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Mattec Millennium Operator`s Manual, Release 3.X

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1. These forty maintenance code numbers have predefined meanings that are specified by the System Manager Maintenance code numbers are used in the recording of past maintenance activities and the scheduling of future maintenance activities You may choose to reserve one or more of the forty maintenance code numbers for use in recording unscheduled or emergency maintenance When maintenance is performed on a machine or tool the user may record this fact either through the use of the MIU keypad or through a ProHelp Millennium terminal This data is then available for historical reporting To define machine maintenance codes follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F6 PMcode Press F1 Mach The computer display will show the complete list of machine maintenance codes and their definitions Copyright 2002 MATTEC 9 2 710 0092 ProHelp Millennium oj x MACHINE Dept Maintenance Code Number Definitions Figure 9 1 Machine Maintenance Codes To change the Dept Figure 9 1 Machine Maintenance Codes place the cursor in that area Press spacebar A picklist will appear Highlight the department of choice Press Enter The first 20 definitions are set Figure 9 1 Machine Maintenance Codes Using PgUp and PgDn keys will display the next 80 codes that can be utilized Place the cursor on the Code to be utilized Type in a description for that code number Use the cursor keys to m
2. F6 OvlOn Press F6 to toggle overlay lines on or off When turned on the report lines will alternate between white and cyan offering easier iid readability for some reports F7 FndFst Find the first occurrence of a specified field For example to find the TE EE F10 FndLst Find the last occurrence of a specified field The ProHelp Millennium Data Exchange Manual 710 0085 provides additional information on what data is available and how to access it 3 6 1 3 Chart Manipulation Charts are always generated on the screen but can be printed once generated Printing is available from the File dropdown list and various controls affecting appearance are available on the Graph dropdown list A sample chart is shown in Figure 3 26 Sample Bar Chart with the Graph dropdown list displayed Copyright 2002 MATTEC 3 31 710 0092 ProHelp Millennium Te File Graph Control Options Size Y Scale Figure 3 26 Sample Bar Chart Graph C Ea YS YM XM Close Reset Figure 3 27 Graph Control These three sliders control Y axis magnification YM X axis magnification XM and shift the Y axis YS The YS control is only useful if the Y axis is magnified so that the chart display is clipped off in this axis It can then be used to shift the axis to display the Copyright 2002 MATTEC 3 32 710 0092 desired portion of the chart A shift control for th X axis is always displayed at the bottom of
3. 5 6 1 Basic SPC Sample Enable Automatic manual variable and attribute data can only be collected if enabled in the job descriptor To enable SPC sampling for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK The SPC SQC Basic Setup screen will be displayed Use the spacebar for picklist of options Use arrow keys to move from field to field Copyright 2002 MATTEC 5 11 710 0092 Figure 5 3 SPC SQC Basic Setup Copyright 2002 MATTEC 5 12 710 0092 The following fields are then available for modification PROCESS SPC FIELD DESCRIPTION Auto Sample Enable Enter Y es to enable automatic data sampling When enabled Y es it means that automatic sampling will occur at random user specified intervals whenever this job is running on a machine Reference Section 5 6 2 for information on modifying automatic and manual process parameter control and specification limits Reference Section 5 6 3 for information on modifying which process parameters automatic and manual are collected alarm conditions and part qualification conditions The number of cycles observations to be included in the sample is specified in the Cycles Sample field Valid values are 2 to 9 except for those
4. Copyright 2002 MATTEC 7 45 710 0092 FIELD DESCRIPTION DT2 through DT20 These correspond to the nineteen possible primary down SU reasons Each field may be set to Y es or N o A Y indicates that the associated down reason is to be treated as a Non Production Reason which means that when it is selected the machine is considered down regardless of whether or not it is cycling Note that the In Production position identified in Figure 7 22 as DT1 cannot be set to Y If cycles actually occur while a reason marked Y is selected those cycles are counted in a special category referred to as Non Production Cycles A name can be specified for these cycles in the NPC NAME field shown in Figure 7 21 The switch position labeled SU indicates Set Up and it is treated differently Like the other positions a Y here indicates that the machine is to be considered down when this reason is selected even if it is cycling Unlike the other positions all cycles detected in this position are counted as Setup Cycles If the machine is cycling within the non production limit and the SU position is set to N the counting of Setup Cycles is in addition to production cycles Display Resolution These fields select the display resolution for each of the types of cycs min rate machines Non rate machines seconds cycle use the acutal cycs hour resolution defined for the machine Choices are meters min 1 l 01 Enable DT 11 20 Enables the second s
5. remedy Assign a serial port to mouse before configuring it No SPC data found in date range cause An attempt to obtain SPC data was performed but failed because there was no SPC data found in the date range Copyright 2002 MATTEC 15 31 710 0092 remedy Check request dates or abort operation No SQC data recorded for cause An attempt was made to access an SQC sample for a specified date and time that did not exist remedy Abort the operation No variation in X or Y axis cause An attempt was made to view a regression analysis where there was no variance in X or Y remedy View the regression analysis when there is a variance in the X and Y axis Nonproduction limit above maximum cause The job standard field for the downtime non production limit is greater than 3276 seconds For high resolution system the maximum limit is 327 6 seconds remedy Change the non production limit value to a valid number Nonproduction limit is 0 must be non 0 cause The job standard value for the downtime non production limit is wrong remedy Set the value to a non 0 number which is greater than the cycle time high limit number Not a family job cause An attempt was made to perform a family job operation on a non family job remedy Abort the operation or select a family job Not enough columns left for this item cause An attempt was made to insert an item into a real time display format but the item was too wide to fit
6. 2002 MATTEC 15 16 710 0092 cause While setting up upper and lower control limits an error occurred where the lower limit is greater than the upper limit remedy Adjust the control limits so that the lower limit is less than the upper limit Error SQC Variable low spec limit above high spec limit cause While setting up upper and lower specification limits an error occurred where the lower limit is greater than the upper limit remedy Adjust the specification limits so that the lower limit is less than the upper limit Error SQC Variable number of decimal places above maximum cause An attempt was made to set up the number of decimal places in an SPC variable that was greater than 4 the maximum allowed remedy Reduce the decimal places field in the SQCVar job descriptor screen Error SQC Variable Sampling enabled but no variables are defined cause Variable sampling was enabled but no variable names are specified in the job descriptor remedy Add variable names to the job descriptor for the specific job or disable variable sampling Error Standard cavities is zero must be non zero cause While establishing job parameters the cavity field was left equal to 0 remedy The cavity field must contain a non zero number Error Standard cycle time is zero must be non zero cause While establishing job standards the cycle time field was set equal to 0 remedy The cycle time field must contain a non zero number
7. All SPC data that is collected or entered into the system is available for viewing and or editing at a computer terminal at any time while the data is on line 5 7 1 Start a Manual Sample Manual process parameter sampling is initiated by an operator at the MIU Reference the MIU Operator s Manual for additional information Once initiated no other MIU keyboard functions are available until manual sampling is finished or aborted If the previous sample has not yet been completely processed by the MIU the message BUSY TRY LATER will be displayed Manual sampling will not begin and the message NOT ENABLED will be displayed if manual sampling is not enabled the machine is out of production or the number of cycles per sample has been set to zero on the SPC SQC Basic Setup screen in the job descriptor Manual samples in progress are aborted during the sample if the non production limit is encountered or if the current job is suspended or ended The collection of the process parameters begins during the active machine cycle and continues for the number of cycles specified in the job descriptor When sampling begins the message Collecting observation n data mmddhhmm will be displayed at the MIU The letter n will specify the cycle number When data has been collected for the specified number of cycles the n will disappear from the display The message Data collection complete for mmddhhmm will be displayed at the MIU when processing
8. Copyright 2002 MATTEC 12 9 710 0092 The Print Window Figure 12 11 Printer Selection shall use standard MATTEC screen dump utilities to print the entire ProSched window matprint iof xi Available Printers HPCE Localtrillian Figure 12 11 Printer Selection The Print Gantt will invoke the same MATTEC utilities however it will print just the Gantt area The Exit button will allow the user to end the current session of ProSched and lose any changes that have been made 12 2 2 1 2 Edit The Edit pull down Figure 12 12 Edit Pull down includes the following push buttons Undo View Job Descriptor Modify Job Descriptor Create New Job Descriptor Prohelp Millennium ProSched File Edit Copyright 2002 MATTEC 12 10 710 0092 Figure 12 12 Edit Pull down UNDO To support the Undo push button each drag and drop operation is recorded in a list of not less than 5000 When activated the Undo button will cause the current machine schedule to revert to the state it was in just prior to the last drag and drop operation The most recent drag and drop operation will be removed from the list of drag and drop operations Each press of the Undo button will cause a drag and drop operation to be forgotten and the ProSched display will be updated accordingly Figure 12 13 Exhausting the Undo List If during the course of a ProSched session the Undo becomes full a warning dialog will be presented to the user This dialo
9. Down machines that should be running but are down appear with the machine number and job number fields in yellow and the downtime reason and accumulated time in the Machine Parameters field Not Scheduled machines that are not running because no job is scheduled are identified with a blue background in the machine number and job number fields and no job number displayed Only machines with jobs approaching completion or with a lot size overrun condition are displayed on this screen The Parts To Go and Hours To Go fields show the remaining run time status of a job in the following manner EOJ if the field is yellow the end of job warning condition is occurring The lot size remaining to run is within a certain time frame of the end of job RED the end of job alert is occurring The runtime to go is less than the alert setting The System Manager miscellaneous function is used to set the time period for which the end of job warning and the end of job alerts occur Please refer to Section 7 5 for additional information on setting the end of job warning and alert times 3 3 1 Real Time Screen Colors View is a display only mode used by most production personnel to see current and historic status of the machine floor Its primary purpose is to provide a color coded real time display of the production machine status and lets the operator see but not modify any data View is the primary mode used during normal daily operati
10. Error Standard utilization above maximum Copyright 2002 MATTEC 15 17 710 0092 cause An attempt was made to key in a utilization that was above the maximum remedy Enter a correct value for utilization 100 is them maximum Error Total part weight exceeds shot weight cause While setting up standards of a job an error was made in defining part and shot weight remedy By definition the shot weight must always be greater than or equal to the total part weight Error total record does not exist cause An attempt was made to use a total record that did not exist remedy Enter an existing total record Error Unable to write to printer cause An attempt was made to send something to the printer while the printer was not properly setup for the operation remedy Inspect the printer to make sure paper is loaded properly the printer is on line the printer is on and the printer is connected to the ProHelp Millennium system Errors have been found in the downloaded file Press ENTER to view report cause Errors have occurred while performing a file download remedy Examine the error report to see what happened EXCEPT xxxx xxxx CALL MATTEC cause The system has encountered some error which should not occur during normal operation It may indicate damage to hardware or to the system s file structure remedy Note the exact text of the message and contact MATTEC for assistance Father jobs not allowed caus
11. F3 Disply Allows you to create or modify a setup sheet or QC sheet for this job Machine Document If you have created the job by copying a part or job and it had a setup sheet or QC sheet defined it will be copied in the new job along with the other part or job standards Profiles Allows you to enable SPC or part qualification for this job Reference SPC Settings Section 5 6 and 5 9 for additional information F9 Sched Press to schedule the job if a machine is specified in the machine field Copyright 2002 MATTEC 4 23 710 0092 FUNCTION KEY DESCRIPTION Displays the engineering standards screen of the job descriptor This screen is the default screen the system displays for a new job descriptor Displays the process variable limits for this job Enter high and low Machine Parameters limits for all signals being monitored on this page On analog signals a DELAY for collecting a value from the beginning of a cycle may be entered Auxiliary Parameters up to 76 auxiliary process parameters Last 50 Cycle Times Serap Don Scrap Downtime Press to modify the material lot being used for this job Reference Material Lot Section 4 1 7 for additional information Press to modify the material needs and usage setup for this job Materials List Reference Section 4 1 8 for additional information Press to add to the amount of setup material used for this job Reference Section 4 1 8 for additional information Displays a Pareto ch
12. 88 lf Hold Parts enabled Total Parts To Go Good Parts To Go Hold Parts Made Predicted Good Predicted Good 21762 19150 88 Cycles To Go Total Parts To Go Actual Cavities 5441 21762 4 Maximum Cycle Time Deviation Standard Cycle Time Cyc Tm Pred Lim 3 seconds 30 seconds 10 Maximum Predicted Cycle Time Standard Cycle Time Maximum Cycle Time Deviation 33 seconds 30 seconds 3 seconds Minimum Predicted Cycle Time Standard Cycle Time Maximum Cycle Time Deviation 27 seconds 30 seconds 3 seconds If job is running Maximum Cycle Time Deviation is not 999 and Average Cycle Time is between Maximum Predicted Cycle Time and Minimum Predicted Cycle Time Predicted Cycle Time Average Cycle Time 28 8 seconds 28 8 seconds If job is running Maximum Cycle Time Deviation is not 999 and Average Cycle Time is greater than Maximum Predicted Cycle Time Predicted Cycle Time Maximum Average Cycle Time 33 seconds 33 seconds If job is running Maximum Cycle Time Deviation is not 999 and Average Cycle Time is less than Minimum Predicted Cycle Time Predicted Cycle Time Minimum Average Cycle Time 27 seconds 27 seconds If job is running and Maximum Cycle Time Deviation is 999 Predicted Cycle Time Average Cycle Time 27 seconds 27 seconds If job
13. After each entry Press Enter Press F1 Done The report will be generated The following fields are included in the Cost and Contribution Report Average Actual Cycle The average cycle time Time Dollars S Bad Parts Avg Cycle Time Actual Cavities Machine Cost Rate Scrap Part Weight Excess Material Weight Scrap Material Weight Actual Cost per pound Act Cycle Time Standard Cycle Time Yield Efficiency Actual Yield Standard Yield ci 7 Machine Dollars Machine Selling Rate Optional Time Produced elling Dollars Produced Selling Price per Part Good Parts Made Material lbs Used The amount of material used Material Dollars Used Material Pounds Used Actual Material Cost Material Dollar Variance Standard Material Cost Material Dollars Used Labor Dollars Used Direct Labor Hrs Direct Labor Rate Ind Labor Hrs Ind Labor Rate Labor Dollar Variance Standard Labor Dollars Used Labor Dollars Used Copyright 2002 MATTEC 10 5 710 0092 FIELD DESCRIPTION Sales Gross Profit Selling Dollars Produced Total Cost Gross Profit per Run Gross Profit Total Run Time Hour Gross Profit per shift Gross Profit per Run Hour Std Yield Hrs The following fields are used in calculations on the report but do not appear in the report itself FIELD DESCRIPTION Standard Labor Dollars Standard Direct Labor Hours Direct Labor Rate Used Standard Indirect Labor per Part Good
14. Copyright 2002 MATTEC 3 36 710 0092 Figure 3 35 shows the report options screen set up to produce a report showing Job Run Hours by Quarter The result is shown in Figure 3 36 Each column covers a calendar year and there is a row for each month quarter or year This cannot be altered although specified dates do affect what data is included in the report In other words a column always covers a year from January first through December thirty first even when data is excluded by the date boundaries or simply does not exist The report shown in Figure 3 37 presents the same data by month for a three year period This is accomplished by changing the Start Date to 1 1 98 and the Period to Monthly Figure 3 38 shows the reports defined by Figure 3 35 and shown in Figure 3 36 as a graph ES ProHelp Millennium Bisi E Figure 3 35 Annual Comparison Report Options Copyright 2002 MATTEC 3 37 710 0092 ProHelp Millennium 0 00 6667 46 0 00 0 00 3548 61 0 00 0 00 15312 15 1091 82 Print copy lovloff FndFst FndNxt Brodprv W trndt zt Figure 3 36 Sample Quarterly Report Ss ProHelp Millennium Run Hour FEB 0 00 0 00 0 00 APR 0 00 21 58 0 00 JUN 0 00 4574 88 0 00 AUG 0 00 978 27 0 00 OCT 0 00 1346 13 0 00 DEC 0 00 1078 46 0 00 Total 0 00 15312 15 1091 82 Print copy lovloff FndFst FndNxt BFndPry W trodt zt Figure 3 37 Sample Monthly Report Copyright 2002 MATTEC 3 38 710 0092
15. Enter If the part descriptor is all new and no standards are to be copied Press F3 AllNew The system will ask for a new part number Enter a unique part number Press Enter The system will display your new part with the copied standards or if all new with no standards Edit the data fields by moving the cursor to the appropriate field and entering the new data At a minimum the cycle time cavities and non production limit fields must be entered before you may escape To save your changes Press Esc Copyright 2002 MATTEC 4 36 710 0092 4 3 3 Edit Existing Part Descriptors To edit an existing part descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F1 Part Enter the part number Press Enter Move the cursor to the data field to edit Enter the new value Use the arrow keys or the Enter key to move the cursor Data values are stored when the Enter key is pressed To save your changes Press Esc 4 3 4 Copy Job Standards to Part Descriptors To copy job standards to a part descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F1 Part Enter the part number Press Enter Press F2 CpyJob Enter the job number to copy Press Enter You will be prompted Are you sure Type Y es to copy the job s standards to the existing part descriptor NOTE Setup sheets QC shee
16. Field Size Picklist Figure 3 22 Field Separator Picklist Copyright 2002 MATTEC 3 29 710 0092 ProHelp Millennium OF xX ProHelp Millennium Iof x Items Items CR Slash i CR LF Dash LF OK Cancel Help OK Cancel Help Figure 3 23 Record Separators Picklist Figure 3 24 Date Separators Picklist ProHelp Millennium Iof x Items None 0 Colon OC Figure 3 25 Time Separator Picklist When all options are set as desired Press F1 Done the selected report chart or ASCII file will be generated Copyright 2002 MATTEC 3 30 710 0092 When a report is browsed the following selections including keys for printing or copying the report after browsing are offered FUNCTION KEY DESCRIPTION F1 Print Press F1 Print to print the report to any printer that is defined to the local ProHelp Millennium node F2 Copy Press F2 Copy to copy the report to any disk drive that is defined to the local ProHelp Millennium node floppy drive hard drive or a remote drive on another system Once copied from the system the user may export the file to an external program such as Lotus 123 or to a Mainframe computer The report will be copied in the format that is specified If Report was selected the report will be copied to a file as it looks when it is browsed If ASCII was selected the report will be copied to a file in the user specified delimited ASCII format
17. Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job Enter the desired job number Press Enter Press F9 Sched If a machine number has already been entered for this job descriptor the machine schedule will be displayed Select the position to schedule the job after Press Enter To add a job to a machine from the scheduler follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F3 Sched Press F1 Mach Enter the machine number Press Enter Press F1 Add Copyright 2002 MATTEC 4 43 710 0092 Enter the job number of the job to be added Press Enter Select the position to schedule the job after Press Enter When there is no job running on the desired machine a dashed line is given as a selection in the picklist In order to enter the job as the first job in the schedule simply select the dashed line The computer now adds the new job to the schedule and recalculates all dates Note that the schedule allows for scheduled idle time of machines If the desired start and end dates entered into a new job descriptor does not conflict with the previous job that is running on the machine then there will be a gap of idle time on that machine If the predicted end date of the preceding job on the machine is later than the desired start date of the new job then the start date of the new job will be the predicted end date of the old job The graphic display of the Gantt sch
18. Press F2 Tool Press F2 Sched Copyright 2002 MATTEC 9 7 710 0092 Enter the tool number If the tool number is known it can be typed in If not Hit spacebar A picklist will appear Press Enter ProHelp Millennium ioj x TOOL 100 CODE DESCRIPTION Figure 9 5 Tool Maintenance Schedule 9 3 Modify the Maintenance Activity Logged at the MIU Each maintenance activity logged at the MIU causes an activity record to be created in the appropriate history file This record is time and date stamped and has the maintenance person I D code entered To modify the machine maintenance activity logged at the MIU follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F1 Mach Press F1 Histry Enter the machine number Press Enter Copyright 2002 MATTEC 9 8 710 0092 ProHelp Millennium Eel MACHINE 01 TIME CODE MAINT LABOR PARTS DESCRIPTION PERSON HOURS COST Figure 9 6 Machine Maintenance History The computer displays the history record for that particular machine The first line is highlighted Use the cursor keys to move the highlighted line to the particular data record which you want to change F1 Add Ln Use to add a line to the machine maintenance history file ea Reference Section 9 5 for additional information Use to delete a line from the machine maintenance history file Reference Section 9 5 for additional information F3 Mach Use to select a different m
