If defective goods are only detected when they are packed and ready and waiting on the pallet, considerable annoyance and expense are inevitable. A manufacturing execution system (MES) helps identify weaknesses on the fly and enables them to be escalated promptly. Gerhard Schubert, the South German packaging specialist, developed its own MES integrating this and numerous other functionalities some time ago. The Crailsheim company has now evolved a Line Cockpit as a new function module for this system, which is set to be unveiled at the forthcoming interpack 2011.
The author: Ralf Schubert Head of Engineering and Assembly, Gerhard Schubert Verpackungs- maschinen
A manufacturing execution system (MES) is designed to implement horizontal integration on the process level with the aim of organising, coordinating and synchronising every aspect of a production order. Ideally, this should completely encompass the functional areas of production (such as detailed planning, production and machine data acquisition or preventive maintenance), quality (for instance, process data acquisition, trend analyses or product monitoring) and human resources (e. g. shift planning or access control). This list alone is a clear pointer to the enormous scope of tasks MES involves. The challenge starts with the data collection stage – after all, not every component is fitted with the necessary interface. The software implementation is highly demanding. As with ERP (enterprise resource planning), this process requires the cooperation of the customer. There is no off-the-peg solution, as no two companies manage their processes in the same way. In the past there were only a handful of enterprises prepared to release the resources needed to embark on such a project. Even in the pharmaceutical industry, which is forced to go through a number of preparatory steps in order to comply with stringent process monitoring and documentation regulations, a complete MES system linked to ERP is a rarity. Systems for production data acquisition are in place at some facilities in the food industry, but it is a long way from here to the implementation of MES.
Despite the enormity of this hurdle, more and more manufacturers are lining up to jump over it. Why? Because in some cases, overall efficiency is only around the 60 % mark. With figures like these, MES offers a tempting prospect: in workshop production and the electronics industry, the use of MES is known to boost efficiency by between 7 and 10 %.
Significant boost to efficiency
This was the backdrop against which Gerhard Schubert took the decision to develop its own MES system. The database model for the system was completed in 2009, and encompasses all the functions and elements that will feature in Schubert’s very own MES. Concrete customer requests will form the basis for more detailed elaboration, ensuring that the final result is tailored precisely to real market needs.
The consequence of this type of project is the control station with integrated quality monitoring already developed for the continuous acquisition, evaluation and archiving of process and quality data. This line management system is a user-friendly software package that is available on the operator touch panels of the machines concerned. In 2010, twelve packaging machines were equipped with the Schubert line management system.
Orders can be entered using the LMS. All machines and all devices automatically receive the required data like lot numbers or expiration dates. System errors and conditions are visualised in 3D images. The system provides continuous data on “overall equipment effectiveness”, in other words the availability and output of the line and the quality it produces. The images of products can be viewed and archived. A batch log is created on completion of the order. The line management system fulfils the requirements of CFR 21 Part 11 and the pharmaceutical industry.
One benefit offered which is unique to Schubert is a vision system developed for use in picker lines. The incident light scanner works without parallax over a width of up to 160 cm. The depth of field is around 125 mm while the maximum image quality is 2,000 pixels per 200 mm.
Versatile image data
Schubert’s latest development is supplementary to the line management system. The Line Cockpit is due to be unveiled at interpack 2011. In contrast to the line management system, the Line Cockpit functions on any computer running Windows. The data of remotely located lines can be accessed over the Internet. A screen mask provides the production manager with a quick overview of all lines. He or she can then check at a glance, for example, how production went overnight the following morning, see which orders are currently being processed and assess whether they are still on schedule. The data recorded by the line management system can be evaluated in many different ways with the Line Cockpit. For instance, prod-ucts or sizes which fared better or worse during production can be identified. For long-term evaluations it is possible to see how change-over times progressed during the previous year. All process data is displayed in easy-to-read charts. In addition to the overview and evaluation functionality described here, the Line Cockpit incorporates functions for managing data points, sizes and orders. Batch logs and audit trails are also available.
Hall 14, Booth A06/B11
Online-Info: www.cpp-net.com/2111457
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