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Process and production monitoring systems.


ControlView supervisory control software package runs on DOS-based PC and communicates with company's Plastics Automation Control Systems to provide data collection, analysis of production, and SPC. At the heart of the system is an industrial data highway with redundant error checking to ensure that data, both sent and received, reach their destinations intact. All process, machine logic, and safety interlock data are stored in the Plastics Automation Controller and available over the Data Highway+ communications link, which is standard on controllers.

Data in ControlView can be viewed on SPC charts in real-time mode in traditional X-bar and R, histogram, and Pareto charts; saved for long-term historical analysis; and mathematically manipulated as input data for alarm checking, process changes, machine status, production reports, etc. Mold setups can be stored on the system and electronically transferred to production machine controllers.


CIMAC 8000 manufacturing network monitor with full SPC capabilities supervises multiple machines and, with an optional integration module, handles auxiliary equipment. Each CIMAC 8000 captures data for display in graphic or tabular form for on-line analysis; data can be transmitted to a PC for review and preparation of reports on process history and trends. System has user-programmable macro function keys to call up repeated tasks.


Offers two products for computer-integrated manufacturing: PCMS PC-based system and BarcoCIM minicomputer system. PCMS works with MS-DOS. Integration of the system into a LAN environment enables multiuseraccess. BarcoCIM system runs on Digital Equipment Corp.'s family of VAX computers and functions with Digital's VMS operating system, which supports multiple interactive user terminals, and can monitor 1000+ manufacturing cells.

Both systems perform production monitoring, scheduling and planning, statistical process monitoring, statistical quality analysis, personnel monitoring and order-status reporting. A 4GL-type report designer enables users to build textual and graphical customized reports. Both systems monitor machines and provide real-time and historical information of machine status. For machines running outside of standard or out of control statistically, the Barco system generates alarms for corrective actions. Bi-directional communication available to facilitate transfer of information from each machine to the host computer system and vice versa. Any data in the system database can be displayed at machine interface box (Barco data unit). Data collection network can connect virtually any type of machine to the Barco system. Interfaces to monitor microprocessor-based machines have been developed. Hardware and software available to include monitoring of auxiliary equipment and integration of the Barco system with a mainframe.


Shotscope S9000 plantwide process and production monitoring system provides real-time monitoring of process and production activities at the injection molding press and throughout the plant. High-resolution CRTs at each press provide simultaneous displays of shot profiles of position, velocity and pressures. SPC data (trend/run time, X-bar and R, histogram and scatter diagrams), as well as production data available in graphics and text. Pick lists allow easy entry of scrap, downtime, material lot numbers, etc. Parameter data is saved, including date and time for every shot from each press. SQC module tracks measurement parameters and allows correlation of process and measurement parameters. Real-time Job Scheduler with color-coded Gannt chart display provides automatic update of jobs in progress based on actual cycle, setup and downtime data. Novell Network integration allows for multiple workstations and communication with other computer systems. System can be used with any press of any age, because it takes data from the press transducers, independent of machine controls.

Shotscope A9000 analyzer has all process analysis and graphic display capability of the S9000 system in a portable package. Designed for molders who require a tool for setup, troubleshooting, and collection and analysis of SPC data. Also meets the needs of materials suppliers, researchers, mold designers and press manufacturers for a portable process-analysis tool. An SQC module for measurement analysis and correlation with process data also available.


Midas 1000, 1500, 2000 and 3000 production and process monitoring systems provide injection molders a full range of products to monitor basic production variables such as cycle times and down-time, as well as complex process variables. Systems monitor in real time a range of selected analog and digital process points such as cycle times, injection pressures, zone pressures, chiller-water temperatures, position velocity and counts. Systems are open-ended to allow variables and process points to be added or deleted. Up to 64 process points per machine are available. Systems interface with several industry-standard programmable logic controllers and allow for input from alternative methods of interfacing for molding machines not equipped with PLCs.

Data are acquired in real time to determine process trends, real-time status, and production quality for each machine and plant as a whole. Status and trend information, as well as out-of-limit controls, are distributed on-line. Systems provide for storage of upper and lower control limits and all process setpoint criteria in a relational database, which can be downloaded to each machine in the network. Machine process data are correlated with part-quality data to identify, predict and prevent potential causes of defective production.

Systems provide real-time SPC/SQC capability on as many production or process variables as required. Upper end of the Midas line can monitor up to 100 production machines. These integrated systems utilize industry-standard hardware and software. Host system utilizes Unix-based workstations. Modular software design allows for tailoring to specific needs without having to customize each installation. Design is open-ended and can be connected to plantwide MIS systems.