19. Press F3 Insert Add or modify the data as required Variab Date 09 05 96 Time 20 14 Sequence Charac Figure 5 9 Variable Sample Entry Screen If the sample specified is a characteristic the cursor will move from left to right through all variable 1 entries If the sample specified is an observation the cursor moves down through all observation entries of the first variable before moving to the second variable entry field The time and date stamp of this sample is displayed on the lower right hand corner of the screen To view the limits that have been entered for this job Press F2 Specs When the Specs screen is displayed and you want to return to the Edit screen Press Esc After data entry is complete you may Copyright 2002 MATTEC 5 33 710 0092 Press Esc to exit this mode and save your changes OR Press F3 Insert to add another variable sample for this job 5 7 6 Attribute Data Entry Attribute data entry is similar in function to the variable data entry procedures outlined in Section 5 7 5 To enter attribute data from a computer terminal for a job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F 1 Edit Enter the sample date Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the d
20. cause A communication error has occurred which is not normal under normal operations remedy Contact MATTEC for assistance Copyright 2002 MATTEC 15 6 710 0092 Configuration file busy Cannot Access cause A configuration file may be modified by one and only one user at a time The configuration file is currently being used remedy Have the other user release the configuration file or perform the operation at a later time Copy to diskette failed cause The copy command to a diskette has failed remedy Make sure diskette is formatted and not corrupt and repeat the command Cost data not available for father jobs cause An attempt was made to access ProHelp Millennium cost data for a father job remedy Reference the individual sons of the desired father job Cycle time low spec limit above high spec limit cause The low limit may not exceed the high spec limit remedy Change the low limit to a value less than the high cycle time limit Data Access Definition file is busy cause The data access definition file may be modified by one and only one user atatime The file is currently being used remedy Have the user release the file or try the operation at a later time Data for specified date has been archived cannot edit cause An attempt was made to edit archived data remedy Abort edit attempt because archived data cannot be edited Data in the standby directory may not be modified cause An attempt was mad
21. After archiving data to the hard disk it is very important to copy this data to an external device e g a tape for permanent storage Once copied to the external device the original archive data on the hard disk should be deleted Reference Section 6 1 for additional information 6 3 Purge Old History Data Purge is the counterpart to archive Once archived the history data exists in two places on the archive device and on the hard disk drive Since the data on the archive device is Copyright 2002 MATTEC 6 6 710 0092 intended for use when historical data is needed the duplicate data on the hard disk may be removed Purge is the only function that frees up space or deletes files from the system It is also used to change active files into standby files Controlling the size and quantity of the files on the hard disk is important to ensure the efficient use of the system The archive and purge functions should be run on predetermined fixed intervals Before purging ensure that all specified data prior to the earliest standby date entered has previously been archived to another device It is not possible to recover data once it has been purged unless it has also been archived You should make it a practice to archive data before it is moved to standby This archive will act as a backup for the standby data Failure to archive and purge can result in overflow situations Reference Section 6 6 for information on scheduling the purge
22. Copyright 2002 MATTEC 3 56 710 0092 4 Job Manager The Job Manager mode is a full editing mode intended to be used to create standards create jobs and to schedule the machines JobMan is not intended to be used to view data and therefore does not display job data in real time The job data is presented in a static state The Job Manager mode supports the following responsibilities 1 The creation and maintenance of master part descriptors Part descriptors contain the standards for the machine parameters that depict how a process must run to produce good parts and be profitable Usually part descriptor standards are developed over a period of time and are the result of production control engineering QC sales and management input To best utilize ProHelp Millennium in monitoring the production floor each part produced must be entered and kept accurate in a part descriptor The creation and maintenance of job descriptors A job descriptor is the area in the system where the statistics of a particular job are recorded accumulated and retained for history Each job runs a part whose standards were previously created in a part descriptor The creation and maintenance of machine schedules where the jobs to be run on each of the monitored machines are shown The starting stopping or suspension of jobs Copyright 2002 MATTEC 4 710 0092 When the Job Manager node is selected the following choices appear FUNCTIO
23. F3 QCMan Figure 3 1 Copyright Screen Press F1 QCEnt e ve Breu The selection will appear as Make a selection A message will appear requesting either machine or desired shift Type in machine number or shift number if shift number is requested the next screen will request a date Press Enter The following screen will appear Copyright 2002 MATTEC 5 3 710 0092 ProHelp Millennium Ioj x Figure 5 2 QC Entry Screen 5 3 Edit Downtime To edit downtime for the present shift of a running job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QCEnt Press F1 Active Enter the machine number running the job Press Enter Press F4 DownTm A picklist will appear Highlight the downtime reason Click OK Enter the quantity of downtime for the selected reason Press Enter Repeat this process as many times as required Negative numbers can be entered A negative number has the effect of reducing the downtime for the selected reason Note The total of all downtime entries may never exceed the shift and job totals accumulated by the system A value entry greater than an acceptable total is simply ignored To edit downtime for a previous shift of production follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QCEnt Press F2 Prev Enter the appropriate shift number Copyright 2002 MATTEC 5 4 710 0092 Press Enter Enter the d
24. OR Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F9 SPCRpt Enter the start and end dates Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist Press F1 Done The selected chart s will be displayed Copyright 2002 MATTEC 5 51 710 0092 rs Millennium rs E V Figure 5 19 Composite SPC Report Screen To specify the parameter data Press spacebar The available choices include automatic manual variable and attribute data Move the cursor to the desired choice Press Enter The picklist is limited to active files only standby data is not displayed in picklist Specify Y es or N o for the following Capability Analysis Sample Data P U X Bar charts The user has the ability to specify the scaling limits for the P U or X Bar Charts and the Range Chart Move the cursor to the appropriate high or low limit boundary to be specified Enter the numeric value for the limit Press Enter Specify Y es or N o for the Range chart Move the cursor to the appropriate high or low limit boundary to be specified Enter the numeric value for the limit Press E
25. Press F5 SummSB Fill in the interactive report screen as appropriate Press F1 Done All jobs in the standby data directory will be displayed 3 5 Machine Schedules The ability to manage production requires good scheduling abilities Personnel materials tools etc must all be available when needed in order to produce the products in the time required The ProHelp Millennium schedules are constructed by the Job Manager and provide calculated end dates for all jobs in the schedules The end dates show the production personnel when to stage the next tool for setup when to make the needed material available when to assign personnel and when current jobs will complete Reference Section 4 5 for additional information Copyright 2002 MATTEC 3 19 710 0092 3 5 1 Display a Machine Schedule The way a schedule looks when it is viewed depends on the settings that the System Manager has chosen The following combinations of dates and time are set by the System Manager Desired Start Desired End Desired Start Forecasted End Desired End Forecasted End Forecasted Start Forecasted End To display a particular machine schedule follow these steps Press F1 View Figure 3 1 Copyright Screen Press F3 Sched Press F1 Mach enter the desired machine number Press Enter The computer will now display the first 20 jobs of the requested machine s schedule with newly calculated start and end dates To display
26. Press F7 SPCSet Press F7 ProEna If SPC is enabled then set every field under Parts Qualification and CNTRL to Y es SPEC to N o If SPC is disabled then set every field under Parts Qualification and SPEC to Y es CNTRL to N o With the above settings the user may turn part qualification on or off and the MIU contact and scrap count will work exactly as in Release 1 3 for the selected job Copyright 2002 MATTEC 5 60 710 0092 6 File Manager FilMan is an abbreviation of the word File Manager ProHelp Millennium is a networked system that collects and records production and SPC data on various storage devices throughout the system as specified by the System Manager The devices can be hard disks floppy disks or streamer tapes The data is stored in areas known as files There are several types of files present in the standard collection of data Descriptor Files These files contain the descriptions of the production data to monitor and how to monitor it They include the part descriptor job descriptor and schedule master files and tend to grow in size as time goes on Production History These files continue to grow in size and number New files are created each day to contain running job records for each shift material use data for each shift process parameter history data machine and tool history and machine and tool maintenance history are created each day to contain SPC data Operator Hi
27. Report Picklists will be displayed ProHelp Millennium Items Setup Sheets Maintenance Planning Production Items Annual Comparison Downtime Auxiliary Downtime Daily Downtime Period Event Log Material Used Operator Efficiency Operator Tracking OK Cancel Help Figure 3 14 Production Picklist Copyright 2002 MATTEC 3 26 ProHelp Millennium Items Future Requirements Job Summary Material Needs Part Summary Schedule Summary Tool Conflict OK Cancel Help Figure 3 13 Planning Picklist ProHelp Millennium Fale x Items Help Log Machine Down Log Machine History Machine PM Due Machine PM History Process Exception Log Process Parameter Log Tool History Figure 3 15 Maintenance Picklist 710 0092 ProHelp Millennium Iof x Items ProHelp Millennium Iof x Items Tool History Tool PM Due Tool PM History Operator Tracking Production Daily Production Period Scrap Daily Scrap Period Scrap Auxiliary Figure 3 16 Production Picklist Figure 3 17 Maintenance Picklist continued continued The only reports excluded are those associated with File Maintenance System Manager SPC and Cost Manager In some cases reports may be accessed through other locations as well Examples of this are Job and Part Descriptor summaries which are available here as well as their traditional location A Specials group is present only if special re
28. and Pulse 4 times will be inserted automatically into these fields Specify N o to indicate that these fields revert to their normal operation For MIUs operating with the stage detection feature you must specify a tolerance level The tolerance level is used by the stage detection algorithm to determine when a change between two stages has occurred The stage detection 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 Copyright 2002 MATTEC 7 51 710 0092 The following is an explanation of the columns displayed with the yellow background on the MIU Installation screen DESCRIPTION Signal Name Listed are the user defined names of the signals being monitored by ProHelp Millennium The first five signals are the timed Pulse inputs The following eight signals are the analog inputs Temperature Pressure etc Current Value Displays the value of the signal at the moment the screen was generated This is not a real time field and will not be updated while the screen is displayed To make this field real time press the F5 CurVal function key PP Process Parameters number Essentially a logical identifier from 1 through 96 with zero indicating an unused position Some models of MIUs do not allow full mapping of physical to logical signals and the only legal value is the physical signal number or zero For example t
29. m MOLD OPN jg MELT TMP BLOWPRES TR R BT Ry n m H20 TMP 1 H20 FLOW J First 1 OIL TEMP fall Figure 3 54 Last Cycle Picklist Copyright 2002 MATTEC 3 51 710 0092 ProHelp Millennium File Graph Figure 3 55 Last Cycle Graph All When an individual signal is selected a chart is produced containing the last 100 MIU retained values of all Primary Machine Signals available for the selected machine Since not all MIUs support this feature the success or failure of this is dependent on the specific MIU installed An example of this chart is shown in Figure 3 56 Copyright 2002 MATTEC 3 52 710 0092 gt lt ProHelp Millennium File Graph Figure 3 56 Last Cycle Graph Individual 3 7 ProStat ProStat is MATTEC s statistical process control program To display a real time trending alarm screen for SPC jobs follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Refer to Sections 5 6 5 7 and 5 8 for additional information 3 8 Data Export The optional data export program is a facility for providing certain ProHelp Millennium files in a delimited ASCII format The purpose of this feature is to provide a very powerful low level means of transferring data from the ProHelp Millennium system to an external system The Daily Production History Export record may contain up to an additional thirty fields If additional primary scrap
30. or melt temperature are monitored against preset limits If a parameter varies outside of limits a process alarm is signaled ProHelp Millennium provides multiple levels of sophistication for the Machine Interface Units MIUs Simple MIUs that count production rates and cycle times can be intermixed with MIUs that allow data display and entry from the machine site Process monitoring MIUs that continuously watch for deviations in temperatures pressures shot size and extruder speed combine with the simple MIUs to make a system that is expandable as the user s needs expand Users of the ProHelp Millennium system have reported a tremendous increase of operator efficiency and machine productivity Benefits of use of the ProHelp Millennium system have been Copyright 2002 MATTEC 1 1 710 0092 1 A 10 to 30 decrease in scrap parts production An increase in machine utilization of 5 to 25 A decrease of indirect labor costs in the range of 10 A customer satisfaction level significantly higher An 8 to 12 savings on material costs due to the elimination of scrap parts Control charts that offer customers proof of process capability 1 1 What the Company Purchased Your company has purchased a computer system which combines hardware and software programs to physically monitor selected machines in your plant The machines are monitored to assure that they are running within the proper cycle times that the sales engine
31. 1 24 Figure 7 14 Sample Next Job Real Time Screen sect ose ted Ree eae s 7 27 Figure 7 15 Next Job Screen Configuration ccecccessscceesseceesseceeseeeeseceesaecessaecesaeeeeseeeeaaees 7 27 Figure 7 16 Real Time Configuration Screen 7 28 Figure 7 17 Master Seip Sheet sin eet 7 32 Fig re 7 18 Voice Option IE oS Ce E 7 38 Figure 7 19 Voice We RRE 7 39 Figure 7 20 Voice Option Parameter Screen s cc 20 s ecssde cesitiasecisdiienee ENEE GEES 7 39 Figure 7 21 Miscellaneous Installation Parameters Gvstem 7 40 Figure 7 22 Miscellaneous Installation Parameters Department 7 40 Figure 7 23 MIU Installation E 7 49 Figure 7 24 Type DIC E EE 7 54 Figure 7 25 Type picklist continuie EE 7 54 Figure 7 26 Sample MIU Configuration Old Ste 7 55 Figure 7 27 Sample MIU Configuration New Style cee eeeeesseseeeeereecsaeceseeeeeeeeneesnaeeneensees 7 56 Figure 7 28 Remote Analog Calibration Mode Screen 7 61 Figure 7 29 IU EE 7 62 Figure 7 30 Language File Maintenance Screen 7 63 Figure 7 31 Systeny Names Ehe 7 66 Figure 7 32 Server Node Configuration Screen 7 69 Figure 7 33 Manual Monitoring Nodes Screen cedceecdes et ENEE he ondianlaeigeteaaes 7 72 Figure 7 34 Location of Data Files ius osesas aszcessacscavestesganencenseed quad ture se cadaeosnascaveniod ganeneantendqoasteretges 7 74 Figure 9 1 Machine Maintenance Codes ege scent ne ies eee einen Rental 9 3 Figure 9 2 Tool Maintenance Codes 2222uzeoegasseeeud esgekgkegetdet eg
32. 12 710 0092 TELD DESCRIPTION Scrap Scrap percentage is used to factor the lot size to allow for anticipated scrap The value entered here must be 0 99 if the system is configured for Lo Res scrap or 0 99 9 if system is set for Hi Res scrap The scrap percentage represents the percent of scrap standard for this job Entering a non zero value modifies the to go values parts and hours as well TOT PTS RUN HRS and MATL LB are all updated to reflect the additional manufacturing needed to compensate for the anticipated scrap crap Shift BAD PARTS SHIFT TOTAL PARTS SHIFT crap Job BAD PARTS JOB TOTAL PARTS JOB 8 Hour Yield The shift yield is calculated by the system and shows how many parts should be made per shift The number of hours for the yield period is defined by the System Manager Refer to Section 7 for additional information 8 Hours Cavities Standard 1 00 Scrap Cycle Time Standard 8 Hours Cavities Shift 1 00 Scrap Cycle Time Shift Yield Job 8 Hours Cavities Job 1 00 Scrap Cycle Time Job The yield values that are calculated are also used to generate the Yield Efficiency values Utilization The number entered here is a value used to determine the maximum amount of actual run time that may be expected from this particular job This value is applied to the forecasted end date that the system calculates for the actual run time of the job and affects only th
33. 1RAACAMI ANIN EE IEN Figure 12 36 Drag and Drop Results Figure 12 36 indicates that Job 02 is a part of Job 11 and that Job 02 is pending while Job 11 is listed as a running job Remember green indicates a job forecasted to complete on time Copyright 2002 MATTEC 12 31 710 0092 We have restarted and are looking at Job 55 This shows as a running job red in the Gantt area Job 55 also has a Part Number 600 which needs to be scheduled which is found in the Unscheduled area with a desired start of 7 25 96 We shall attempt to move this job to start and end within the desired time PART NUMBER min PART NUMBER NUMBER DESIRED START DESIRED END Figure 12 37 Drag and Drop Operation Screen As mentioned in Section 11 2 4 Drag and Drop Operation one reason for an incomplete process would be if the drop effects a running job We tried to move this job to the other 55 job listed on the Gantt and commit The results were Figure 12 38 Commit Screen Failure ATTENTION x Sg This move would effect currently running job JOB55 The transfer has been aborted Figure 12 38 Commit Screen Failure Copyright 2002 MATTEC 12 32 710 0092 What we were able to do was move Job 55 Part Number 600 into a pending situation under Job 11 Figure 12 39 Drag and Drop Operation and press Commit to secure a new schedule xX Prohelp Millennium ProSched Iof x Se oT a Ze SS x See Seel Ke Ree SE 08728796 09
34. 2002 MATTEC 7 37 710 0092 Bla ESA WO E H LUM Figure 7 18 Voice Option Help Screen Dept Each Department must be configured individually through a picklist Node The Monitoring node name Sound Dir This is the directory in which the wav file directories are kept The default directory is shown but the voice files can be placed in any directory as long as they are referenced here Note the help directory name does not have to be on the sound dir line This is because within the setup screen the system automatically knows which sub directory is to be used with the names of these voice files Play Bell Enable or disable this system announcement which plays a bell to preclude the announcement of a help call reason Play Dept Enable or disable the announcement of the department name Play Help Enable or disable the announcement of the actual help call reason Num Plays How many times the announcement is repeated during each interval Repeat Interval The duration of time between the repeating of the voice announcement Copyright 2002 MATTEC 7 38 710 0092 Dept Systea Node 1 trillian Sound Dir usr prohelp sounds eng lish Play Bell Play Dept Play Down Num Plays 1 Repeat Interval 45 ii Insert the voice 123 file names for 13 down reasons 14 15 16 ante 18 19 20 Down Down Down Down Down Down Down Down Down Down ssa E E CC E E Oonan UNE ce 8 E E E a O owane GOAtz An tt
35. 3 1 Copyright Screen Press F2 JbDesc Press F4 NewJb Press F1 Single This selection only appears on systems with the optional Family Molding program If the standards from an existing job are to be copied to your new job Press F1 CpyJob If part standards from an existing master part descriptor are to be copied Press F2 Cpy Pt If the job descriptor is all new and no standards are to be copied Press F3 AllNew Any selection will cause the system to prompt for a new job number Enter a unique number Press Enter If you are copying a job or part descriptor you must now enter the number to be copied Press Enter When copying a job or part descriptor that has a Setup sheet associated with it the message COPY SETUP SHEET FROM oldjob TO newjob will appear To copy Press Y es If you do not wish the setup sheet to be transferred to the new job from the job or part being copied Press N o After creating the job you may create a different setup sheet for the new job When copying a job or part descriptor that has a QC sheet associated with it the message COPY QC SHEET FROM oldjob TO newjob will appear To copy Press Y es If you do not wish the QC sheet to be transferred to the new job from the job or part being copied Press N o After creating the job you may create a different QC sheet for the new job Copyright 2002 MATTEC 4 21 710 0092 If copying a job descriptor that has
36. AS511 e Cincinnati Milacron VISTA XTL VSX e Battenfeld Unilog 4000B e Cincinnati Milacron ACT e Maruka Toyo e SCI Calderaremaster e Siemens Demag e Moog Mopac Modicon protocol e Buhl PPC 90 e Klockner MPC 80 e Siemens CPU 944 3964R e Gefran Elettronica e Toshiba EX100 e Nissei e Mitsubitshi MAC VI e HPM CMD90 e Nissei 8000 e Van Dorn 4500 e INOEX SAVEOMAT e INOEX SAVEOMAT 93 Copyright 2002 MATTEC 7 59 710 0092 The system will return to the MIU setup screen and will display the name of the PLC type in the PLC field Once the choice of the PLC has been made it is necessary to define the parameters that will be collected and monitored Eleven 11 selected processes besides CYCLE TIME may be monitored To configure the PLC interface follow these steps Press F7 PLC A new screen with terminology appropriate for the type of PLC selected is displayed Values entered in these fields define the data values that will be monitored You will need documentation from the specific control manufacturer to properly set up this feature The previous sections are meant as a summary of PLC selections and configuration Current documentation from MATTEC and the PLC manufacturer must be obtained to configure this option 7 12 5 Remote Analog Calibration Mode It occasionally becomes necessary to set analog calibration at the MIU For security purposes ProHelp Millennium must be set in Remote Analog Calibration mod
