the machines, may be sent to
another system.
We support all standard protocols/.
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
DPA functionality
1 Stage - Monitoring
Functions:
• Data analysis – graphs and charts
• Data analysis - reports
• Data analysis – real time data (andon)
• Notifications about deviations – by SMS and e-mail
Advantages : low price, user friendly interface , short integration terms, supports
wide range of CNC’s, data collection based on software (you don’t lose warranty
from CNC builder).
Perspectives – Fully functional MES system
Functions :
• ТРM (maintenance), Direct Numeric Control, Advanced planning, Order
management, Tool management, Production logistics, WMS.
Advantages : individual solution for production problems, modular integration
system.
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
1. Data analysis
Various graphs and charts
1. Data analysis
Various graphs and charts
2. Real time board
Real time shop floor plan, where rectangles represent the current status of your CNC’s and
additional information, such as cycle time, current program name, list of alarms, etc.
3. Notifications
CNC data can be transferred in a multiple ways:
• Periodical e-mail reports
• SMS - process deviation notifications,
• Reports optimized for another systems(ERP: SAP, 1C),
• Web interface.
ERP
API
DPA Server
Different types of notifications
For example if one of the CNC’s is standing still for more than an hour, foreman
gets an SMS.
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
4. Reports
Various reports
«Экстенсив» Тел./:факс +7 (343) 263-71-74, http://x-tensive.ru/pda
Advantages for personnel
Implementation of monitoring system, shall allow:
Operator – to control own productivity in real time (andon)
Foreman – to receive immediate notifications about any
deviations in production process
Manager – to constantly monitor shop floor situation and make
decisions based on actual, real time data
Top managers – to analyze and compare progress with previous
periods (reports, KPI, OEE, MTBE …)
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Results
• Real time performance and machine load information
• Ability to promptly react on production events
• Staff members are aware of the fact that their performance is
being measured
• DPA is a production process optimization tool
УОМЗ: DPA Implementing increased
the machine effectiveness in 3 times
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Project stages
• Choosing shop floor area
• Assembling data networks
• Starting up DPA
• Configuring reports and notifications
• Personnel training
Integration period – 4 weeks!
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Evolution
• DPA – is a base for a future integration of complete modular MESSolution.
• Machine operating time data may later be used by maintenance
subsystem.
• The system allows to gather and analyze practically any
subsystems parameters of the machine.
• The system is able to collect data from any PLC based equipment.
X-tensive LLC +7 (343) 263-71-74, http://x-tensive.ru/dpa
Thank you for the attention!
If you have any questions please contact:
info@x-tensive.ru
X-tensive LLC
http://www.x-tensive.ru/dpa
© 2015 X-tensive
X-tensive LLC +7 (343) 263-71-74,
http://x-tensive.ru/dpa