Markets The Manufacturing Manager, a comprehensive, fully integrated, manufacturing, distribution, and financial management software package. It is written in Progress relational database and designed for "open systems" computing environments. Software currently runs on MS-DOS PCs, PC LAN networks, Unix, and Digital's VAX/VMS computers.

Functional features include informational pop-up windows, multiple-screen overlays, on-the-fly file maintenance; and user-defined menus, screen colors, and formatted reports.

Standard applications include a Quotation Module, which quotes suggested multilevel product pricing, prints formal quotes, determines production costs, maintains revision levels and costs, and develops product manufacturing standards. Order-entry and release-entry modules update requirements for production scheduling and material planning modules. Production scheduling module provides forward and backward (finite and infinite) scheduling, JIT scheduling, forecast scheduling and production capacity planning of all machines and secondary operations. Products are automatically scheduled to machines that produce each product most efficiently. Various reports include material planning, manufacturing efficiency, utilization, analysis, and product-costing reports.

Inventory module maintains raw, WIP and finished goods; offers user-defined units of measure, displays product costs, maintains lot code and serial number traceability; provides an infinite level "bill of materials" to include formulations or recipes; and maintains multiple warehouse and location capabilities.

Optional applications include tool quoting and tracking, which maintains development and revision costs. Electronic Data Interchange (EDI) interface provides automotive/appliance "accum" or other release capabilities. Bar-code printing and reading interfaces are provided for shop-floor reporting and inventory management. Process control and monitoring interfaces provide direct connect to production machines.


EPM series system integrates hardware and software for complete real-time production and engineering monitoring, including SPC and SQC. Machine data acquisition units (IMACs) are provided in EPM series 300, 4000, 5000 and 6000. All IMAC series are software compatible and can be used in the same system, allowing for easy upgrading. Systems support bar-code and a-c gauging instruments; and the 4000, 5000 and 6000 series support outputs for stacklights or other indicators.

Series 300 is the entry-level IMAC for production monitoring and basic SPC, IMAC, which accepts six digital inputs, is a small unit with full-touch keypad and 2 x 40 backlit LCD display.

Series 4000 offers the same type of monitoring features as Series 5000 and 6000, but accepts fewer input signals from machines. IMAC accepts six digital, seven thermocouple, and four analog inputs.

Series 5000 rugged unit with full-touch keypad and 2 x 40 VFD display, monitors a maximum of 32 paramaters derived from a possible set of 10 digital, 15 thermocouple and eight analog input signals.

Series 6000, a rugged unit with full-touch keypad, optional touchscreen and 640 x 480 VGA resolution LCD or EL display, is based on a 386 microprocessor with options to use a 387 coprocessor or 486 microprocessor. Unit monitors a maximum of 16 digital, 15 thermocouple, and eight analog inputs. Large display enables presentation of intracycle profiles, SPC and SQC charts at the IMAC.

EPM Series 200 remote data-entry terminal can be used to input defect and packed production counts at remote locations. Information entered at the terminal is integrated with that collected by the IMAC at the machine. Software provides reporting facilities for production, engineering, maintenance, SPC and SQC; production-floor status display provides machine status at a glance; and scheduling facility provides basic job-queue generation, as well as estimation capability, "what-if' analysis, queue rippling and Gantt displays. Configurability via edit selection facilities, and mold and machine maintenance programs also are supported. Production reports support history and analysis capabilities, and intracyde profile analysis.

System supports statistical sampling of parts at the IMAC on the machine. Part measurements can then be entered at the IMAC or entered later in the a-c lab via gauging stations. Reports are then available to analyze control and capability aspects of both part characteristics and process parameters, as well as perform correlation analysis between the two.


Factory Data Manager provides a factory network to collect and validate by user and by sensors and programmable controllers. At base level, it is a labor data-collection system that tracks jobs, what component was worked on, and the process involved. Data are then used to cut paychecks and update cost and MRP systems. Similarly, material issues and production status are provided.

Software provides an interface for the host manufacturing computer. Direct and indirect plant labor recording, quality-control data entry, material movement, job and employee status, and time and attendance are standard features. System supports a factory network of portables and fixed micro-terminals with attached bar-code or magnetic-card readers. It provides generation of ID cards, plant travellers, material tickets, etc., for fast entry via simple wand and keyboard operations. Edit files can be downloaded from host computer to ensure 100% shop data accuracy. Software also supports SPC data collection, product-liability tracking and mainframe-style restart/recovery capability. It supports AIAG-approved bar-code label generation for laserjet and Epson emulation printers. MAP capability is assured.