37. Alert If Y es the MIU will flash the green warning light for the operator to take SPC samples for variables and attributes Preset time frames for the sampling are set in the individual job descriptors Copyright 2002 MATTEC 7 43 710 0092 FIELD DESCRIPTION Deflt Speed Units This field represents the default speed units for all the machines in the plant Valid choices are seconds cycles cycles hour cycles minute and meters minute This value has the affect of changing the job or part descriptor values of cycle times to the selected units until a machine number is specified in the descriptor Once a machine number is specified that machine s speed units are used Enhanced Part Qual When set to Y es the system uses the enhanced part qualification rules that exist in Release 1 4 and later When set to N o the system uses the part qualification rules that exist in ProHelp 1000 Release 1 3 Reference Section 5 9 for additional information Default Prod Units Valid choices are PARTS or CASES These are the default production units used when creating a job or part descriptor Enable Ext SPC Enables an additional 10 parameters for SPC data collection Kanban Class If using Kanban allows the selection of class Scheduling Reset Elapsed DT When set to Y es the Elapsed Downtime field available to the Real Time Display is reset each time the selected Downtime Reason changes even though the machine remains down Whe
38. Consider the corrective action necessary What is the effect of your proposed corrective action Will ProHelp Millennium lose any production data Will other users of the system be affected by your proposed action Please call the MATTEC Customer Service Department for help and advice 1 2 11 System Manager The System Manager is a person appointed to be the expert on the MATTEC 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 are 1 2 Communicate any problems to MATTEC s Customer Service Department Install new software updates when sent by MATTEC s Customer Service Department All updates come with simple installation instructions that non engineers can usually implement Determine and initialize the installation variables for downtime names scrap part names shift start and end times machine numbers Backup the system s hard disk data files to protect against accidents Daily backup is recommended weekly backup is mandatory Copy old job histories and production reports to floppy disks or other approved devices for historical storage Utilize the archive and purge functions of the system Periodically reset the tool and machine history files after the data has been backed up to floppy disk This is usually done once a year Set the passwords in the system in order to allow only authorized person
39. D EE 5 51 5 8 10 ProStat SPC Calculations 2c2s00 22 Seed EENS 5 53 5 9 Part Qualification eisen iv Sivas ote eee Ties ew ee eege esteem a lee Ss 5 56 5 9 1 Selecting Machine Processes for Part Qualification 0 0 ceecceceseeeesseceesteeeeteeeeeees 5 56 5 9 2 Enable Part Qualification for a Job 5 57 5 9 3 Operation of Part Qualification o cccceisecceiecisascaseaspevedtabeusdecessaccadadesasnadeetaceensecvedees 5 58 5 9 4 Release 1 3 Part Qualification 0 cc ccccccsscccccccecsesesscecececeesesenssececeseeesersseeeeeceess 5 59 6 EE 6 1 6 1 Open Uny TEE 6 2 6 2 Archiving Datacies sanausiaudnuinusduniuiiannienwpaiusaiasiias a a aE 6 5 6 3 Purse Old History Data zae E esac E ee ase 6 6 6 4 Condensed Production History i cccei vegies tevesncviiasaees jeaybuasdiva shes sda vavenadesetandawedecehuadanes be 6 8 6 7 Data BAC EE 6 9 6 5 1 Manual Data Backup i sccccisisdsesccasacceeeihevesctusoecaeds toccudnasdesactawavceseleseaateavssaceeseareanes 6 10 eda Backup E EE 6 11 6 6 Automatic Archive Purge and Backup 6 12 6 7 Retrieve ProHelp Millennium Archived Data eee eeeeesecsneceeeeeseeeeaeecnaeeneenaees 6 15 6 8 Retrieve Old ProHelp 1000 and ProHelp Archived Data 6 17 G9 R store Backup E EE EE 6 17 6 10 Edit Shift Prod ction DALE sacks caiiwesies acescadtextcesuenahoraesuntosedanossqethwenaadeghosagenaeceattyead tenses 6 18 6 11 Edit Job ee ee EE 6 19 GI Tool History ReSet cscssccaverscc
40. Ee EE 15 1 Copyright 2002 MATTEC vil 710 0092 TABLE OF FIGURES Figure 3 1 Copyright Sere E 3 2 Figure 3 2 View Mode Menu Selections eseeeseeeeesesesessesseeeresressesstrerssressessresresseestesesseeseseresreses 3 4 Figure 3 3 Standard Real Time Screen jose ates aac ilies eae ais adenine 3 5 Figure Ree 3 15 Proure 3 5 Last sO Cycle Times Sere ei cse n e E a sec ss A S AEE aE S A 3 17 Figure 3 6 Machine Schedule wcai iecieedncieei alin nnn easi 3 20 Fig re 3 7 Gantt Schedule Sereen cierren e Ai R aie A A E s 3 23 Figure 3 8 Tool Base Field Gantt EE 3 24 Figure 329 ProSched Startup S EE 3 24 Figure 3 10 ProSched Screen viiscaiinssacsatasversccessaseadascecedeadvonaacessvavaavedennacceasaceadasteveseadeonadeedadccevartes 3 24 Figure 3 11 Tool Base Field ProSchedsic 25 casein Ane caiies Bate aes dee ae ae 3 25 Figur 3 12 Reports EE 3 26 Freure 3 13 Planning Picklistcc hice eee A iea a eee eR Gel eee ey REAS 3 26 Figure 3 14 Productron Picklist us cop 2iceetediciebaiiiesee EENEG erecta ales 3 26 Pioure 3 15 Maintenance E EE 3 26 Figure 3 16 Production Picklist continued 0 0 0 0 eeeccecesececeeececesececeeeeeceeeecseeeeseeesseeeeneeeeaees 3 27 Figure 3 17 Maintenance Picklist continued 255 20 lt 0320i050205 54 saveadesaaceeadsacesstassearciancdad ateqctaeeaaeets 3 27 Figure 3 18 Sample Report Options Screen 0 e ce ceeceeeseecesececseececeeeeecneeeeeeeeeeneeeeseeeeseeenaeees 3 27 Figure 3 19 Eeer See eene 3 29 Figu
41. Enter key or the arrow keys to position to the end date and time fields Enter the exception period end date and time Press Enter Active Specifies this period as active Y es or inactive N o regardless of the weekly shift array Comment This optional field is provided for entering a reason comment for the exception period FUNCTION KEY DESCRIPTION F1 Add Press F1 Add to enter any additional exception periods F2 Delete Press F2 Delete to remove an individual exception period F10 Clear Press F10 Clear to remove all exceptions for the plant To save and activate your changes when complete with all exception period scheduling Press Esc 7 4 3 Shift Breaks A Shift Break is a planned period of time within a shift that a machine is not operating Each is defined by an offset from the start of a shift and a duration in minutes A maximum of twelve Shift Breaks can be defined for each shift tag in each department As with other shift configuration items changes made to Shift Breaks may not take effect immediately An orderly system shutdown and power up must be performed to activate changes When changes to the shift configuration invalidate a Shift Break the Shift Break will be removed and a message will notify the user that this has occurred The effect of Shift Breaks is similar to that of Shift Exceptions Non production time accumulating during a Shift Break is not reported as down time and all production
42. Family Molding program Select to perform all job control functions within a single screen including the addition and deletion of component jobs 4 5 1 Start a Job The Start function can be used to start monitoring activities To start a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F1 Start Enter the machine number on which to start the job Press Enter Enter the job number to be started Press Enter The system requires that the desired machine not have a running job and that the selected job not be running on another machine Any job that is not in the run state can be specified Copyright 2002 MATTEC 4 48 710 0092 If the machine selected has a running job on it presently the system will prompt to end or suspend the present job To return to the prior menu Press Esc OR the appropriate function key If the specified job is not in the machine s schedule the job is automatically placed in the schedule as the first job All other jobs in the schedule are moved down This ability simplifies the occasional need to move a job from one machine to another or to start monitoring without actually placing the job in the schedule 4 5 2 Enda Job The End function is used to stop monitoring the job on the selected machine and to mark the job as completed It can be used when a job is to be stopped permanently before having completed the lot size and can also be u
43. FilMan Figure 3 1 Copyright Screen Press F3 Backup Press F2 BkpLog Press F1 VuLog Fill in interactive screen as appropriate Press F1 Done The Backup Log Report will be displayed Reference Section 6 5 2 for additional information Example Command Line Execution Backup The following is an example of executing the backup command from the command line mbackup B d usr prohelp mat_backup f In the above example the following occurs 1 The backup command will be executed mbackup B 2 The backup will be copied to the directory usr prohelp mat_backup d usr prohelp mat_backup 3 A full backup will be performed f 4 The results of the backup can be seen by viewing the Backup Log Report 6 7 Retrieve ProHelp Millennium Archived Data When trying to use data that has already been archived and purged off the system the system will display an error message The retrieve function must now be used to retrieve the archived data so that it may be displayed Retrieving archived ProHelp Millennium data is a two step process In the first step the user must manually copy the archived data from the storage device e g a tape to the hard disk using standard Open Unix copy utilities In the second step the archived data must be read into the ProHelp Millennium standby directory To copy the archived data from a tape if you used the cpio copy utility described in Section 6 1 to the hard disk directo
44. He en He He He Oe OH Oe ER e E WE lt lt lt A Figure 7 19 Voice Option Down Screen Dept EEE Node 1 trillian Sound Dir usr prohelp sounds eng lish Play Bell Play Dept Play Parm Y Num Plays 2 Repeat Interval 10 CYCLE TM N 12 HOLDPRES HOLD TM N 13 BACKPRES GATE TM N 14 Signall4 Auxiliary is only INJT TM N 15 Signall5 set to yes when RECOVERY N 16 Signal16 MELT TMP N17 Signali7 Youneve ay NOZL TMP N 18 Signal18 H20 TMP N 19 Signal19 DEWPOINT N 20 Signal20 H20 FLOW INJ PRES N 21 Auxiliary HESS FESCH WE E E H E a 0 N N N N N N N N N N N 1 3 4 5 6 T 8 9 10 11 Figure 7 20 Voice Option Parameter Screen 7 11 Miscellaneous Installation Parameters The configuration parameters described here affect basic operations and are applied at system power on This means that any changes made to the miscellaneous installation parameters requires a system wide reboot To access the Miscellaneous Installation Parameters function follow these steps Copyright 2002 MATTEC 7 39 710 0092 Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F1 Misc E ProHelp Millennium Bisi x Figure 7 21 Miscellaneous Installation Parameters System The parameters shown in Figure 7 21 affect the entire system There are other parameters that affect only a single department Department Installation
45. InjPk Tm could be reversed on the configuration screen with no apparent change in function Copyright 2002 MATTEC 7 55 710 0092 INJECT 1 000 Figure 7 27 Sample MIU Configuration New Style 7 12 2 Parameter Types Primary and Auxiliary Certain MIU models allow for monitoring a total of 96 process parameters This includes Cycle Time but does not include the three auxiliary counters All capabilities are available for twenty of these while the remaining 76 have a subset of those capabilities available The twenty parameters with full capabilities are called primary process parameters and the others are called auxiliary process parameters Auxiliary Process Parameters FIELD DESCRIPTION Specification Limits These limits are available on a job by job basis They are modifiable in both the Part Descriptor and in the Job Descriptor Specification Limit Limit checking is performed by the MIU Out of limit Checking and conditions are enunciated at the MIU via red green and Alarming white lights At the host out of limit conditions are indicated by color coding of process parameter fields on the Real Time Display Exception Logging All specification limit violations are written to the host s and Reporting Exception Log file and appear on the Exception Log Report the MIU a parameter is available at the MIU Consecutive Cycle This chart is available from the MIU and host menus Chart Last 100 Additionally it is a
46. JbDesc Press F4 NewJb Press F2 Family Press F3 AllNew Enter the new family job number Press Enter The system will display the first screen of the family job descriptor ProHelp Millennium of x 0 0 0 0 00 0 00 PEND Figure 4 8 Family Job Descriptor The job number field will be filled in with the number just entered The part number field always displays the name FAMILY as a non modifiable default Enter other information as appropriate After the general information fields are entered the cursor will move to the COMPONENT JOBS field Enter the single jobs that were created in Step 1 as component jobs Any single job not scheduled to a machine may be specified as a component job Copyright 2002 MATTEC 4 54 710 0092 Because all members of a family share a single machine certain characteristics must be identical Machine parameter limits and the material list are among the items affected All members use the family job s definitions for both of these Material weights are taken from the individual component jobs but the material codes come from the family Predicting dates for a family job and for individual members is one of the more involved aspects of family molding and some rules are necessary In order to properly predict dates for the overall family all members must specify the same SCHED FROM setting In other words either all must specify Start or all must specify End A desir
47. Ln To delete lines from the maintenance history Press F2 Del Ln Use the cursor keys to position to the fields to make data entries for the person performing the maintenance labor hours etc To save your changes Press Esc 9 7 Maintenance History Reports To view the Machine Maintenance History Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4 Report A picklist will display Copyright 2002 MATTEC 9 13 710 0092 lt ProHelp Millennium Miel ES Setup Sheets Planning Production Highlight Maintenance A picklist will display ProHelp Millennium To Items Cancel Help Highlight Machine History The Machine Maintenance History Report can be shown for one or all machines one or all departments one or all maintenance codes and for all history or for a history within a certain time frame Fill in the interactive screen as appropriate Press F1 Done The Machine Maintenance History Report will be displayed Copyright 2002 MATTEC 9 14 710 0092 TOT RUN 1 Down Down Down ST R E 466 17 0 00 0 00 0 00 0 00 CET AT TACT 2 87 466 1 0 00 0 00 0 00 Ee SS Down 0 00 HRS 0 0 OF TOTAL Down 0 00 HRS 0 0 OF TOTAL Down 0 00 HRS 0 0 OF TOTAL Down 8 0 00 HRS 0 0 OF TOTAL Print copy lovloff WFndFst amp FndNxt BrFndPry QfFndcst Figure 9 7 Maintenance History Report To return to the copyright screen Press Esc several times To view the Tool Ma
48. MACHINE NUM NUMBER OPERS A 07 01 97 01 0 00 0 00 03 0 00 0 00 05 0 00 0 00 0 0 00 0 00 03 0 00 0 00 BO 0 00 0 00 Total 0 00 0 00 0 00 0 00 03 0 00 0 00 Copy lovloff FndFst amp FndNxt Brndprv MFndLst Figure 3 44 Future Requirements Schedule Daily Report The above screen Figure 3 44 was accessed by using Detail Machine ProHelp Millennium DEPT INJECT FROM rop WEEK START NUMBER d HOURS 07 01797 01 0 00 928409870 23411 0 00 4408 0 00 459008 120 38 Fam lyTool 16 83 SonTool_2 0 00 1234098 Print copy lovloff BFndFst BFndNxt BFndPry W itodtczr Figure 3 45 Future Requirements Schedule Weekly Report Copyright 2002 MATTEC 3 44 710 0092 The above screen Figure 3 45 was accessed by using Format Report Detail Individual MATERIAL MATERIAL CODE NEEDS 0 00 LBS EE Ee 0 00 L ps SE EH ABS BLACK 749 02 Ups ALAR S200 OO LBS Lex1289889 0 00 LBS O POLYPROW OO LBS ie DVC 0 00 LBS 9 Polypropylene 45 55678 0 00 LBS Tota 248 02 CLBS A AUG SP LBS 1231 0 00 s E EES e El 1354 0 00 LBS Print Bcopy 0vloff FndFst BFndNxt Brndprv W trodt zt Figure 3 46 Future Requirements Schedule Monthly Report The above screen Figure 3 46 was accessed by using Report Browse Material Month Detail Individual Schedule Desired Copyright 2002 MATTEC 3 45 710 0092 X ProHelp Millennium File Graph
49. Names ugeet ieda Seele deed 7 65 PLL System Wide Default IN IN Se ep etal std ds dec sacle gah e 7 65 7 14 2 Create or Delete a Ieper ee deeg EE 7 67 7 14 3 Department Scrap Downtime and Help Names 7 68 7 14 4 Individual Machine Signal Names s sssneseeseesesseessseesseessessserssseessseesstessessseeesseeessees 7 68 Se Machine Class Niege eege 7 68 Copyright 2002 MATTEC v 710 0092 le Network Setpa etin eat ael tae aod ate feea eagle aes eae ee es 7 69 714 64 Manually Monitored Miachines y5 sg coceccs scsycsseacovisess ao3s lt sasiecdasadecsaczascasteacees 7 70 7 14 6 2 Variable Speed MIU Communication 0 0 00 ceecceceecceeesececeeeeeceeeeesneeeeneeeeaees 7 72 els SPE CAUSE REASONS EE 7 72 Tel TOCA ON OF D ta File S ET 7 73 We TRACES VStEM SCH eege Eege 7 74 7 17 Configuration Summary Report 7 75 S SPRUNG E EE 8 1 Bok Cha nge Cava es Ol A ee EE 8 1 me Change Material Setup Ol Web EE 8 1 8 3 Modify a Machine Schedule s2 20cc 53cdsssaienss sededacaiastacevcundendasacsanadaausieaes Ed 8 2 S4 hetten eelere 8 3 9 Maintenance Mee Sierra eet mass soavaden nes E Eat 9 1 9 1 Mamtenance Code gereegelt 9 1 9 2 Schedule Preventative Maintenance 4 05 3sisssjscdeseccvaedsdvecadessccsccennecsnanabontsaevs DESEN 9 4 O24 Machine Maintenance See cule ere Ee eege 9 6 9 22 WOOL Maintenance sosedi nne joecautin evn cun Ee 9 6 9 3 Modify the Maintenance Activity Logged at the MILT 9 8 9 4 Modify the Last Time PM
50. Part Name A Show Partial Labels L e Customer ID v Color Tool Name ll Tool Base ID E A Primary Matl Done Apply Cancel A Monochrome Copyright 2002 MATTEC 3 23 710 0092 Figure 3 8 Tool Base Field Gantt If the selection is F4 ProSch the following will display Prohelp Millennium ProSched Startup ol x Class Filter ao v Department Filter me v Number of days to consider 100 OK CANCEL Figure 3 9 ProSched Startup Screen Make the appropriate selections The following screen will display reference Section 12 for more information on this selection Prohelp Millennium ProS ched File Edit View Q7 S 3 SJ el Be x Scheduled Jobs Z Figure 3 10 ProSched Screen On the menu bar select Preferences Copyright 2002 MATTEC 3 24 710 0092 File Edit View ON F 2 el a The following will display ProSched Preferences Job Number Part Name Customer Name Tool Number Primary Mail Code None OK Apply Save CANCEL Figure 3 11 Tool Base Field ProSched Copyright 2002 MATTEC 3 25 710 0092 3 6 Reports and Charts 3 6 1 General Operation 3 6 1 1 Report Access To assist in finding and requesting specific reports all standard general interest reports are divided into four groups and are accessible as follows To access most ProHelp Millennium reports follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4
51. Profile Cara tree Asien 4 30 Pisure 4 7 Machine Sch dule sagas casnccvadetorsdaqayboassavngnesdaeeeavesagenusseacndavad seas eoneseveasednenenesaeumnaceeacneess 4 42 Figure 4 8 Family Job Descriptor vas secsasssdeccdecassaesasveeddanes sutton es NEEN N E bused ceeds nedsante dessaceasssedaneaavs 4 54 Figure 4 9 Manual Production Entry Template Screen eceeeseceesseceesseceesseceeeeeeseeeeseeeeaees 4 62 Figure 4 10 Manual Production Entry Setup Screen ce eeccceeesccessseceesseceeneceeseceesseeeesaeeeeaees 4 63 Figure 4 11 Manual Entry Production Screen oo cece eeeesceseecsseceseceseeesseecaeceseesseeesaeenseesseeenees 4 63 Figure 3 1 OC Scrap ENY oreng senine n p ES E ANE E EE A ASE IE E EE 5 2 Figure 5 2 OC Entry Screen iii iei e E E a Be ee et ee Bee 5 4 Figure 323 SPC SOC Basie EE 5 12 Figure 5 4 SPC Process Parameters ooa a ae e ee a a Oe ae 5 16 Figure 5 5 E 5 18 Figure 5 6 SQC EE 5 20 Pi Cite 5 7 SQC Variable Enable EE 5 21 Figure SS IC El 5 22 Figure 5 9 Variable Sample Entry SCreetic sci cecsctesssccissscassstcassseccenscccsatesensneleasscsendeawscaceessdvedensnes 5 33 Figure 5 104 Chart EE 5 36 Figure 5 1 Single Chart Set EE 5 37 Fig re 5 12 XBar EE 5 39 Figure 5 13 Histogram Graph sseni nesie iine aerias r a aN SEENEN a E Ea Eea eases 5 41 Figure 5 14 SPC Summary E EE 5 42 Figure 5 15 Calculation Limits Screen ssi0c iscspsccdsesstverdevsdeeszansccecdcedaeadsensbacscave d e Seene 5 44 Figure 5 16 U Attribut
52. RITmDf Press F3 Files Press F2 Load Choose the desired file This could be one of the defined menu selections FJ through F8 the F9 Std screen or one of the screens under F10 Other When you have completed creating your new display you must save this new display back on to hard disk Be sure to give it a different display name than the original basic display that you started with otherwise the new display will override your basic format Press F3 Files Copyright 2002 MATTEC 7 22 710 0092 Press F1 Save When the display is saved the original menu will be displayed Press Esc several times to return back to the copyright screen 7 6 5 Change the Lengths of the Data Fields To change the lengths of the data fields in a real time screen follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5 RITmDf Press F3 Files Press F2 Load Choose the desired file This could be one of the defined menu selections F1 through F8 the F9 Std screen or one of the screens under F10 Other Press F2 Delete Enter the number of the item you want to change Press Enter Enter the new length or the number of digits to the left of the decimal Press Enter Continue selecting item numbers and change the length as you choose To return to the real time display writer menu which allows you to insert delete and create new displays Press Esc twice Remember that eac
53. SQC cycles per sample or observations per sample above maximum remedy Set the value of cycles per sample between 2 and 9 SQC cycles per sample or observations per sample below minimum remedy Set the cycles per sample value between 2 to 9 SQC machine parameter average is outside of control limits remedy Set the average within the range of the low control limit and the high control limit SQC machine parameter low control limit above high control limit remedy Set the control limit to a value less than or equal to the high control limit SQC samples per run above maximum remedy Set the samples per run value to a number between 1 to 10 SQC variable average is outside of control limits remedy Set the average value within a range between the low control limit and the high control limit SQC variable low control above high control limit remedy Set the control limit to a value less than or equal to a high control limit SQC variable low spec limit above high spec limit remedy Set the low spec limit to a value of less than or equal to the high spec limit Copyright 2002 MATTEC 15 40 710 0092 SQC variable number of decimal places above maximum remedy The number of decimal places may be 0 to 4 Standard cavities is 0 must be non 0 cause The job descriptor standard for the cavity value is 0 remedy Change the value to be 1 or greater Standard cycle time is 0 must be non 0 cause The job standards value for cycle time
54. The alarm conditions are checked after a variable sample is taken at an MIU Valid choices are none XLimits Rlimits and XRLimits default An alarm condition occurs if the selected variable limits exceed the variable control limits An appropriate alarm message is displayed at the MIU on the SQC status screen and on real time screens Copyright 2002 MATTEC 5 21 710 0092 The alarm conditions are checked after a variable sample is taken at an MIU Valid choices are none XRuns RRuns and XRRuns default An alarm condition occurs if a run Trend or Shift is detected for the selected variable as defined by the V A SAMPLES RUN field An appropriate alarm message is displayed at the MIU on the SQC status screen and on real time screens 5 6 6 Attrib Attribute Setup To modify the setup for attribute data follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F10 Attrib The SQC Attributes screen will be displayed Use the spacebar for picklist of options Use arrow keys to move from field to field Tob top10 SQ J A C ATTRIBUTES Figure 5 8 SQC Attributes The following fields are then available for modification FIELD DESCRIPTION Copyright 2002 MATTEC 5
55. View F2 JobMan or F6 PrdMan from the copy right screen Figure 12 1 Copyright Screen ProHelp Millennium Ioi x Ai eu TobMan Boc Man Bsysman BFilMan BPrdmMan GMntMan BcstMan BSPusR1 Mlang M Figure 12 1 Copyright Screen In this example we are using Option 3 PrdMan Dependent upon the Option used the second screen name only will change accordingly You have reached the Production Manager screen Figure 12 2 Production Manager Screen At this point you must Press F3 Sched Copyright 2002 MATTEC 12 2 710 0092 ProHelp Millennium ferm AbDesc Sched Boni PR BkKanban M Figure 12 2 Production Manager Screen In any of the Options used the Scheduler screen will now appear Figure 12 3 Scheduler at which point you should Press F4 ProSch ProHelp Millennium Iof x Surmry Boantt HProsch E Figure 12 3 Scheduler You are now in the proper location to start the ProSched session Copyright 2002 MATTEC 12 3 710 0092 12 2 1 Startup Dialog ProSched displays a modal dialog Figure 12 4 ProSched Startup on startup that will prompt the user for the information needed to begin a new session of ProSched The dialog is divided into two areas the control area top of screen and the action area bottom of screen Prohelp Millennium ProSched Startup Class Filter ALL Je Iv Department Filter Deptt Number of days to consider 190 Figure 12 4 ProSched Startup Control
56. also permits editing of samples Operational Procedures The operational procedures for all functions under ProStat are similar The date or a date range must be specified for beginning any SPC function The date is the actual date the samples were collected In most cases you will be interested in displaying or charting data from today s operations Just enter in today s date followed by the Enter key Copyright 2002 MATTEC 5 9 710 0092 The file structure for SPC is based on a date sort key If you want to examine processes or control charts for parts that were made in the past use the Mold History Report to identify when the job was run Then specify the proper date range for the SPC functions Job number fields and parameter fields can be selected through picklists To display the available choices press the spacebar The available choices for that particular parameter are displayed Use the cursor keys to move to the desired choice and press Enter The choice is automatically picked and entered into the particular field Use the cursor keys or the Enter key to position to additional fields Make the field selections as required When you are finished making all of the entries for the particular function to be performed Press F1 Done The system will then perform the function and display the results to you To print a chart Click File Select Print To exit a chart Click File Select Close To modify th
57. amount of space and accessed with reasonable speed The standard Annual Comparison Report utilizes this data and it is available to Intelligent Query Hours Hours Run hours of family components and single jobs sons and bachelors Job Down Hours Down hours of family components and single jobs sons and bachelors Good Production Standard Production Per Hour Material Used Weight of primary and additive type material in good production Material Scraped Weight of primary and additive type material scraped Copyright 2002 MATTEC 6 8 710 0092 Direct Labor Operator logged in time Hours Earned Labor Earned Hours Standard Operators Hours Operation of the Purge feature is changed to support this data Three dates are now required In addition to Active and Standby dates a Condensed date is now supported This divides production data into four categories Category No Older Than No Newer Than System Startup Condensed date 1 Condensed date Standby date 1 on line in condensed form Standby date on line in read only normal form Le Active date Current date on line in modifiable normal form 6 5 Data Backup The backup function copies every single active definition configuration and history file from the ProHelp Millennium system Only active data will be backed up standby data is not backed up and must subsequently be archived instead Backup is critical and should
58. are 1 2 or 3 remedy Use one of the valid shift identifiers Job Xxxxxxxxxxxx end date out of range cause The lot size or cycle time for this job or for a preceding job in the schedule is too large remedy Inspect the job descriptors for the jobs in the schedule and reduce the incorrect lot size or cycle time Job already Complete cause An attempt has been made to add a completed job to a machine schedule remedy Completed jobs may not be added to a schedule however a new job descriptor may be created based on the descriptor for the completed job This new descriptor may then be added to the schedule Job already exists cause A NewJb operation was attempted which specified a job number for which a job descriptor already exists remedy Verify the entered job number If is correct the existing descriptor must be deleted or it may be edited to create the desired descriptor Job already running Copyright 2002 MATTEC 15 22 710 0092 cause An attempt was made to start a job which is already running on another machine remedy Verify the entered job number The job must be ended or suspended from the machine on which it is currently running before it can be started on another machine Job already scheduled on Machine XX cause An attempt was made to schedule the same job on more than one machine remedy A job may be scheduled on only one machine To move a job from one machine to another the job must
59. bar codes e job descriptor data e graphics for use in identifying production units A visible label provides immediate useful information for the production units A unique product identification PID number created by the PID feature provides a link to the specific job and process parameters which made those production units Up to 10 unique labels may be configured for each part job When used in conjunction with other ProHelp features including SPC and material lot tracking PID can provide the basic information needed for Traceability and recall liability The data printed on a label may only be a small subset of all the information available for a PID The PID feature saves information even though barcode printers may be disabled It is possible that label serial numbers may not be unique within a customer s operations due to serial number requirements placed on the customer by the customer s trading partners To avoid the possibility of having the same label serial number identifying different production units the PID feature automatically generates unique 20 alpha numeric character PID numbers that identify the different production units An archive purge feature provides PID database legacy data management functions such as archiving and purging For more detail on this function reference PID Manual 710 0079 Copyright 2002 MATTEC 13 1 710 0092 14 Calculations Many key features of ProHelp Millennium provide c
60. be run daily to assure that the collection of data from recent days is protected It must be run every week at a minimum The backup would be used to rebuild the system in case of a hard disk failure Backing up ProHelp Millennium data is a two step process In the first step the data being backed up will be copied by ProHelp Millennium to the hard disk In the second step the user must manually copy the backup data to an appropriate storage device e g a tape using standard Open Unix copy utilities Reference Section 6 1 for additional information It is possible to backup data to a hard disk only but this should only be used as a secondary backup You should always copy the backup to a removable storage device that may be safely stored Important Only active data files will be copied onto the backup In order to protect all standby files they must be archived separately Reference Section 6 6 for information on scheduling the backup program to execute automatically Copyright 2002 MATTEC 6 9 710 0092 6 5 1 Manual Data Backup To perform a manual backup of the system to the hard disk follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F3 Backup Press F1 Man Ibone list E Figure 6 3 File Backup Directory You must specify a directory name to which the backup data will be Name copied For simplicity the directory usr prohelp mat_backup has been created for you to copy the back
61. can be entered A negative number has the effect of reducing the scrap category and increasing good parts To move hold parts to good or scrap parts for a previous shift follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QC Ent Press F2 Prev Enter the appropriate shift number Press Enter Enter the date Press Enter Enter the job number Press Enter To edit scrap parts for the shift Press F5 ScrapP To edit good parts for the shift Press F6 GdPtSh To edit good parts for the job Press F7 GdPtJb If you edit good parts for the job F7 GdPtJb the job does not allocate parts to any particular shift Therefore the sum of all shift production reports will not equal the total for the job in the job history To save your changes Press Esc 5 6 ProStat Statistical Process Control ProStat MATTEC s real time Statistical Process Control program is designed to assist the user in implementing a total program of quality and process control through the application of statistical methods to machine and part related data ProStat allows the user to collect and process data for specified jobs during their entire run Real time screens display the SQC Status of all jobs where statistical process standards are being applied and alerts the user to any trends or shifts that are detected in process or part data The feature being described here allows for monitoring a tota
62. copy the results of the export to an ASCII delimited file and have an external database read in the results of the file and process it as required For additional information on the optional data export program reference the ProHelp Millennium Data Exchange Manual 710 0085 3 9 IQ Report Writer ProHelp Millennium offers a version of IQ Software s Intelligent Query and Access product with the ability to access the ProHelp Millennium real time database Through this optional product users can make ad hoc queries export selected data and produce complex reports To access the IQ Report Writer you must load and configure IQ for Windows according to the instructions found in Application Note 720 0097 For questions concerning configuring this option please contact the Mattec Technical Support Group Copyright 2002 MATTEC 3 54 710 0092 When using the IQ Report Writer the formats for data exchange include delimited ASCII dBase II and II DIF Excel Worksheet Lotus 1 2 3 version 1A version 2 and version 3 Word for Windows and WordPerfect among others Information from the following ProHelp Millennium database files is currently available for use with the Intelligent Query report writer that is sold by MATTEC These files can include real time information that is available in ProHelp Millennium e Condensed Production History e Daily Production History e Down Log e Exception Log e Extended Downtime e Extended
63. count it as bad and place the count in scrap category 10 In addition the MIU will provide a contact closure that the user may connect to a diverter or robot to place these parts away from good production Parts are qualified in two ways e SPC Machine Process XUCL and XLCL Control Limits e Machine Parameter Specification Limits Regardless of which limits are used to qualify parts each cycle of the machine will be monitored against the limits for 100 part qualification For part qualification to work each machine s MIU must be setup Section 5 8 1 and the job descriptor running on the machine must have part qualification set as described in Section 5 8 2 Part qualification is an automatic way to monitor and collect bad parts based on control or specification limits The user should be cautious in selecting machine parameter limits that determine a bad part Use only those parameters that you know from experience and careful studies always produce a bad part when their limits are exceeded Indiscriminate use of this feature could produce a large count of bad parts which in fact are acceptable or could allow bad parts to go undetected 5 9 1 Selecting Machine Processes for Part Qualification Any or all of the processes being monitored by the system on a machine may be selected to qualify a part Even greater flexibility is added to this feature by allowing the user to chose the high limit or low limit or both limits of a process to qual
64. creating new jobs by copying the part To create a QC Sheet for the part descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F1 Part Enter the part number Press Enter Press F4 Disply A picklist will appear Highlight QC Documents Click OK You will be prompted Press Y to create setup sheet any other key to continue N Type Y es to create the setup sheet The first screen of the QC sheet will appear It will be blank The white block on this screen represents the portion of the QC that may be displayed at the MIU At this point you may either create an entirely new sheet by typing in information or use the F1 Copy functions to copy an existing QC sheet To exit and save all information Press Esc When using the F1 Copy function three choices are presented Copyright 2002 MATTEC 4 39 710 0092 FUNCTION KEY DESCRIPTION F1 CpyJob Copy a job s QC sheet to the current part F2 Cpy Pt Copy a part s QC sheet to the current part F3 CpyMst Copy a master QC sheet to the current part Any choice will prompt for the sheet number to be copied Enter the sheet number Press Enter The entire sheet will be copied into the part descriptor Only QC sheets copied from master setup sheets will have protected and unprotected fields QC sheets created in the Job Manager mode are created in an unprotected mode and may be edited Part descr
65. dates will be displayed that correspond to dates represented in the chart area As the chart area is scrolled horizontally the top header will be synchronized to the chart area Vertical scrolling of the chart area will not effect the data displayed in the top header The format of the dates Copyright 2002 MATTEC 12 23 710 0092 displayed will be determined by the date format field in the ProHelp Installation Parameters Prohelp Millennium ProSched ile Es File Edit Figure 12 28 Gantt 12 2 2 4 Machine Schedule Area The Machine Schedule Area will consist of scrolling text area left header top header The text area will list the jobs scheduled on each machine The format of lines of this list will be determined by the use of the Scheduled Jobs Figure 12 22 View PopUp cascading pop up Immediately to the left of the scrolling text area is a left header area where the job number of each job listed is displayed The left header is set to track vertical scrolling of the text area but it will remain fixed as the text area is scrolled horizontally The top header of the machine schedule shows column names for the text data shown below it The column names will be synchronized to any horizontal scrolling done in the text area The top header remains unaffected by vertical scrolling of the text area Copyright 2002 MATTEC 12 24 710 0092 Prohelp Millennium ProSched of x File Edit View BE Of 2 oe oll LIR l JO
66. described below FUNCTION KEY DESCRIPTION F1 RealTm Displays all standard and custom real time screens F2 JbDesc Used to view all screens of a job descriptor In this mode all production values are constantly updated and shown in real time The Job Manager mode must be used to modify data F3 Sched Used to view the schedule of each machine Schedules are generated and displayed based on the real time data available at the time the schedule is requested A displayed schedule is NOT updated in real time once it has been generated The Job Manager mode must be used to modify data F4 Report Allows access to most standard system reports Used to access the MATTEC SPC SQC program ProStat Charts and histograms may be generated but no data may be entered or edited The QC Manager mode must be used for data entry or edit This is a real time display showing only the SPC SQC status of running jobs with SPC enabled Alerts to Shifts and Trends and also to samples that are out of control limits are shown This screen displays no production data F7 Pgraph Used to generate a graph of machine parameters that are automatically recorded with the parameter record frequency feature in the job descriptor F8 Export Used to export the shift history or SPC data collected by ProHelp Millennium This feature differs from a report export in that only the raw data is included This function allows the user to receive raw shift history da
67. eet 4 47 AS Abee Meder eet Ee 4 47 ASTU Starta EE 4 48 ASD Foda JOD ccicssasacitsviseistestineteisaliieaseieasiaeas A A A DATA T A aiT 4 49 AS Suspend A EE EE 4 49 4 54 Start the Next Aere cninn a a bate eat sat de deem saad a A EA 4 50 4 55 Start Ine Next SOW E 4 51 45 6 Job Selection at MIEL 2 esistdee iek eileen nasi aia 4 51 Ge Family Moldin Sn a A E T G 4 52 46 f Created New Family JOB ET 4 53 E SGOpyia Family CT E 4 55 4 6 3 Edit an Existing Family Job wissccccsssescitasessvesavesccsaasnivaieassavcesasecyausaaessaceassacedenspenedaes 4 56 4 6 4 Display the Schedule of Component Son jobs s ssssesssessssesssseesseessersseessseessseessese 4 56 4 6 5 Enter Scrap at an MIU for Family Jobs 4 57 4 6 6 Dual Cycle Time Monitoring ee 4 57 4 7 Operator Tracking ocicccs nn scasecasdaceassainasscasedanaidseaecvenedenatnaved casa a R E E EEEa 4 57 SE WEN BEER DE EE 4 58 4 7 2 Operator Tracking Reports cre sui eenegen Eed Zeite dan s iioi en Ee id 4 59 ENER Data e E 4 60 5 Quality Control Manager i cc scispincteyssvelanscpeaciusuainesi i Seele Nee 5 1 E Edit Scrap EE 5 1 5 2 Full Family Production Qualification cecscecesseecesneeceeeeeceeeeeceeeeeceeeecsneeeeseeeenaeeeenas 5 3 SE GER 5 4 5 4 Pareto Charts Downtime and Scerap 5 5 5S3 Modify GEIER 5 6 5 6 ProStat Statistical Process Control csccivavasservboastengtonaganaveneed soadeves eege Eege 5 7 SEET Eeleren eege oR 5 11 5 6 2 ProLim Automat
68. exception periods F2 Delete Press F2 Delete to remove an individual exception period F10 Clear Press F10 Clear to remove all exceptions for the plant To clear all of the defined exception periods follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F3 WrkSch Press F2 PItExc Press F10 Clear To clear all periods Press Y es To save and activate your changes when complete with all exception scheduling Press Esc Departments and or machines may be scheduled as active or inactive regardless of the plant exception schedule Machines in the department scheduled as inactive may be scheduled to run on an individual basis Departments and machines are scheduled as Exceptions in the same manner as the plant To set department or machine exception periods follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F3 WrkSch Press F3 DptExc for department exceptions OR Press F4 MchExc for an individual machine exception To select a department Press spacebar Copyright 2002 MATTEC 7 10 710 0092 To select a machine type in the machine number When the department or machine number is entered the system will display the Shift Exception Schedule screen for departments or machines The format of this screen is identical to the Plant Wide Exception screen Press F1 Add Enter the exception period start date and time Press Enter Use the
69. first screen of the setup sheet will appear It will be blank The white block on this screen represents the portion of the setup sheet that may be displayed at the MIU At this point you may either create an entirely new sheet by typing in information or use the F1 Copy functions to copy an existing setup sheet To create a new descriptor simply begin entering information on the screen To create a second screen etc when the screen is full Press PgDn on the keyboard Up to nine screens may be created To exit and save all information Press Esc Copyright 2002 MATTEC 4 38 710 0092 When using the F1 Copy function three choices are presented FUNCTION KEY DESCRIPTION F1 CpyJob Copy a job s setup sheet to the current part F2 Cpy Pt Copy a part s setup sheet to the current part F3 CpyMst Copy a master setup sheet to the current part Any choice will prompt for the sheet number to be copied Enter the sheet number Press Enter The entire sheet will be copied into the part descriptor Only setup sheets copied from master setup sheets will have protected and unprotected fields Setup sheets created in the Job Manager mode are created in an unprotected mode and may be edited Part descriptor setup sheets are active on the system as long as the part descriptor they are associated with remains on the disk QC Sheets It is possible to create a QC sheet in the part descriptor that can be copied whenever
70. for the shift data specified remedy Attribute data for previous shift dates cannot be input Attribute data may be entered for the current shift date if first enabled in the job descriptor Specified language not available cause An attempt was made to use a language that is not available to the specific version of ProHelp Millennium remedy Select a different language Specified location already occupied cause An attempt was made to enter an MIU into a location that was already occupied remedy Choose a location that is not occupied Specified Monitoring Nodes exceeds maximum permitted in system cause An attempt was made to add a monitoring node that was not purchased with the system remedy Call MATTEC to purchase more monitoring nodes the maximum allowable number of nodes is 64 SQC attribute average is outside control limits remedy Set the attribute average within the values set for the low control limit and the upper control limit SQC attribute low control limit above upper control limit remedy Set the attribute low control limit lower than the upper control limit SQC auto sample period above maximum remedy The auto sample period cannot exceed 180 minutes Set the value between 10 minutes and 180 minutes Copyright 2002 MATTEC 15 39 710 0092 SQC auto sample period below minimum remedy The auto sample period cannot be less than 10 minutes Set the value between 10 minutes and 180 minutes
71. forecasts will treat the time defined as Shift Breaks as non production time The Shift Breaks definition screen is accessed with the Breaks function key of the Shift Configuration Figure 7 8 Shift Configuration Screen screen Copyright 2002 MATTEC 7 11 710 0092 Press F4 Sysman Press F3 WrkSch Press F 1 Shifts Press F8 Breaks ProHelp Millennium iol x Figure 7 8 Shift Configuration Screen This results in a prompt for a shift tag Enter any tag number Hit Enter Once the tag has been entered an interactive display of the applicable Shift Breaks is shown Copyright 2002 MATTEC 7 12 710 0092 ProHelp Millennium of x Al Figure 7 9 Shift Breaks Interactive Screen To enter shift times Click any field In Start Offset column Enter number of hours from original start time to shift break In Length column Enter number of minutes for each break Figure 7 9 Shift Breaks Interactive Screen shows two fifteen minute breaks and one half hour break This could be a half hour lunch break and fifteen minute breaks in both the morning and afternoon Start Offset is specified from the beginning of the shift That is if the shift in the example begins at 8 00 AM the first fifteen minute break is scheduled for 10 00 AM 2 hours from the start of the shift start time Individual breaks may be eliminated by setting both Start Offset and Length fields to zero