Systems for CIM provide data-acquisition terminals on all molding machines, along with up- and-downstream processes. Local-area networks (LANs) connect data-acquisition terminals to supervisory command center, which in turn, connects up to 92 other users. Remote terminals allow off-site communication with the system, which provides total SPC, SQC and MIS programs for analysis and troubleshooting. Unlimited reporting is possible using a combination of pre-formatted and user-format-table report options. Custom programmable DAT acquisition terminals allow the system to be applied to virtually any process in the plant. DAT unit may be upgraded to DAC-III process control and monitoring as a full closed-loop system for injection units with no such control.


Company, along with its business partner network, provides full information systems solutions (hardware, software, integration and consulting).

Consulting and integration include quality-management services, plant-integration services (including process monitoring and control), engineering-design services, engineering-management consulting services, manufacturing services (continuous-flow manufacturing, integrated yield management), and international trade.

Software packages available for mold design, mold costing, mold analysis, flow analysis, FEM, integrated accounting, manufacturing planning, mold and tool tracking/history, equipment maintenance, bar coding and data collection, inventory control, capacity planning, order entry, EDI, purchasing, human resources, SPC/SQC, machine monitoring and control, process control, brand management, and sales-force automation.

Hardware platforms include PCs, industrialized PCs, data-collection equipment, advanced Unix workstations, mid-range business computers, and mainframes.


Provides interactive software systems for complete business and user-oriented solutions. Applications use Oracle platform, a relational database management system. Products include CIIM (computer-interactive integrated manufacturing), CIID (computer-interactive integrated distribution), and IFAS (integrated financial accounting system). CIIM, as a complete MRP-II solution, incorporates all of CIID and IFAS. Both CIID and IFAS may stand alone as independent operating solution segments. Each segment consists of interactive modules that can be purchased in starter kits or complete sets. All can be installed collectively or individually, allowing customers to phase into the system. All three segments can be used to control and monitor manufacturing, distribution, and accounting systems.


Offers Molders Shop Automation real-time, process and production monitoring system for injection molders, extruders and blow molders. One PC can monitor up to 128 machines with centralized production control information at various locations. Features include "what if" scheduling; user-created reports; rejects analysis; bi-cavity monitoring of family molds; mold maintenance; and control and capability studies.

Molders SPC software provides on-line SPC, secondary gauging and post-analysis capabilities without all features of Molders Shop Automation, which can be added later without upgrade penalty.

Molders Office+ and Mold Builders Office+ software modules automate accounting, order entry, inventory control, invoicing and purchasing functions. MRP-II is available for these programs, and an entry-level Molders Office+ system can be later expanded without up-grade penalty.

A Total Automation package combines production and office systems into an integrated, company-wide system.

Customized terminals at each machine include a CRT that displays information in easily understood terminology. Output relay contacts enable interfacing with machine control signals.

An IBM Business Partner, Intrac supplies IBM and IBM-compatible hardware systems; and complete installation assistance and training, periodic software upgrades, custom software, and system assistance via modem.


Offers AIMS v2.0 (Advanced Integrated Manufacturing Software), which is an MRP-II software package written specifically for injection molders and mold makers. Package provides automated tools for estimating, order entry, production scheduling, bill of materials, materials requirements planning, purchasing, receiving, shop-floor control, job costing, shipping, billing, inventory control, sales analysis, accounts receivable, accounts payable, payroll, and general ledger.

Latest version includes functions for monitoring machine utilization, productivity and efficiency; scheduling based on process time for accurate shop calendars; project management for tracking costs of building a mold; and Gantt chart for graphical formatting.

AIMS is totally integrated so that information can be shared by all modules and users. Built-in security codes protect sensitive information such as sales/finance. Easy to use and understand, AIMS will run on a stand-alone PC or a network like Novell.


ProHelp process quality control and real-time production monitoring system includes functions for bar coding and parts traceability, SPC/SQC programs, production reports, scrap and downtime reports, and machine-efficiency reports. Multiuser capabilities allow as many as 64 interactive PCs on the system with ability to monitor up to a maximum of 4000 machines. System is suited to injection, blow or extrusion processes.

Information collected by the central computer is available to management and production personnel. In-process quality-control and preventive-maintenance techniques can be applied to all molds and machines. Color CRTs are used to show status of all production machines. Machines running outside standard values for cycle time, temperatures, or other process variables activate alarms for corrective action.