72. general information fields appear on the upper left hand portion of the screen with a light blue background If you are creating a part that is to run on a rate machine versus a cyclic machine or vice versa then enter a value in the machine number field that represents that particular machine number The cycle time field and other fields will toggle to the proper name Copyright 2002 MATTEC 4 32 710 0092 TELD DESCRIPTION The part number is a 22 character alphanumeric field identifying the item Part Name This optional field can be any string of up to 10 alphanumeric characters that helps you recognize the part being produced This field is for display only and plays no part in any calculation or report sorting Tool Number Each part has an 11 character alphanumeric tool number This is an optional field However ProHelp Millennium provides a year to date tool usage report sorted by this number In ProHelp Millennium the tool number assigned in the job controls the collection of mold tool history and is the number used to retrieve the collected information Each part has an optional 11 character tool base number Customer Name The customer name is an optional 16 character alphanumeric field intended to display the name of the customer for which the job is being run This field plays no part in any calculation or search field plays no part in any calculation or search Machine Number This is the machine that you expect
73. histories for the present shift and the total job The sum of all scrap reasons should always equal the total of bad parts Scrap parts are entered at the computer or MIU for the job presently running To specify scrap for prior shifts of production or different jobs the computer must be used Scrap may be edited from one category to another by the QC Manager mode Refer to Section 5 1 for details NOTE The DOWNTIME and SCRAP names are defined by the System Manager These can be defined differently for each department 4 1 7 Material Lot To edit a job descriptor s material lot follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight Material Lot Click OK The purpose of the lot tracking is to provide a means of recording up to 20 changes in material for a job run Recorded with the lot number are the time date and current machine cycle number when the lot change occurred Entry of a material lot number is made at the MIU or at a computer terminal Lot numbers are 12 characters long Entries at the MIU are automatically time and date stamped and have the machine cycle number entered Alphanumeric entries may be made at any terminal on the system Copyright 2002 MATTEC 4 17 710 0092 4 1 8 Material Need and Usage ProHel
74. individual son job as well as for the father job that ties the component son jobs together A family job consists of two classes of job descriptors These are the father job which identifies all jobs to be run simultaneously and the component or son job which is a job identified in the father job descriptor A job which is neither a father or son job is known as a bachelor job When a job descriptor is created it must be identified as a single bachelor or son or family father job descriptor This classification cannot be altered throughout the life of the job A family father job descriptor contains twenty job number fields which are used to specify component son jobs Any single job not already running scheduled or a member of another family may be added to a family simply by specifying its job number as a component job in the family job descriptor Similarly a job may be removed from a family by blanking the field containing its job number in the family job descriptor A total of 10 component jobs may run in a family at one time All such changes to the make up of a family of jobs may only be performed when the family is not running Running family jobs must be suspended for changes to be made A job which is specified as a family member in a family job descriptor is referred to as a component or son job A son job may not be scheduled directly but is placed in a machine s schedule as part of a family Only family father
75. is not put in Job Descriptor this will also be displayed in yellow Action area Figure 12 4 ProSched Startup OK Cancel The OK push button will be pressed by the user to indicate that the user has completed data entry in the control area When OK is activated ProSched will analyze the information entered into the control area If the information is valid ProSched startup will proceed and the Startup Dialog will be dismissed If invalid information was entered in the control area an information dialog will be displayed and the Startup Dialog will reappear The Cancel push button is designed to allow the user to abort the startup of ProSched Activating the Cancel push button will cause the Startup Dialog to be dismissed and no further output will be issued by ProSched Copyright 2002 MATTEC 12 5 710 0092 If all data has been entered into the ProSched Startup screen Press OK Please wait processing data will appear on the screen At this point it is collecting data based on the criteria entered into the ProSched Startup screen Please wait processing data Figure 12 6 Processing Data 12 2 2 Main Window The main window for ProSched is composed of 5 different areas 1 Menu Bar 2 Tool Bar 3 Gantt Area 4 Machine Schedule Area a Unscheduled Job Area These items will be described in more detail in the following sub sections Copyright 2002 MATTEC 12 6 710 0092 Prohelp Millennium ProSc
76. is not running Predicted Cycle Time Standard Cycle Time 30 seconds 30 seconds Run Time To Go Cycles To Go Predicted Cycle Time 156700 8 seconds 5441 cycles 28 8 seconds 43 53 hours 156700 8 seconds Copyright 2002 MATTEC 14 3 710 0092 If job is running Total Time To Go Run Time To Go Standard Utilization 48 36 hours 43 53 hours 90 If job is not running Total Time To Go Run Time To Go Standard Utilization Standard Setup Time 52 94 hours 46 30 hours 90 1 5 hours Note that the full Lot Size is used since the assumption is that the job has not started Copyright 2002 MATTEC 14 4 710 0092 15 Error Messages The ProHelp Millennium system detects and reports many different error conditions The vast majority of these are reported via a magenta purple error message in the lower left hand corner of the screen This message remains on the screen until cleared by pressing Enter or Esc Some of these messages begin with the words System Error and contain text which will mean little to you If a System Error occurs you should note the exact text of the message and contact the MATTEC Customer Service Department System errors generally indicate a problem which you did not cause and which you can not be expected to solve without assistance e g damage to hardware or to the system s file structure The lower right hand portion of the scree
77. job and end a running son job This function applies only to systems with the optional Family Molding program F6 FamMtx Select to perform all job control functions within a single screen including the addition and deletion of component jobs Reference Section 4 6 for additional information on job control functions The Next function ends the currently running job on the selected machine and starts the next job in the machine s schedule This is very similar to the End of Job function at the Machine Interface Unit The Next function stops the current job and starts the next job immediately The End of Job function at the MIU may be disabled or have constraints placed upon it e g lot size check before it works reference Section 7 11 To perform a next job change for a machine follow these steps Press F6 PrdMan Figure 3 1 Copyright Screen Press F4 Contrl Press F4 Next Enter the machine number to perform the next job function on Press Enter The currently running job will be ended and the next job in the machine schedule will be started If no job is currently running the system starts the first job in the machine s schedule If no jobs are scheduled monitoring for the machine goes against a null job Copyright 2002 MATTEC 8 4 710 0092 9 Maintenance Manager The Maintenance Manager mode of ProHelp Millennium provides for preventive maintenance reports and maintenance activity logs Maintena
78. job descriptor active in the system has a unique number and provides current and historical information related to the production of a part The ProHelp Millennium job descriptors report on parts made machine cycles hours run hours down tool usage and material usage ProHelp Millennium jobs also report on when where and how well they were run To view a job descriptor follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job The selected job descriptor will be displayed To view a job descriptor in the standby directory follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F4 ViewSb enter the job number to view Press Enter This function must be used when it is desired to view job descriptors that have been stored in the standby directory By using the view standby function you will directly access the standby directory All job descriptors that were retrieved back onto the system from an archive must be viewed this way Copyright 2002 MATTEC 3 14 710 0092 ProHelp Millennium O x Figure 3 4 Job Descriptor When the first page of the job descriptor is displayed the system puts up a new menu on the screen The new menu provides the ability to choose other jobs for display or to select more detail about the job history Pre
79. job is not running or does not have the selected signal available cycle time values are displayed To view the Last 50 Cycle Times for a job follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number spacebar will activate picklist OR Press F2 Mach enter the machine number of a running job spacebar will activate picklist Press F3 Disply A picklist will appear Select Last50 Cycle Times Press OK Copyright 2002 MATTEC 3 16 710 0092 ProHelp Millennium Job Mach Disply Bsicnal RR RR SEO CUT Figure 3 5 Last 50 Cycle Times Screen Press F4 Signal The following displays ProHelp Millennium Iof x Items PARSHTM a COOLTIME MOLD OPN MELT TMP ProHelp Millennium Iof x BLOWPRES H20 TMP H20 FLOW 3 4 2 Job Downtime and Scrap To view job downtime and scrap parts follow these steps Copyright 2002 MATTEC 3 17 710 0092 Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear from which to select the type of information needed Make your selection Press OK To look at another job or machine Press F1 Job OR Press F2 Mach 3 4 3 Pareto Charts of Downtime and Scrap Pareto Charts for downtime and scrap may be generated for the prese
80. jobs that also have process exception logging enabled will be logged When the department process exception logging is turned off no process exceptions will be logged for any jobs in that department To view the Process Exception Log Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F5 ExcRpt OR Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F10 more Press F1 ExcRpt Fill in the interactive screen as appropriate Press F1 Done The Process Exception Log Report will be displayed The Process Exception Log Report may be filtered by department machine number job number part number signal and exception type Copyright 2002 MATTEC 5 24 710 0092 To view the Process Exception Log Graph follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F6 ExcCht OR Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F10 more Press F2 ExeCht Fill in the interactive screen as appropriate Press F1 Done The Process Exception Log Graph will be displayed The Process Exception Log Graph may be filtered by department machine number job number part number signal and exception type To print the graph Click File Select Print To exit the graph Click File Select Close 5 6 8 Automatic Limits Calculation The automatic limits calculation function allows SP
81. machines in this department No maintenance schedule found for Tool xxxxxxxxxxx cause A maintenance schedule doesn t exist for this tool remedy Create a maintenance schedule for this tool No records found cause An attempt was made to pull a report for a specific date where there was no data available remedy Enter a date that has data that is still on line Copyright 2002 MATTEC 15 30 710 0092 No samples found cause No samples exist for the specified job date and data type remedy Create samples or specify another data set No samples found in recorded SQC data for cause An attempt was made to access an SQC sample for a specified date and time that did not exist remedy Abort operation No samples found in specified SQC data cause An attempt was made view specific samples but they were not found remedy Either create samples or wait until samples have been written to the Host computer No sample records found cause A specified data item is not available remedy Verify the associated MIU has been configured to record the particular data item specified No sample records in file cause No data has been recorded as specified remedy Verify that the job is running the MIU is collecting data and is communicating Wait until data has been recorded No serial device assigned Aborting mouse installation cause An attempt was made to enter a mouse type without defining a serial port for that device
82. maximum allowable shot weight value remedy Enter a valid shot weight Error SQC attribute average is outside control limits cause An attempt was made to manually key in attribute data control limits remedy When manually keying attribute data the average must always fall within the control limits Error SQC Attribute low ctrl limit above upper ctrl limit cause While setting up upper and lower specification limits an error occurred where the lower limit is greater than the upper limit remedy Adjust the specification limits so that the SQC Attribute low control limit is lower than the upper control limit Error SQC Attribute sampling enabled but no attributes are defined cause The SQC attribute flag was turned on but no attribute variable names were defined remedy Either disable the SPC attribute sampling flag or set the attribute names in the job descriptor Error SQC auto sample period above max cause An attempt was made to key in a sample period that was above the maximum allowable remedy Enter a sample period between 10 and 180 minutes Error SQC auto sample period below minimum cause An attempt was made to key in a sample period that was below the minimum allowable remedy Enter a sample period between 10 and 180 minutes Error SQC cycle per sample or observations per sample above maximum Copyright 2002 MATTEC 15 15 710 0092 cause A value for cycle per sample or observations per samp
83. must be less than Xucl and greater than XIcl The upper control limit for X This value must be greater than Xbarbar and The lower control limit for X This value must be less than Xbarbar and Xucl The average range This value must be less than Rucl and greater than Rlcl The upper control limit for the range This value must be greater than Rbar and The lower control limit for the range This value must be less than Rbar and The lower specification limit This value must be less than USPEC The number of decimal places for this variable X and Range values will use 1 The upper specification limit This value must be greater than LSPEC additional decimal place Valid choices are 0 to 4 5 6 5 VarEna Variable Alarm Enables Copyright 2002 MATTEC 5 20 710 0092 To modify the alarm conditions for variable data for a job variable data follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F9 VarEna The SQC Variables Enable screen will be displayed Use the spacebar for picklist of options Use arrow keys to move from field to field ProHelp Millennium eat Tob top10 QC VARIABLES ENABLE Figure 5 7 SQC Variable Enable The following fields are then available for modification
84. occupies multiple lines of the display The first line identifies the father and shows all machine related data such as actual cycle time and whether or not the machine is down Each running son job occupies a line below the father and shows part related data such as parts made parts and hours to go and yield efficiency To start the family job and end follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F6 FamMtx Enter the machine number currently running the family job Press Enter 4 6 1 Create a New Family Job Family jobs are created in two steps First create the component son jobs Second create the family father job Create each component son job first These jobs are created exactly like standard bachelor single jobs Reference Section 4 2 1 for additional information Be certain to enter in the correct information for cycle time number of cavities shot weight and part weight in each of the son job descriptors Correct schedule and material forecasting on running and scheduled jobs depends on this information Copyright 2002 MATTEC 4 53 710 0092 Son jobs that will be started at a future date during the family job run should also be created at this time After the component son jobs have been created maximum of 20 in one family create the father job To create the father job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2
85. of the data at the MIU is complete Copyright 2002 MATTEC 5 27 710 0092 The message OUT OF LIMITS or SHIFT or TREND is displayed at the MIU when processing of the data is complete and any parameter has exceeded the specified control limits or if a run condition is detected Examination of calculation results will show the parameter s in excess of control limits 5 7 2 Gage Input at a Terminal Part data such as dimensions weights etc may be input directly in a job with different types of electronic measuring instruments thus eliminating the need to type in the values at the keyboard The following things are necessary to use a gage to input variable data into ProHelp Millennium e The data entry must be done at a ProHelp Millennium node The communication port must be set to accept the GageTalker or similar device Reference the ProHelp Millennium Software Installation Manual 7 10 0067 for additional information e The gauging devices must communicate with ProHelp Millennium through a device referred to as a GagePort This is necessary to convert the many types of individual gage protocols to one specific protocol type that is readable by ProHelp Millennium When you edit SPC sample data values from the gage device are inserted by pressing send on the gage The send key will have the same effect as the Enter key on the keyboard The value from the gage will be inserted in the field and the cursor will move
86. put your new plant layout display onto a function key Reference Section 7 7 for additional information 7 6 7 View Custom Displays To view your custom real time and or grid screens follow these steps Press F1 View Figure 3 1 Copyright Screen Press F1 RealTm Press F8 Custom FUNCTION KEY DESCRIPTION Any real time screens configured for the current user will appear as the legend in F1 through F8 Reference Section 7 7 for information on configuring real time screens as Function keys F9 Std F9 Std always displays the standard MATTEC real time screen F10 Other F10 Other causes an index of all real time screens defined on the system to be displayed by pressing the spacebar Select the appropriate screen and press Enter The exception screen function keys are usable when viewing your custom made screen You may departmentalize your screen show only machines that are outside of limits show only machines that are down etc To set your custom display to show only a portion of the machines as defined by the exception keys you may set a default value for your display under the configuration screen function of the System Manager mode Reference Section 7 7 for additional information 7 6 8 Next Job Real Time Screen ProHelp Millennium not only gives you cycle by cycle information on the current running jobs but options have been added to the real time choices that allow a user to create a real tim
87. real time screen simply Press Esc or Click in the upper left hand corner of the screen For example Click the help JD number for any machine requesting help and a message will be displayed indicating the type of help that has been requested Press Esc to clear the message Copyright 2002 MATTEC 2 4 710 0092 The real time screen may also be dragged larger or smaller to display more or fewer machines as required If you drag the window too small an appropriate error message will be displayed telling you to increase the size of the window The following describes each field on the real time screen for which mouse support is available Analog or Pulse Names Click on any of the analog or pulse names and a new window with the last 100 process samples chart for that machine parameter is displayed Click on the File Menu and select Close to close this window Cycles Per Minute Hour Current Click on the current cycles per minute or hours fields and a new window with a chart of the last 100 cycle times will be displayed Click on the File Menu and select Close to close this window Cycle Time Current and Average Click on the current or average cycle time fields and a new window with a chart of the last 100 cycle times will be displayed Click on the File Menu and select Close to close this window Down Time Run Job or Shift Click on the down time run job or shift field and the downtime page of the job descrip
88. reasons are enabled ten new count fields immediately follow Copyright 2002 MATTEC 3 53 710 0092 the existing ten count fields If additional primary downtime reasons are enabled ten new count field immediately follow the existing ten occurrence count fields and ten new time fields immediately follow the existing ten downtime fields Five types of data are available for export e ProdHs Production History e SPC Statistical Process Control e JobHs Job History e AuxDTm Auxiliary Downtime e AuxScr Auxiliary Scrap Data contained in this file is raw data No calculated numbers e g yield efficiency are included Instead the data used for those calculations is provided This should be particularly useful to ProHelp Millennium users desiring to maintain databases external to ProHelp Millennium or to engage in other types of data manipulation The user specifies a target disk to receive the data This may be either a floppy or hard disk file that is defined to the local ProHelp Millennium node The file produced will be in ASCII format with user control over record and field separators and fixed versus variable length fields Automatic Data Export The production history export and SPC data export may be generated from the command line without user interaction The output of the export may be copied to a file This powerful feature will allow an advanced ProHelp Millennium user to automatically run either data export
89. relative to today e g L30 tells the archive command to archive any data that is at least 30 days old Required if archive is the selected command None SXXX where xxx is a positive number relative to today e g s120 tells the purge command that any data older than 120 days should be deleted Required if purge is the selected command None aXXX where xxx is a positive number relative to today e g a60 tells the purge command that any data older than 60 days should be moved to the standby directory Required if purge is the selected command None f Tells the backup command to execute a full backup None i Tells the backup command to execute an incremental backup Figure 6 6 Automatic Archive Purge and Backup Options NOTE Only those options that are allowed when the archive purge or backup is run interactively should be used when executing the archive purge or backup automatically When setting up the archive purge or backup to be run from the command line it is wise to also have open a window that shows you the interactive screen of the function Copyright 2002 MATTEC 6 14 710 0092 Error Messages Status and error messages that are encountered during the execution of an automatic backup are written to the backup log Error messages that are encountered during the execution of an automatic archive or purge are not displayed To view the Backup Log Report follow these steps Press F5
90. short to click on Click on the machine number with the mouse All jobs scheduled for this machine will be displayed Select the job to be displayed Click OK To view that machine s schedule Click View Schedule To print the Gantt chart Click File Select Print To exit the chart Click File Select Close 4 4 4 Schedule Summary Report To display the Schedule Summary Report for all machines follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F3 Sched Press F2 Summry Fill in the interactive screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Press F1 Done The Schedule Summary Report will be generated The Schedule Summary Report lists the machine number job number part number parts or production to go available run hours between jobs and the desired forecasted start or end dates for all scheduled jobs 4 5 Job Control Contrl is short for Job Control This function is one of the Job Manager s methods of keeping ProHelp Millennium in step with the monitored machines ProHelp Millennium must be directed to Start collecting data for a job and to End collecting data when the job is done It is very important that the commands to start and end be given at the same time job changes are taking place on the actual machine The Machine Interface Units can be used to tell ProHelp Millennium that the current job s
91. signal names follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU Select the desired machine number Move the cursor to the machine signal names and type in the desired name The first name will always be cycle time and the second name will always be the cycle time signal To save your changes Press Esc After entering new machine parameter names you must reboot all nodes on the system All affected MIUs must be rebooted 7 14 5 Machine Class The machine class field is an additional field similar to the department field that is used as a filter for reports and displays Multiple MIUs can be configured within departments and classes Multiple departments can be created within classes or multiple classes within departments Each individual MIU installation field for department and class is used to create this mix To create or delete a machine class follow these steps Copyright 2002 MATTEC 7 68 710 0092 Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F8 Class To add a machine class Press F1 Add OR To delete the currently selected machine class Press F2 Delete Class field names are six character alphanumeric fields Remember schedules are created for departments not classes The machine class field is simply an additional field that is typically used in reports and on the real time screen to filter the machines that are grouped
92. specific amount of product is produced Machine speed units may be specified in terms of seconds per cycle cycles per hour cycles per minute or meters per minute Material usage is a major factor for plants operating rate machines A value for the material consumption rate is calculated and displayed on the real time displays and job descriptors With a rate system setup the following colors are used on real time displays COLOR MEANING FOR ALL MEANING FOR MEANING FOR SIGNALS EXCEPT SIGNAL 1 SIGNAL 1 SIGNAL 1 Above the Upper Limit Machine Speed is Too Below the Lower Slow Limit Fast Limit Within the Upper amp Lower Limits Lower Limits Definitions of Real Time Display Color Codes 4 3 Part Descriptors Part descriptors are master templates containing engineering standards machine parameter limits SPC SQC information setup sheets and QC sheets Once created part descriptors remain a permanent part of the system They may only be removed on an individual basis by the delete function Part descriptors contain no production data such as lot size or desired end dates They are intended to be used as master descriptors that may be copied over and over when creating a job descriptor Copyright 2002 MATTEC 4 31 710 0092 To edit a part descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F1 Part Enter the part number to modify Press Enter Once th
93. steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F8 Regres OR Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F7 Regres Enter the start and end dates Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To generate the chart for a part number multiple job runs with the same part number reference Section 5 7 for additional information To select the parameter data type for the X axis and Y axis for the chart Press spacebar The first parameter selected will be for the X axis The second parameter will be for the Y axis The allowable choices are displayed Any process parameter from automatic samples manual samples or variable data samples are selectable Position the cursor to the first choice Press spacebar Copyright 2002 MATTEC 5 47 710 0092 Move the cursor to the desired selection Press Enter Position the cursor to the second choice Press spacebar Move the cursor to the desired selection Press Enter Press F1 Done The linear regression analysis chart will be displayed The message Collecting data for
94. that occurs during a manual or automatic backup An event is logged when each of the following occur e The backup is started e The backup is completed e An error is encountered during the backup The fields in the Backup Log Report are described below FIELD DESCRIPTION VALUES Date The date on which the event occurred Any valid date Time The time at which the event occurred Any valid time 24 hour clock Comment A description of the event A text value describing the event Backup Log Field Descriptions The format of the Backup Log Report is shown in Figure 6 4 Backup Log Report Copyright 2002 MATTEC 6 11 710 0092 ProHelp Millennium O x LOG REPORT 18 53 TIME COMMENT Figure 6 4 Backup Log Report To clear the Backup Log follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F3 Backup Press F2 BkpLog Press F2 ClrLog The following message will appear WARNING Do you want to delete all entries from the log Y N Press Y es to delete all entries in the backup log OR Press N o to retain all entries 6 6 Automatic Archive Purge and Backup The ProHelp Millennium archive purge and backup programs may be executed from the command line without user interaction This powerful feature will allow an advanced ProHelp Millennium user to automatically execute the backup program for example copy the backup to the hard drive copy the backup data on t
95. the Enter key Using F1 login plus efficiencies causes efficiency history to be maintained In addition it automatically causes an entry to be made in the tracking history e g it is not necessary to login a second time using F3 Copyright 2002 MATTEC 4 58 710 0092 F3 login minus efficiencies makes an entry in the tracking history only no efficiency history is maintained The maximum number of operators who may be logged in at any single machine and have efficiency information maintained is five If five operators are already logged in with efficiencies being kept and a sixth operator attempts to login also with efficiencies the error message CAN T LOGIN FULL is displayed at the MIU There is no practical limit to the number of logins for tracking purposes only minus efficiencies Two display codes are also provided in connection with operator efficiency history Code 127 causes the operator number of operator 1 to be displayed If no operator is currently logged in a 0 is displayed Code 128 causes the operator number of operator 2 to be displayed MIU 4 5 6 7 and 8 For all login and logout functions at an MIU 4 5 6 7 or 8 follow these steps At the Main LCD display three selections are then presented corresponding to the type of transaction 1 Log In Eff Operator login with efficiencies 2 Log In Trak Operator login for tracking only no efficiencies are kept 3 Log Out All op
96. the chart Graph Size Line Chart Bar Chart Stacked Bar Chart C Scatter Chart switch Axis Clos Figure 3 28 Graph Options One of four different chart types can be selected and the X and Y axis can be switched Figure 3 29 Graph Size One of five graph sizes can be selected These range from 1 smallest to 5 largest Graph Y Eg a Absolute Normalize Auto Close Figure 3 30 Y Axis The Y Scale control helps in the display of values with different ranges of values The three choices are Copyright 2002 MATTEC 3 33 710 0092 Absolute all plots are drawn using the actual values and the chart is scaled to contain the highest and lowest values of all parameters This means that if one parameter has values between 20 and 120 and another has values between 20 and 30 the second parameter will be plotted in the lower 1 10 of the chart Normalized allows all parameters to occupy the entire chart This may be thought of as displaying each value as a percentage of the parameter s total range Automatic selects either Absolute or Normalized based on the relationship of the values As long as each parameter s range is at least 5 of the chart Absolute is used If not the chart is drawn in Normalized mode 3 6 2 Specific Reports This section describes some but not all of the standard ProHelp Millennium reports Only the more complex reports are described individual
97. the final product Auxiliary materials are materials that are consumed during the production process but do not become part of the final product Examples of auxiliary materials include machine oil and packing boxes Code Each material that is used for a job must have a unique 22 character identifier Units of Measure The units of measure fields describe how quantities of material are accumulated for the standard and actual values For primary and additive materials the standard units of weight are used This value is defined by the System Manager For auxiliary materials the Job Manager specifies the units of measure that are used material needs job by ProHelp Millennium every time the machine cycles Total Material The total amount of material standard and actual is a non Total Shot Weight modifiable field and is the sum of the primary and additive materials Excess Material The total part weight allows a method of defining the excess Total Part Weight material Total Material Total Part Weight that the production process consumes Regrind The regrind defines the percentage of the primary input material for which regrind material may be substituted The standard regrind percentage is used for forecasting material needs The job s current regrind percentage is the actual composition of regrind material currently being used Setup Material When forecasting material requirements of a non running job the standard se
98. the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To select the Limits Press spacebar The available choices include table limits sigma individual limits or sigma estimate limits Use the cursor key to select the proper choice Press Enter Use the cursor to position to the Auto Store field If you want the limits to be automatically stored enter Y es If you want to be prompted before the limits are saved enter N o Position the cursor to the Parameter field Press spacebar Use the cursor keys to position to the desired choice Press Enter Copyright 2002 MATTEC 5 43 710 0092 Position the cursor to the sigma multiplier field Enter a numeric value from 0 0 to 9 9 Press Enter Remember that this value represents the plus and minus sigma multiplier For 3 sigma enter 3 0 Press F1 Done A series of questions will appear if AIP has been selected in the Parameter field To calculate control limits for a single day of a job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F 1 Edit Enter the sample date Press Enter Make selections for the job
99. the maximum twenty values of the specified type may be selected The other three selections allow only a single value to be specified so that a total of twenty three sets of values may be plotted on a single chart Separate boundaries may be entered for all four selections but any boundaries entered for an AIP selection are ignored and automatic scaling is used just as if zero boundaries were specified Once a chart is displayed controls are available which allow the items chosen to be included or excluded on an individual basis With the Multiple SPC Chart SPC by Part is not supported and neither special cause text or limit lines appear on the chart The single set of control limit values appearing at the right side of the chart are those of the most recently accessed parameter i e last touched by the mouse Press F1 View or F3 OC Mon Figure 3 1 Copyright Screen Press F5 ProStat Press F2 Chart Make a selection of Single or Multip Enter the start and end dates Press Enter Copyright 2002 MATTEC 5 36 710 0092 Enter the job number from the SQC directory If the job number is not known Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired jobs Press Enter Make selections for all available fields Use the spacebar for available picklists ProHelp Millennium OO x Figure 5 11 Single Chart Set up 5 8 2 XbarR Chart Moving Range Char
100. the original orders change 5 Alert the sales department when the job is completed and if appropriate notify the customer that his goods are shipped 1 2 3 Production Scheduling Department The Scheduling Department provides the person who has an understanding of production requirements and knows how to prioritize jobs so that production goals will be met This person should be aware of pending orders and may also be responsible for order entry This person must know what tools run best on the machines The responsibilities of the Scheduling Department are 1 Review daily all new orders and the status of all existing orders 2 Assign new orders jobs to run on a particular machine Assign the job to the proper priority within the machine s schedule 3 Review the real time schedule display several times throughout the day Alert production management to problems Reassign jobs to different machines to assure the best completion dates 4 Review the year to date tool usage report before scheduling any job to a machine Determine the best fit for machine cycle time efficiency and good product yield Schedule the job to the machine that runs the tool the best Copyright 2002 MATTEC 1 4 710 0092 5 Alert the materials people and the setup people about those machines that have tool changes coming due Assure that the proper materials and the proper tool for the new job are prepared on time The scheduling person must understand
101. the schedule If the SCHED METHOD DESIRED then the desired method will be used The rule is as follows If the END date of the previous job on the schedule is LESS than the DESIRED START date of the next job then the START date for the next job will be the DESIRED START date for that job This would result in a period of idle time between the end date of the current job and the desired start date of the next job If the END date of the previous job on the schedule is GREATER than the DESIRED START date of the next job then the START date for the next job will be the FORECASTED END date of the previous job Operation of the Drag and Drop Scheduler is described in Section 12 4 4 1 Display a Machine Schedule Copyright 2002 MATTEC 4 4 710 0092 The way a schedule looks when it is viewed depends on the settings that the System Manager has chosen The following combinations of dates and time are set by the System Manager Desired Start Desired End Desired Start Forecasted End Desired End Forecasted End Forecasted Start Forecasted End To display a particular machine schedule follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F3 Sched Press F1 Mach Enter the desired machine number Press Enter The computer will now display the first 20 jobs of the requested machine s schedule with newly calculated start and end dates Figure 4 7 Machine Schedule To display the sched
102. the second set of 20 jobs that are scheduled on the machine Press F10 Othr20 Operation of the Drag and Drop Scheduler is described in Section 12 Figure 3 6 Machine Schedule Copyright 2002 MATTEC 3 20 710 0092 To display the schedule for another machine either Press F6 Mach OR Use PgUp and PgDn keys PgUp and PgDn show the next machine in the order the machines are listed on the real time screen 3 5 2 Gantt Chart Schedule The ProHelp Millennium scheduler can generate a graphical Gantt chart of the entire plant s machine loading To display the Gantt chart schedule follow these steps Press F1 View Figure 3 1 Copyright Screen Press F3 Sched Press F3 Gantt Fill in the interactive screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Select the proper department and machine class Select the number of days the Gantt chart is to cover Any number from 1 to 365 may be specified Press F1 Done The Gantt chart schedule will be generated Periods for which no job is scheduled appear on the chart as a single gray colored line Scheduled jobs will appear in red or green Jobs which meet the desired end date are colored green Jobs which fail to meet the desired end date are colored red By default the Gantt chart will display in color with the job number displayed in the colored bar if it fits To display the part name customer I
103. time minutes downtime minutes Statistical Process Control SPC sample data and the first entry for scrap reason and quantity If power is lost to the monitoring node the MIUs continue to collect data When power is restored the collected data is then sent by the MIU to the computer for storage After 18 hours without communicating with the monitoring node the MIUs overflow their counters and data integrity is lost If power is lost to an MIU then it fails to see the machine run and cannot communicate with the monitoring node and that machine is recorded as down for the entire period Copyright 2002 MATTEC 710 0092 2 1 Power On Off Procedure Power On Step 1 Step 2 Step 3 Step 4 Step 5 Power Off Turn power on at the primary node first The primary node must be booted before the other nodes can be utilized Turn power on to all other nodes in the ProHelp Millennium network Turn power on to all peripheral units including the computer monitor and printer See Section1 3 for detailed component descriptions A characteristic of personal computers is that they have the built in responsibility of loading the base operating system when power is turned on This is called booting the system They also do a self check to assure that all system components are okay When power is applied you will see and hear the results of these activities Lights will flash numbers will appear on the monitor and the printer w
104. time the cycle signal pulse is made The format is 12345 678 digits Copyright 2002 MATTEC 7 50 710 0092 FIELD DESCRIPTION Stage Pulse Stage Tol Specify Y es in the stage enable field to indicate that the MIU is using the optional stage detection feature The stage detection feature is a software algorithm that with a single solenoid contact and analog pressure transducer will automatically determine the duration and pressure for up to three discrete stages The derived pressures for up to three stages are automatically inserted into the Analog 6 Analog 7 and Analog 8 parameters The derived time duration for these stages can be optionally inserted into Pulse 2 Pulse 3 and Pulse 4 for the respective stage The single pressure transducer used to derive the stage data must be connected to the Analog 6 input and the single solenoid signal must be connected to the Pulse 1 contact at the MIU In order for the stage detection algorithm to be able to derive the discrete stage information the Analog 6 pressure transducer must be calibrated to use at least half of its dynamic range and the Pulse 1 solenoid signal must occur only at the beginning of the injection stage Failure to comply with either of these requisites will results in erratic behavior of the stage detection feature For MIUs operating with the stage detection feature specifying Y es in the Stage Pulse fields means that the derived duration times of Pulse 2 Pulse 3
105. to all field types e The active field is the one into which entered characters will be placed All modifiable fields are marked by magenta letters e The entry of data into a field is completed by Pressing Enter This action also causes the next field to become the active field Pressing Enter without actually typing any other keys moves the active field through all modifiable fields on the screen Copyright 2002 MATTEC 2 9 710 0092 e Picklists with pop up windows are available in numerous places throughout the system There are often screens that require you to input information in order to generate reports or graphs Picklists are a convenient way to select the desired parameters that need to be input When a picklist is available move the cursor to the desired field Press the spacebar and the picklist is returned To make a selection move the cursor to your selected choice by using the arrow keys and Press Enter e The active field is also moved by the cursor left and cursor right keys Cursor right moves to the next field similar to Enter and cursor left moves to the previous field e Pressing any key which is valid for the active field initiates field entry e Pressing Backspace erases the previously entered character e While modifying a field the Insert key may be used to add characters in the middle of the field Pressing Insert once causes characters typed to be inserted at the cursor and characters wil
106. tremendous savings can occur in increased productivity and decreased scrap parts The ProHelp Millennium System is a combination of computer hardware computer software and Machine Interface Units MIUs that are combined into an efficient system to provide real time production monitoring production reports process alarms plant scheduling aids and SPC 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 may be generated on a shift and daily basis or the user may 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 Millennium is built on top of the Open Unix operating system Open Unix is a UNIX System V Release 5 operating system from Caldera It can easily be connected to virtually any Ethernet or Token Ring network utilizing TCP IP as a communications protocol Color monitors vividly display the real time status of each piece of machinery within the plant Machines that are operating outside of preset limits on cycle time production rate and efficiency rate are highlighted in color on the computer monitors Process parameters such as hold pressure screw speed motor rpm
107. value press the spacebar This field is the desired completion date and time for the job This is the time the customer wants his parts The user must specify either the desired end date for the job or the desired start date for the job The system will calculate the forecast end or start date The System Manager miscellaneous function is used to configure whether the end date or the start date is to be specified Refer to Section 7 5 This field is the desired start date and time for the job The job needs to start by this date and time in order to meet the desired end date ProHelp Millennium fills in this field with the actual start date and time as a result of starting the job via the computer or the MIU Copyright 2002 MATTEC 4 10 710 0092 Actual End ProHelp Millennium fills in this field with the actual end date and time when the job is ended via the computer or the MIU Figure 4 3 Job Descriptor Standards The standards are actual production targets and must represent real profitable goals Variation of these standards is never taken lightly because failure to meet the true values can result in lost dollars The standards page has three columns of data STAND holds the engineering standards SHIFT contains the average performance of this shift JOB consists of the accumulative performance of all machine cycles for this job The shift and job columns are color coded Red means the value is below standar