SPC software collects samples of every machine's process values. Upper and lower control limits are compared to actual recordings, and alarms are generated if processes go outside limits or if shifts or trends are detected in the sample. System can also interface with a variety of machine controllers, as well as corporate MRP systems.


MopacNet combines molding-floor data gathering and remote setup with the process-control capability of its Mopac 22 injection process controller. Network monitors production quantities, rejects, operators, and downtime for up to 99 machines. Also monitored are 15 process variables that are compared with control limits and may be used to segregate parts at machine. Monitored data are stored for immediate analysis or for later retrieval. Analysis may be done with the supplied SQCpack tools, or using other common software programs.

Each machine is equipped with an interface unit, which gathers data from the machine. Machines having a Mopac 22 do not require additional interface unit. Non-Mopac-equipped machines require an S*entry (System-entry) data-acquisition unit. Machine units are connected as branches on a four-wire cable leading to a PC in the office, which may be connected to a network such as Ethernet, where it acts as a distribution point to other PCs.

MopacNet polls connected machines at a periodic rate. Status of each machine is displayed at the central computer, along with job information, production data and process data. Data are recorded on computer's hard drive, which can retain up to 31 days of data before it is stored in archives. Recorded data may be recalled for analysis or transferred to another computer for analysis. Computer automatically prints job and shift reports and provides audit trail reports for changes to production and process data if desired. Operator tracking and down-time analysis reports on demand.

Production data are stored indefinitely by date and shift. Printouts for any dates or shift and for any or all machines include production reports, downtime reports, reject reports, management summaries, and process-variable alarm reports. Downtime for any period and machine may be displayed as a bar chart for analysis and printed out.

Data are stored in DBase files, which may be read and organized by user with DBase software.


Offers software products utilizing Object Oriented Programming (OOP) technology for shop-floor management. Products are Windows-based and are for manufacturers with as few as eight machines and as many as 2000.

Integrated application groups include access control, area data collection, bar-code design and printing, finite scheduling, labor tracking, MRP interface, RF area data collection, time and attendance, SPC, PLC interface, process graphics, preventive maintenance, and sensor-based real-time production monitoring. In development are inventory control and lot tracking.

Many of the application groups are available off-the-shelf and used as is, while some may require customization, such as labor tracking rule modification for incentive pay calculations. Most customization can be accomplished by user or obtained from NextGen.

Some application groups can run on PCs; others require a networked NET BIOS compatible environment such as Novell, LAN Manager, or Pathworks, with the appropriate server.


Guaranteed MRP system, which incorporates Digital Corp.'s DECforms, features two levels of on-line help (novice and expert-user modes), data entry from pop-up selection lists, multiple natural-language capability, and more. Fully integrated modules include shop-floor control, inventory management, purchasing, material requirements planning, order processing, sales analysis, and bill of materials. Accounts payable, accounts receivable, general ledger and fixed-asset modules complete the system. RMS files are used, and common data-dictionary formats are provided for ease of use with all report writers. System is equipped with file-purge and reorganization functions, as well as re-start functions to recover from processing interruptions.


OPM family of products are shop-floor data-collection solutions that facilitate a step-by-step approach to real-time data collection and SQC/SPC, and provide a migration path from standalone monitors to plantwide data collection and corporate information systems.

OPM8 standalone multifunction monitor tracks and displays cycle time, machine rate, shift averages, production rate, setup time, downtime, rejects, and parts fabricated. Displays cycle time to 0.1 or 0.01 sec and production rate in minutes or hours. Key switches are available for reset of shift/job totals.

OPM9 networked production-monitoring system tracks, displays, and communicates cycle time, machine rate, parts to go, hours to go, batch count, shift averages, production rate, setup time, downtime, rejects, and parts fabricated. Information collected by OPM9 is logged on an off-the-shelf PC. Easy-to-use PC software provides management reporting, SPC charting, job scheduling and tracking, real-time status displays. Supports up to 99 monitors as far as 4000 ft away. OPM9 uses existing machine signals.

OPM20 networked SQC/SPC monitoring system monitors production, run time, downtime, setup time, unscheduled time, scrap, machine productivity, and job scheduling. It collects, analyzes, stores, trends, and communicates real-time shop-floor data from pressure and temperature sensors, digital gauges and scales, and direct machine inputs. System maintains processes and products with SPC on machine and in real time as products are fabricated.

OPM20 systems support up to 99 monitors as far as 4000 ft away, integrate shop-floor data with the corporate-wide data network, and close the loop between factory and any third-party MRP system with Universal Job Queue, which also provides on-line job-end forecasting that uses actual real-time production data. Maintenance scheduler tracks run time and number of cycles on molds and machines, and flags those due for preventive maintenance.