108. was Pertformed AAA 9 10 95 Greate Maintenance History EE 9 12 9 6 Define Maintenance for a Machine Not Montored A 9 13 9 7 Maintenance Etoile ER 9 13 9 8 Preventative Maintenance Due Report 9 15 9 9 Preventive Maintenance Pobeieren Eeer A 9 17 10 Cost Manag t EE 10 1 10 1 Modify Standard Cost Data Job Descnptor 10 1 10 2 Modify Standard Cost Data Part Descptor 10 3 10 3 Edit Actual Hours and Material Heger iesen dees Een 10 3 10 4 The Cost and Contribution Report iscacssccivecies sdesscceacsestssctennsacdastebes edavesecdvonntcosemehonnaeees 10 4 105 THE JOD Cost REPO EE 10 6 11 Manual Entry of roden 2ce ukeeig geng Seele igpiactaswaseaessdeventens 11 1 WZ STOR CUMS DEE 12 1 LSK Installationer a a a suisa hats ees a cea ducetats teeadentaet ti 12 1 ke OMA E 12 1 LSZ target eege deelt edit Wd E ee a ee 12 4 12 224 M n EE 12 6 12221 Men EE 12 7 12222 AOD Eege Ea E A E a R N a A ENA 12 22 12 223 E E EE 12 23 12224 Machine Schedule Te dais rosokan e Reade utevades a a ee ak 12 24 e WE BEE Be 12 25 e CE CTS ON EN 12 26 12 2 4 Drag and Drop Operation isisccicasscasccetssassadevas sscadsusesdeatasachadeasebscade neces dadassseedeuaasbaat 12 26 122A T e E EE EE 12 27 Copyright 2002 MATTEC vi 710 0092 ID 242 Dynamic Dyna Scrolling cicjecsvcsa cus ees eces acntaventdeidestanen deeb umes dans aes eesacttaceoees Product WD CRUD EAA E SE he ae ee ee iM Recetas Sia seh eal La tad BS 13 1 Calculations EEN 14 1
109. will default to the scheduling method specified by the System Manager If you wish to change this for a particular job move the cursor to the SCHED FROM field Press spacebar Select the scheduling method to be used Press Enter If any one job is ever scheduled to last longer than 8760 hrs one year has 8760 run hours the job will be shown in purple on the real time scheduler It will not calculate an end date past this one year period The machine number field is modifiable for all unscheduled jobs When you insert a machine number the job descriptor will display the per machine signal names and per department scrap and downtime names When the machine number field is blank the system wide default names are used and the signal values and limits are assumed to have no decimal places Unscheduled jobs may be added directly to a machine schedule from the job descriptor display To add a job to the schedule follow these steps Enter the desired machine name into the machine number field Press F9 Sched Select the proper position of where the job is to be inserted Press Enter When editing a job descriptor the following choices are available FUNCTION KEY DESCRIPTION F1 Job Press to select another job descriptor by specifying the job number F2 Mach Press to select another job descriptor by specifying the machine aS EE F5 Get Pt Press to copy a part descriptor to this job after the job has been created
110. with file names to determine whether or not the file is critical you should contact the MATTEC Customer Service Department to discuss the problem Unable to copy SPC data file Copyright 2002 MATTEC 15 47 710 0092 cause ProHelp Millennium tried to copy an SPC file that did not conform to standards remedy Check the integrity or existence of the specified file Unable to locate Scrap Net administrator cause An attempt was made to access the ScrapNet device while it was not properly configured or active remedy Verify that the ScrapNet device is properly configured in the ProHelp Millennium system Unable to open communications port cause ProHelp Millennium tried to open a communication port that did not exist or was already opened remedy Contact MATTEC for assistance Unable to open file cause ProHelp Millennium tried to open a file that did not conform to standards remedy Check the integrity or existence of the specified file Unable to read comm status cause ProHelp Millennium attempted to read the communication status of a connected device but failed remedy Contact MATTEC for assistance Unable to read file cause ProHelp Millennium tried to read a file that did not conform to standards remedy Check the integrity or existence of the specified file Unable to read SQC data for filename cause ProHelp Millennium tried to read an SPC file that did not conform to standards Co
111. 00 12000 66 T PENDI gram std Mtlbst SUMatl BMtlLot Bo 0 Figure 12 15 Job Descriptor Screen To return to the ProSched screen Hit ESC CREATE NEW JOB DESCRIPTOR Activating Create New Job Descriptor will display a modal dialog that will prompt the user for a job number ProSched will verify that the job number entered is not currently a valid job number Copyright 2002 MATTEC 12 12 710 0092 If the job number is already in use an information dialog will be presented to the user and the Create New Job Descriptor processing will be stopped Once a new job number has been entered Job Descriptor will be invoked on that new job number When the user has exited Job Descriptor the new job will appear in the list of unscheduled jobs presented in the Unscheduled Jobs area refer to Section 12 2 2 1 3 12 2 2 1 3 View The View pull down includes the push button Preferences In addition there are two cascading pop ups labeled Scheduled Jobs Unscheduled Jobs Prohelp Millennium ProSched File Edit View IESSE A Preferences i E Scheduled Jobs Unscheduled Jobs Figure 12 16 View Pull down PREFERENCES When activated the Preferences push button will cause the ProSched Preferences to be displayed Figure 12 17 Preferences Bar Labels The ProSched Preferences will be composed of a control area and an action area The ProSched Preferences is a non modal dialog ProSched Prefere
112. 04 96 09710796 094 16736 enf 18 06 12 00 18 00 00 00 06 00 300 o OD e 11 CH 4907 RUNN 11 02 02 12000 PEND 02 ek 600 1000 PEND 55 13 EE 12000 RUNN 01200 107027961 05259 07731796 13 EI J Ce HUMBER DESIRED START DESIRED END H 199964020110 1000 159964020110 JOBO8_B Partformachineos o JOBO8_B NEWOOL part 100000 NEWOOL NEWOO2 part 100000 NEWOO2 e Fanati s e EI j Figure 12 39 Drag and Drop Operation X Please wait processing data New Schedule is now being transmitted Figure 12 40 Commit New Schedule The final screen after Commit has been initiated will be Figure 12 41 Commit Results X Commit Results Ed rest ea Copyright 2002 MATTEC 12 33 710 0092 Figure 12 41 Commit Results 12 2 4 2 Dynamic Dyna Scrolling During a drag and drop operation the window that contains the drag source can be automatically scrolled by moving the cursor outside of the source area Moving the cursor to the right of the area will result in the source area being scrolled to the right Moving the cursor above the source area will scroll the source area up Copyright 2002 MATTEC 12 34 710 0092 13 Product ID PID MATTEC Corporation s Product Identification PID feature incorporates functions which provide the customer with a means to generate Product Identification PID in the form of printed labels The label may include e
113. 13 710 0092 PROCESS SPC FIELD DESCRIPTION Sample Period This field specifies the average time in minutes between automatic samples Allowable sample periods are between 10 and 180 minutes The actual sample interval used for data collection is twice the specified time period The specific point within the interval where process data is collected is random The sampling algorithm ensures that each machine cycle has the same probability of being sampled Changes to the sample period become active at the end of the current sample period Auto SPC Lim Num Cycles This field describes the number of consecutive cycles used for automatic limits calculations Reference Section 5 6 9 for additional information Process Exception Log This field allows you to enable process exception logging for the current job Reference Section 5 6 8 for additional information VARIABLES SQC FIELD DESCRIPTION Variable Sample Enable Enter Y es to enable variable data sampling This allows variable data dimensions weights to be entered and processed by the system Reference Section 5 6 5 for information on modifying variable control and specification limits Reference Section 5 6 6 for information on modifying the alarm conditions for variable data Observations Sample This field is for display purposes only and displays the value of the Process SPC CYCLES SAMPLE field This is the number of observations in each variable sample Suppress Double R
114. 2 Edit Ee EE 12 11 Figure 12 13 Exhausting the Undo List eseeeeseeeseseeeseseseseesseseresresseseresresseestsnrssrensessresreesesse 12 11 Figure 12 14 Modify Popu peisnscciisscasasselasdecssescdsavenjeacdi eeni i Edge sa i 12 12 Figure 12 15 Job Descriptor Screens Eegen ee EE 12 12 Ereegnesser a i E a E Ee 12 13 Figure 12 17 Preferences Bar EE 12 14 Figure 12 18 Preferences Sched Disp oedgeeietskesrkiuSgeegete Eed GET 12 15 Figure 12 19 Preferences Sched Method 22 egene edd 12 16 Fipure 12 20 Preferences RESOl tION geed eege 12 17 Figure fl 2 21 Preterences EE 12 18 Fig re Eeer 12 19 Fisure 12 23 Machine Schedule EE 12 20 Figure 12 24 Unscheduled Jobs ageleet eege deene egeerh 12 20 Figure 12 25 Unscheduled JOBS EE 12 21 Figure 12 26 Adjusting the View ccsisevcssccasssseecanavsiacaiss seacdasensaaddaavasesaasesvedeaavenaceesedsauennvesaacas 12 22 Figure 12 27 OOM EE 12 23 Figure 12 28 GAME GE 12 24 Fig re 12 29 Machine Schedule sini active Ge aaas ee ES EOE ade i 12 25 Figure 12 30 Unscheduled J ODS tctsctssicsteicieth nen ngehid adelante ells 12 26 Figure 12 31 e EE 12 28 Figure 12 32 ProSched Main Sereen EE 12 29 Figure 12 33 Drag and Drop Operation Screen 12 30 Figure 12 34 Commit Scree EE 12 31 Fig re 12 35 Commit Keen ine a ee ee Bae i Ee Bide 12 31 Figure 12 36 Drag and Drop Results s ssseeeeesssessssessesesseresresseserestessesersstesseseteressressessresreeseese 12 31
115. 22 710 0092 Attribute Type Valid choices are U default and P U attributes measure the number of nonconformity per sample Ten different attribute names can be used if U is selected U ale P attributes measure the proportion of nonconformity in a sample One attribute name is allowed if P is selected Name This is the name of the attribute s that can be collected Data may be collected for all non blank attribute names At least one attribute name must be specified if attribute data sampling is enabled Phar greater than Ulcl Plcl Pucl than Ubar Pbar and Ulcl Plcl Ulcl The lower control limit for the U P value This value must be less than Plcl Ubar Pbar and Uucl Pucl 5 6 7 Process Exception Logging ProHelp Millennium offers a log which will record any process exceptions resulting in a violation of specification limits control limits SPC sample violations and part qualification violations for process parameters that have been enabled A single record for each violation is written meaning that if all process parameters are out of limits during a single cycle each parameter causes a new record to be written The Job Manager specifies the types of violations that are logged for each job The following choices are available when creating a new job Cycle Control Limits Only control limit violations for each machine cycle are logged Cycle SPC Violations Any SPC sample violations are logged Par
116. 3 9 710 0092 3 3 2 Standard MATTEC Real Time Screen The MATTEC real time display consists of a single line summary of the status of each machine The data is comprised of the following and date information as well as the column headers Machine Number The display of machine numbers is in alphanumeric sequence by machine name within each department Each department is separated and a single line contains the department name shift number and shift date The machine number contains the 6 alphanumeric characters assigned to each machine at configuration time The machine number has 5 background colors that are described in Section 3 3 1 Jobs which have SPC enabled will display an between the machine and job numbers Job Number The job number contains the 12 alphanumeric characters used to identify the job currently being monitored The job number field has 4 background colors that are described in Section 3 3 1 HP displays a single character call for help code The code displayed is a number 1 8 Help call names are defined by the System Manager and may be different for each department The following are typical help call reasons 1 Parts Pickup 2 Relief Operator 3 Maintenance 4 Supervisor 5 Setup 6 Tool Repair 7 Quality Control 8 Material Help calls are canceled at the MIU and removed from the real time screen A Help Call Log Report is available Parts Made The parts made field is a six digit num
117. 4 2 30 0 seconds 28 8 seconds Standard Yield Per Hour 1 Hour Standard Cycle Time Standard Cavities 100 Standard Scrap 648 3600 seconds 30 0 seconds 6 100 10 Actual Yield Per Hour Good Parts Made Run Time 425 850 2 00 Yield Efficiency Actual Yield Per Hour Standard Yield Per Hour 65 6 425 648 Earned Hours Good Parts Made Standard Yield Per Hour 1 31 850 648 Earned Labor Hours Earned Hours Standard Operators 0 66 1 32 O45 Actual Scrap Scrap Parts Made Total Parts Made 153 150 1000 Maximum Scrap Deviation Standard Scrap Scrap Pred Lim 2 10 20 Maximum Predicted Scrap Standard Scrap Maximum Scrap Deviation 12 10 2 If job is running and Scrap Pred Lim is not 999 Predicted Scrap Smaller of Actual Scrap and Maximum Predicted Scrap 12 12 If job is running and Scrap Pred Lim is 999 Predicted Scrap Actual Scrap 15 15 If job is not running Predicted Scrap Standard Scrap 10 10 Predicted Good 100 Predicted Scrap 88 100 12 Good Parts To Go Lot Size Good Parts Made 19150 20000 850 lf Hold Parts not enabled Total Parts To Go Good Parts To Go Predicted Good Copyright 2002 MATTEC 14 2 710 0092 21762 19150
118. 796 037 03 36 03 10 36 03 16 36 S 02 2000 PEND egeegeeeeeeleeeeergeegeeg 62 02 02 12000 PEND 02 13 12000 RUN 01 00 10202796 05 23 07731796 13 JOB55 PARTForJOB55 91770 RUNN OOS000077i67 96 16059 T0655 JOB PART NUMBER NUMBER DESIRED START DESIRED END 123456789012 123456789012 1BAACANA ANN 1EAACANA ANN LI i Figure 12 33 Drag and Drop Operation Screen With this move we now have a forecasted end date even though the desired start has not changed since we moved the unscheduled job to the scheduled area Notice that Job 02 which was originally in the Unscheduled Job Area has moved and is now showing in red in the Machine Schedule area and also in the Gantt chart And is no longer showing in the Unscheduled Jobs area If all information looks good we must Commit Please wait processing data Analyzing the results of the commit Copyright 2002 MATTEC 12 30 710 0092 Figure 12 34 Commit Screen X Commit Results Ed The schedule was updated Figure 12 35 Commit Results Results were good no failures therefore you can either restart or exit Refer to Section 12 2 2 1 1 for information on Commit x Prohelp Millennium ProSched Bisi x DL EEEF Li RS JOB PART PROD NUMBER NUMBER TO GO STAT DESIRED START FORECAST END NUMBER LL 02 02 12000 PEND LE 13 12000 RUNN NUMBER NUMBER DESIRED START DESIRED END 2 123456789012 123456789012
119. ATTEC 7 19 710 0092 The message Selection is displayed Press spacebar A picklist displays with item choices Highlight the choice To select Press OK The next screen to enter will appear as Enter the number of digits to the left of the decimal Press Enter The screen will now display the information selected from the picklist screens If this is the first item on a new screen no sequence number message is displayed If this is not the first item a message Enter the sequence number of the new item is displayed This message enables you to position your new field anywhere within the existing fields that you have already created Enter the proper sequence number Press Enter Note that the first item entered for a new display must always go into sequence number 1 Thereafter additional items can be interchanged with any of the other items that are already on your display The message Enter the top header for this item Press Enter The message Enter the bottom header for this item Press Enter You may choose to simply enter the default headers that are displayed The fields that you have selected are now shown on the display format You may now select to insert other fields or to delete fields The field in the top right hand of the screen shows the columns remaining on your new display This number is incremented and decremented as you add and delete fields Please note that it is possible to s
120. Assist the production foremen in adjusting the machine parameters to get the tool running properly 4 Review all SPC charts as necessary to assure that quality parts are being made The engineers must be familiar with the Job Manager functions of ProHelp Millennium in order to create and edit tool standards 1 2 2 Order Entry Department The Order Entry Department provides the person to take the information from a work order request and transfer it to the ProHelp Millennium system This could be in the form of a shop order which requires a certain quantity of a particular product to be Copyright 2002 MATTEC 1 3 710 0092 produced in a given time frame This information is entered into the ProHelp Millennium system in the form of a job descriptor The Order Entry Manager should become a proficient user of ProHelp Millennium and its Job Manager function The order department will involve daily interaction with the ProHelp Millennium system monitoring and updating order activity The Order Entry Department s responsibilities are L Create new jobs with the lot size and the desired delivery dates from the customer s P O 2 Copy all part and tool standards from the engineer s part descriptor file to this new job 3 Save all past job histories on printed paper floppy disks or tape so that the accounting and sales departments can have future reference to this data 4 Update lot size requirements and delivery dates when
121. B AVAIL NUMBER RUN HRS DESIRED START FORECAST END Figure 12 29 Machine Schedule Reminder If you would like to escape out of this screen Go to View Press Off 12 2 2 5 Unscheduled Jobs Area The Unscheduled Jobs area will consist of scrolling text area left header top header The text area lists jobs found in the ProHelp system that are not currently a part of any machine s schedule The ProSched will search for these jobs at startup only If an unscheduled job is found by ProSched and that job has a machine class or department that does not belong in the set specified by the user in the ProSched Startup Dialog Figure 12 4 ProSched Startup the job will not be included in the Unscheduled Jobs list The format of lines of this list are determined by the use of the Unscheduled Jobs Figure 12 24 Unscheduled Jobs Cascade cascading pop up described above Immediately to the left of the scrolling text is a left header area where the job number of each job listed is displayed The left header is set to track vertical scrolling of the text area but it will remain fixed as the text area is scrolled horizontally Copyright 2002 MATTEC 12 25 710 0092 The top header of the Unscheduled Jobs will show column names for the text data shown below it The column names are synchronized to any horizontal scrolling done in the text area The top header remains unaffected by vertical scrolling of the text area Prohelp Millenniu
122. C data to be sampled at every cycle for a predefined number of cycles for a running job The consecutive SPC data is then used to compute new SPC control limits The new SPC control limits are automatically updated in the Host and the MIU Normal SPC sampling at regular intervals as defined in the SPC setup of a job is resumed after automatic SPC limits calculations are completed Automatic SPC limits calculations can be used for automatically setting the SPC control limits from a fixed number of consecutive SPC samples at the beginning of a job Starting consecutive SPC sampling for automatic SPC limits calculations is a two step process First parameters for automatic SPC limits calculations are defined at the Host during the creation of a job or while the job is running Second the automatic SPC limits calculation is initiated at the MIU any time while the job is running Reference the MIU Operator s Manual for additional information Copyright 2002 MATTEC 5 25 710 0092 To enable automatic SPC limits calculations for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F5 Basic The following fields are then available FIELD DESCRIPTION This field describes the state of the automatic SPC l
123. Copyright 2002 MATTEC 1 2 710 0092 these groups to improve productivity In this section these individuals are identified as users of the system and their duties are specified Anyone who is to become a ProHelp Millennium user should read Section 1 Introduction Section 1 1 What the Company Purchased and browse the MIU Operator s Manual The responsibilities of all users of the system are summarized on the following pages 1 2 1 Engineering Department The industrial engineer in a manufacturing plant often wears many hats This person may do everything from feasibility studies to the acquisition and implementation of new methods equipment and materials which are intended to improve the production process Therefore the degree to which the engineer becomes involved in the ProHelp Millennium system is going to depend on how it is implemented in your plant The primary responsibilities of the Engineering Department are 1 Set all tool standards for cycle time limits cavities to run part weights shot weights and process limits for temperature and pressures These standards can go into the part descriptor file where they may be easily recalled for use The engineering department determines the high and low limits that are allowed for cycle times and process parameters 2 Review the real time production screen several times throughout the day to determine if the machines are running within the standards set 3
124. D or tool number or to modify other defaults Click File Select Preferences Make changes as required To make your changes take effect Click Apply OR Done To display job related information Click on any job with the mouse The machine number job number parts to go and related information will be displayed To view the entire job descriptor Click View Job Descriptor The job descriptor will be displayed in a new window To display job related information for jobs that are too short to click on Click on the machine number with the mouse Copyright 2002 MATTEC 3 21 710 0092 All jobs scheduled for this machine will be displayed Select the job to be displayed Click OK To view that machine s schedule Click View Schedule To print the Gantt chart Click File Select Print To exit the chart Click File Select Close 3 5 3 Schedule Summary Report To display the Schedule Summary Report for all machines follow these steps Press F1 View Figure 3 1 Copyright Screen Press F3 Sched Press F2 Summry Fill in the interactive screen as appropriate Press F1 Done The Schedule Summary Report will be generated 3 5 4 Tool Base Support There are two different types of operations in which one tool e g mold base is used to hold one or more other tools e g molds One such operation is family molding where the base may be identified in the family Job Descriptor and the tools it
125. Enter Y to continue any other key to abort is displayed The clear function will erase the complete plant layout and enable you to start a fresh grid pattern The delete key will enable you to delete any particular machine on the grid Position the cursor to be on any one of the four corners of the box around the desired machine Press F2 Delete The machine is deleted The grid pattern for your plant layout can use any row between row 2 and 23 and any column between 1 and 80 The error message Machine will not fit on the plant layout screen indicates that the cursor was positioned to a location that will not allow the total number of selected items to be displayed Move the cursor towards the middle of the display press the insert key and enter the machine number again The same machine number may be duplicated in many positions on the grid Always create the real time display first before creating the grid pattern This helps eliminate positioning machines in grid patterns that will not be able to display all of the desired data Once a grid is created it is possible to add additional items to the real time display Be careful not to create a situation in which the machines on the bottom of the grid pattern are not able to display all of the desired data items Use the delete and the clear functions to rectify any layout problems that you created Copyright 2002 MATTEC 7 25 710 0092 Use the standard configuration keys to