Business Planning and Control System (BPCS/AS) is a fully integrated line of 50 applications for multiple open-systems platforms, including OS/400 and Unix computer environments. System includes CIM, process industries, multi-plant and multiple CPUs, distribution/logistics, accounting and financials, sales and marketing, facilities management, and retrieval applications. Built on company's AS/SET computer-aided systems engineering (CASE) product line, BPCS/AS utilizes workstations, PCs, and graphical user interfaces with its "Assistant" products.

Main/Tracker line automates planning and control of all equipment and facilitates maintenance safety inspection and warranty-tracking functions. All types of capital equipment and facilities can be managed through Main/Tracker, including stationary and mobile equipment and machinery, transportation equipment, buildings and grounds.


Focus series of CIM systems provide real-time production and processing control, coupled with an advanced statistical process/quality management system. Modular in design, systems allow users to start at any level and grow into more sophisticated configurations.

New Focus-Lite, an entry-level version of Focus-100, is a full-function production monitoring system, which includes cycle time and production reporting, downtime tracking, reject-tracking, real-time scheduling, material forcasting, and job tracking. System is expandable to include more PCs, SPC capability, network integration, and fully compatible and upgradable to Focus-100 and Focus-2000 systems.

Focus-100 real-time production-control and process-management system includes job scheduling, material and labor tracking, machine and tool maintenance history, automatic SPC and SQC data gathering, run and trend alarming, machine process profile, "signature analysis," and storage-scope graphical overlays. PC stations make master files, historical data, and real-time data for on-screen viewing or printed reports.

Focus-2000 includes all features of Focus-100, but incorporates an advanced MS Windows-based Graphical User Interface (GUI), which simplifies system access by pointing to icons or list entries. System is compatible with MS-DOS, Novell Netware and other networks. It incorporates the Ingres Relational Database Manager. User interface is built on standard SQL (Structured Query Language), allowing user-formatted displays and configurations.

Manufacturing-Cell Interface Modules (M-CIMs) can be configured to monitor 1, 2, 4, 8 or 16 machines. Different combinations of M-CIM units allow for different levels of functionality at different operations within a single system. Units can be purchased in two styles: 1) keypad version, which has a 40-character vacuum fluorescent display with user-definable "soft" keys and a numeric keypad; and 2) ELTS version, which features a 640 x 400 pixel electroluminescent touchscreen display at machine, allowing plant-floor personnel access to the same screen shown on system PCs. Fault-tolerant design permits M-CIMs to continue operation for days in the event of a computer or network failure. Up to 4 MB of battery-backed memory provide fail-safe storage for data.


See SSA.


Ultramax software improves quality and productivity of molding processes by analyzing control settings and measured results to understand cause-and-effect relationships. It guides the user run-by-run to process settings that deliver results that best meet user's quality and productivity objectives. Dimensional variations are reduced, defects eliminated, and cycle times shortened by learning better combinations of temperatures, pressures, speeds, hold times, cooling rates, and other important influences. Ultramax also advises adjustments to compensate for changes due to materials, environment and process. Package is used during normal production to provide continuous improvement without production interruption. It builds models, provides tolerance and sensitivity analysis, data management and plotting of information; and runs on 386 and 486 PCs, Unix workstations, and a variety of mini and mainframe computers.


XRP-II Resource Planning System is a Unix-based, fully integrated, modular manufacturing planning and control system that uses CASE technology and a relational database manager to provide flexibility for customizing applications.

XRP-II spans the range of MRP-II planning functions and adds critical real-time factory control with machine monitoring/automated data collection. Support for repetitive and just-in-time manufacturing is included in design. Base system includes Unix operating system, Unify relational-database management system, XRP-II kernel, and Datalock and Datarite utilities for editing, query and report generation. Application modules include data collection, product information, purchasing management, materials requirements planning, master scheduling, job costing, accounts receivable and accounts payable, general ledger, inventory management, customer order entry, work-order processing, shop-floor control, and labor performance.

Unix operating system ensures long-term hardware and software growth, and upward compatibility. Other features include standard relational database for reliable, fast data access and flexible SQL ad-hoc reporting; security system; context-sensitive help for users; automatic downtime cause detection and job-driven software; and planning, execution and feedback requirements for closed-loop manufacturing.
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Title Annotation:Manufacturing Handbook & Buyers' Guide 1994/95
Publication:Plastics Technology
Article Type:Directory
Date:Jul 15, 1994
Previous Article:Tooling suppliers' data sheets.
Next Article:Total machine control systems.

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