126. Enter in a machine number that has a maximum of six characters Invalid Case Lot Size Copyright 2002 MATTEC 15 19 710 0092 cause An invalid case lot size was used in the job descriptor remedy Enter a valid case lot size Invalid communications port cause An attempt was made to access a communication port that is not defined on the ProHelp Millennium system remedy Abort the operation INVALID DATA average number of items inspected is less than 0 0 cause Control limits cannot be calculated if there are no samples remedy Provide valid data perhaps using the SPC editor INVALID DATA average proportion nonconforming is greater than 1 0 cause More than 100 of the samples are defective remedy Provide valid data perhaps using the SPC editor Invalid department cause The department number entered does not exist remedy Verify and reenter the department number Invalid DOS filename cause The target file specified in copying a file to floppy diskette contains an illegal character remedy Enter a valid DOS filename Invalid interface unit type cause An invalid IU type was entered at the MIU installation screen remedy Enter a valid IU type Invalid IU location Copyright 2002 MATTEC 15 20 710 0092 cause An attempt was made to place an interface unit at a non addressable position remedy Check location for addressability and reenter Invalid job number cause An operation was attempted which spe
127. Enter the appropriate machine number Press Enter The move instruction allows for a job scheduled on one machine to be moved to another machine The job is deleted from the original machine schedule automatically and added to the target machine Copyright 2002 MATTEC 8 2 710 0092 To move a job from one machine schedule to another follow these steps Press F6 PrdMan Figure 3 1 Copyright Screen Press F3 Sched To select the machine number that holds the job to be moved Press F1 Mach Enter the machine number Press Enter Press F7 MovMch Select the job number to be moved Press Enter Enter the target machine number to which the job will be moved Press Enter The system will now automatically delete the job from the first machine and add it to the target machine One job at a time can be moved between machines Schedules are recalculated when the new job is added Reference Section 4 4 for additional information 8 4 Job Control Contrl is short for Job Control This function is one of the Production Manager s methods of keeping ProHelp Millennium in step with the monitored machines ProHelp Millennium must be directed to Start collecting data for a job and to End collecting data when the job is done It is very important that the commands to start and end be given at the same time job changes are taking place on the actual machine The Machine Interface Units can be used to tell ProH
128. Figure 12 37 Drag and Drop Operation Screen 12 32 Copyright 2002 MATTEC iv 710 0092 Figure 12 38 Commit Screen Failure cceresorsogtio ns sealant contd ioiical pes hn cn aes atte teeters 12 32 Figure 12 39 Drag and Drop Operations csc as oc5 52sec gyazscecasseceaes ccaateccoaassuecay taotecsaensceossartnees 12 33 Figure 12 40 Commit New Schedule ios j i c ewan lerniuiniiiienuindinnnildageion 12 33 Figure 12 4l Commit EE 12 34 Figure 14 1 Assumed Values for Examples sssnsessseseesseesssesesssseessseesseesseesseesssresseesseesseeesseee 14 1 Copyright 2002 MATTEC H 710 0092 TABLE OF TABLES Table 7 1 Miscellaneous Installation Parameters System Table 7 2 Miscellaneous Installation Parameters Department Copyright 2002 MATTEC 1 710 0092 1 Introduction to ProHelp Millennium MATTEC Corporation s ProHelp Millennium 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 extrusion aluminum die casting and metal stamping industries The basis behind the benefits from the ProHelp Millennium 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 Millennium is the device to alert employees to problems immediately when the problems occur Therefore
129. Figure 3 1 Copyright Screen There are many modes of operation each corresponding to the functions that individual people have within the system These modes are described as follows FUNCTION DESCRIPTION KEY F1 View Anyone may view the real time screens production and downtime reports and machine schedules in this mode No data values may be changed in this mode and no password is normally required to enter this mode F2 JobMan This is a password protected mode The Job Manager may edit lot sizes change standards change schedules and create new job and part descriptors F3 QC Man This is a password protected mode The Q C Manager may enter scrap part quantities and reasons from prior shifts of production This mode also allows editing of scrap parts to good parts and editing of downtime reasons The optional ProStat SPC software is accessed via this mode F4 Ave Mon This is a password protected mode This mode allows changing of shift start and end times Name changes for downtime scrap reasons and process parameter signals may be made General system and MIU configuration screens are in this section F5 FilMan Thbis is a password protected mode The File Manager functions involve saving backup disks archiving historical data and purging disk space Machine and tool history files and help call files may be reset Copyright 2002 MATTEC 3 2 710 0092 setup material used for a job No other standard
130. Figure 3 47 Future Requirements Monthly Chart The above screen Figure 3 47 was accessed by using Detail Combined Schedule 3 6 2 3 Tool Conflict Report This report may be requested for any number of days into the future and will indicate where overlapping jobs require the same tool and the length of time of the overlap To access the Tool Conflict Report Press F1 View Figure 3 1 Copyright Screen Press F4 Report Highlight Planning The following picklist will display Copyright 2002 MATTEC 3 46 710 0092 ProHelp Millennium I bel ES Items Future Requirements Job Summary Material Needs Part Summary Schedule Summary Tool Conflict Figure 3 48 Tool Conflict Report Picklist Highlight Tool Conflict The following screen will display A Figure 3 49 Tool Conflict Report Double clicking the fields Format Action and Tool will display a picklist After selecting all choices in the setup screen Click OI Copyright 2002 MATTEC 3 47 710 0092 ProHelp Millennium A Figure 3 50 Tool Conflict Results Report As the example shows there are no conflicts found with this tool 3 6 2 4 Process Parameter Graphs 3 6 2 4 1 Samples discretionary This allows the graphing of previously recorded process parameter values The recording of these values is optionally enabled by specifying a recording frequency in a Job Descriptor see Section 4 1 3 To access this func
131. Help Millennium exists in groups For data such as job and part descriptors the entire screen is used to display each member of the group Other types can display several items at once A good example of this type is the browsing of reports where several lines of the report are displayed on a screen For data which is displayed one item at a time four keys are used to position the data displayed on the screen These are Home End PgUp and PgDn Home and End will display the first and last item respectively PgDn steps to the next item and PgUp steps to the previous item Where several items are displayed at once the Home End PgDn and PgUp keys operate on sets of items with a set being the number of items which fit on the screen If twenty lines of a report fit on the screen then PgDn displays the next set of twenty and PgUp displays the previous set of twenty Home displays the first set of twenty and End displays the last group of twenty In addition the cursor down and cursor up keys indicated by down or up arrows on the keyboard operate on single items When the screen contains lines one through twenty of a report pressing cursor down will display lines two through twenty one Pressing cursor up will return the display to lines one through twenty Data Entry There are several types of data fields contained in ProHelp Millennium and there are some specific rules for each However many rules apply
132. ITIES from the MIU Allows the operator to request a job change from the MIU MIU Job Sel Enab Allows the operator to select the jobs involved in a job change if supported by the MIU in use The more advanced MIU models support the selection of which scheduled job to start and whether to end or suspend any running job Where a family job is running this ability is available for individual component jobs Setting this parameter to N o disables this ability so that the job sequence defined in the machine schedule cannot be altered by the machine operator Susp Job Handling This parameter determines how a suspended base job is handled Choices are First Keep the suspended job in the schedule as the first non running job Last Keep the suspended in the schedule as the last job Remove Remove the suspended job from the schedule Susp Son Handling This parameter determines how a suspended family component job is handled Choices are First Keep the suspended job in the family job as the first non running job Last Keep the suspended in the family job as the last job Remove Remove the suspended job from the family job Neg Hold Parts Allows entry of negative hold parts Copyright 2002 MATTEC 7 42 710 0092 FIELD DESCRIPTION Scrap Pred Lim A value entered here is used as a control for the internal calculations that use the ACTUAL SCRAP This makes the system predicto
133. J Warning and EOJ Alert values If no preventive maintenance operation is due within the specified window an at symbol is displayed in the PM Notification Flag If one or more PM operations are overdue or are due within the specified window an M or T is displayed depending on whether the earliest due operation is for the machine or tool The letter is displayed on a red background if the operation is overdue The normal background color is yellow Copyright 2002 MATTEC 7 15 710 0092 FIELD DESCRIPTION Schedule This option defines the method with which scheduled job start dates Method will be calculated If SCHED METHOD FORECAST the forecasted method will be used The rule is as follows The END date of the previous job on the schedule becomes the START date for the next job on the schedule If SCHED METHOD DESIRED then the desired date method will be used The rule is as follows If the END date of the previous job on the schedule is LESS than the DESIRED START date of the next job then the START date for the next job will be the DESIRED START date for that job If the END date of the previous job on the schedule is GREATER than the DESIRED START date of the next job then the START date for the next job will be the FORECASTED END date of the previous job Schedule From End or start Allows the user to specify the desired start or desired end date for a job Schedule The possible combination of date a
134. K Proceed as above Only one user may request the last cycle s profile graph data from the MIU at a time If another user has requested the same data the message Requested profile graph data busy will be displayed The MIU must wait for the current cycle to complete before collecting the data 4 2 7 Rate System Each machine in the plant may be specified as a rate machine or a cyclic machine These are defined by the System Manager Rate machines have production specified in terms of pieces per minute or length per minute Cyclic machines have production specified in terms of cycle time or parts Copyright 2002 MATTEC 4 30 710 0092 count Job descriptor parameters production report fields and real time display values display these values as appropriate You may have a combination of rate and cycle machines defined for your plant The Machine Class and Department parameters defined by the System Manager will allow you to organize most reports and displays into rate groups and cyclic groups of machines Refer to Section 7 Please note that ProHelp Millennium currently limits the number of decimal places for cycle time so a range of frequencies will convert to the same rate value MIUs measure cycle periods only then internally convert values to rates A length multiplier is specified in the MIU configuration which permits conversion of a cycle period to a linear rate value For every occurrence of the cycle a
135. LED JOBS Apply Save Figure 12 21 Preferences Misc CANCEL The cascading pop up Scheduled Jobs consists of several choices Off Prod To Go Hours To Go Copyright 2002 MATTEC 12 18 710 0092 Available Run Hours Prohelp Millennium ProSched File Edit View Production To Go Hours To Go Available Run Hours Figure 12 22 View PopUp When Off is activated the Machine Schedule Area refer to Section 11 2 2 4 will not be displayed By selection of one of the following choices Prod to Go Hours to Go or Available Run Hours the Machine Schedule Area Figure 12 23 Machine Schedule will display the following fields at the bottom of the screen Job Number Part Number Prod To Go subject to change per choice Desired Start subject to change per selection in View Sched Disp Section 12 2 2 1 3 Desired End subject to change per selection in View Sched Disp Section 12 2 2 1 3 Forecast Start subject to change per selection in View Sched Disp Section 12 2 2 1 3 Forecast End subject to change per selection in View Sched Disp Section 12 2 2 1 3 The third column of this screen will change headings and criteria dependent upon the above three choices Example Available Run Hours when selected will cause the Available Run Hours to be displayed in the third column instead of Prod to Go The decision to show Desired Start or Desired End and Forecast Start or Forecast End is made by lo
136. N KEY DESCRIPTION porem E to view all the real time screens These screens are described in Section 3 3 The job descriptor choice is used to create or edit job descriptors F3 Sched The scheduler is used to modify machine schedules display the plant schedule summary and display the Gantt schedule F4 Control The control function is used to start stop or suspend specific jobs on specific machines F5 PtDesc The part descriptor function is used to create and maintain master part descriptors F6 Import Allows you to input job descriptors part descriptors and machine schedules from an external system into ProHelp Millennium Reference the ProHelp Millennium Data Exchange Manual 710 0069 for additional information F7 RITmDf The real time screen definition function allows the creation of custom real time screens Reference Sections 7 5 and 7 6 for additional information F9 Kanban To provide automatic Kanban Just In Time scheduling functions within the ProHelp Millennium system Copyright 2002 MATTEC 4 2 710 0092 For ProHelp Millennium to monitor machines and count parts for specific jobs several procedures have to be established 1 A job must be created with a lot size standard cycle time cycle time limits and a non production limit set above the cycle time high limit Since most companies deal with weekly and monthly production schedules ProHelp Millennium allows multiple jobs to be c
137. PRO SPLAY BURNS BUBBLES 05 27 97 3 0 0 0 0 Figure 4 11 Manual Entry Production Screen Copyright 2002 MATTEC 4 63 710 0092 The entered values are used to define the first row Additional rows up to a total of 200 may be created by pressing the F2 AddRow key which also prompts for e Date e Shift Tag picklist appears e Job Number hit spacebar for picklist To delete any line of information Press F3 DelRow At least one line of information must remain on the screen To exit this line Press Escape Arrow keys Used for moving through the active field Home End Page Up Used for moving through the active field and Page Down keys Home key Pressing once will move the active field to the beginning of a line Pressing twice will move the active field to the first row End key Pressing once will move the active field to the end of line Pressing twice will move the active field to the first field of the last row F1 Send Causes Data Import Records to be produced for all rows containing data Press F1 Send The following message will appear if successful Operation completed successfully to invoke the Data Import function with the delrecnoerr option described in ProHelp Millennium Data Exchange Manual 710 0085 If no errors are encountered a message is displayed informing the user that the import was successful and the Manual Entry feature exits when the message is acknowledged If errors are e
138. Parameters are shown in Figure 7 22 To access Department Installation Parameters Press F1 Dept E xterm lolx Figure 7 22 Miscellaneous Installation Parameters Department Copyright 2002 MATTEC 7 40 710 0092 System wide parameters are described in Table 7 1 Department parameters are described in Table 7 2 DESCRIPTION NPC Name The name to be used for Non Production Cycles NPC SP RPT 1 Users with special reports created by MATTEC set this field to SP RPT 2 a name for their report The report will then appear as a selection under the F1 View F4 Report menu SP USR 1 Users with a special password protected function created by MATTEC set this field to a name for the function This name will then appear as F9 on the copyright screen mmddyy or ddmmyy Auto Logoff Set to Y es to automatically log MIU operators off at the end of each shift Units of Weight Weight measurement standards entered here appear as the shot and part weight and in all material reports lbs grams kg Units of measurement are universal throughout the system Parts Wst Set at the number of parts that make up the unit of weight Increments must be in multiples of 10 parts per 1 10 100 or 1000 Wt Dec Pl Measurement of weight is a maximum of 6 digits Placement of the decimal place determines the resolution of measurement and maximum amount of weight that may be entered in the pieces per field of the job descriptor Stan
139. Parts 1 Standard Scrap Indirect Labor Rate Total Cost Optional Time Machine Cost Rate Labor Dollars Used Dollars Scrap Dollars Material Standard Material Cost Good Parts 1 Standard Scrap Standard Cavities Standard Shot Weight Standard Material Cost Note Optional Hours may be either Run Time Setup Time or Run Time all down time as configured by the System Manager F 4 SysMan F8 Install F1 Misc Within the miscellaneous configuration page change the field labeled Cost Total Time to Y to include all down time or to N to include only down time charged to set up Changing the Cost Total Time option will also affect the operation of the Job Cost report Move through this screen by use of the cursor keys To exit Press Esc 10 5 The Job Cost Report The Job Cost Report is a wide carriage report and requires 132 column paper The Job Cost Report can be printed only for completed jobs For family jobs only component son jobs have cost information associated with them To generate the Job Cost Report follow these steps Press F8 CstMan Figure 3 1 Copyright Screen Press F4 JobCst Fill in the interactive screen as appropriate Press F1 Done The report will be generated Copyright 2002 MATTEC 10 6 710 0092 The following fields are included in the Job Cost Report DESCRIPTION S Standard Material Used Good Parts 1 Standard Scrap Standard Caviti
140. PrdMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the appropriate job number OR Copyright 2002 MATTEC 8 1 710 0092 Press F2 Mach enter the appropriate machine number Press F6 MtlLst The job descriptor is now displayed The cursor is positioned at the actual percent regrind field Enter the new percent regrind Press Enter To return to the prior menu and save your changes Press Esc To add to the amount of setup material used for a running job follow these steps Press F6 PrdMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the appropriate job number OR Press F2 Mach enter the appropriate machine number Press F7 SUMatl The job descriptor is now displayed Enter the new amount of setup material that has been used Press Enter To return to the prior menu and save your changes Press Esc Reference Section 4 1 8 for additional information on Material Needs and Usage 8 3 Modify a Machine Schedule Schedules can be easily changed Jobs can be moved from one machine to another Priorities can be altered Ended jobs can be restarted The only rules to remember are that running jobs must be ended or suspended before they can be changed and running jobs cannot be switched from machine to machine To modify a machine schedule follow these steps Press F6 PrdMan Figure 3 1 Copyright Screen Press F3 Sched Press F1 Mach
141. ProHelp Millennium Production amp Process Monitoring System Release 3 x Operator s Manual MANUAL 710 0092 February 11 2002 Copyright 2002 MATTEC 710 0092 ATTENTION You can obtain service support by visiting Mattec s web site at http www mattec com by emailing the help desk at helpdesk mattec com or by telephone at 513 683 1075 NOTE All ProHelp Millennium System features are described herein Your installation may not include all these functions due to the software options you purchased or the computer hardware purchased or the type of machine interface units purchased Copyright 2002 MATTEC 710 0092 TABLE OF CONTENTS 1 Introduction to ProHelp Weed geggr Ae geheie lonseosaaaeeas 1 1 1 1 What the Company Purchased lt 3 icc lt icisoscsccassaccevasgspetasuesadeussensadnasegnaceasnascana DEENEN 1 2 1 2 Identification Ot RESPOrnsi Di HG E 1 2 1 2 1 cBngineerin Ieper Ed eee 1 3 L222 Order Entry De parent 2523 9 3 5 65 cee senscctye a a E a EE cevynecausev E octane 1 3 1 2 3 Production Scheduling Department 9 13 2 j310c s02ccessisecanasusscd cvasddeeeesecenasedesdaceassseanentess 1 4 1 2 4 _ ProdichonG KEE een seele ENEE 1 5 12 5 SHOP POLCMICH sss 0 clsacarvnatedaeawoedasegh quadeansbeanaaerateseiaaadecsadtavaacayeacsensegtesaaeaseesecs a a a 1 6 12 0 Setup EE 1 7 12 7 Material Controller syic sscascsntcvassssisaseeiaaanavacavsancateashavaacaseosaccassaveabastesedeadwonaaeetat
142. ProHelp Millennium File Graph EICH Figure 3 38 Quarterly Chart 3 6 2 2 Future Requirements Report 3 6 2 2 1 Operation This feature provides Reports and Charts showing estimated requirements for e material e operators e machines e tools Requirements may be shown for any period with resolution of a shift day week or month Estimates may be based on the forecasted production schedule or on the desired dates entered by the user Figure 3 39 shows the interactive screen used to request the report To access the Future Requirements Schedule Press F1 View Figure 3 1 Copyright Screen Press F4 Report Highlight Planning Copyright 2002 MATTEC 3 39 710 0092 The following picklist will display ProHelp Millennium of E Items Future Requirements Job Summary Material Needs Part Summary Schedule Summary Tool Conflict Highlight Future Requirements ProHelp Millennium of x Yi Figure 3 39 Future Requirements Options Most of the fields shown in Figure 3 39 are common to many reports and should be familiar Interval Detail Value and Schedule are specific to the Future Requirements Report and interact to define the report produced Choices for each of these are shown in Figure 3 40 Copyright 2002 MATTEC 3 40 710 0092 Material Direct Labor Mach Hours Tool Hours Setup Hours and Setup Labor Shift Day Week and Month Detail Combined Individual Indiv Mach and M
143. Quality Control Department is responsible for implementing ways to improve the quality of the product monitoring the quality throughout the production process and for inspecting the final product before it is released for shipment As a user of the ProHelp Millennium system the Q C group should become familiar with the monitoring features of the system Studying the View mode will provide an understanding of these features One of the major responsibilities of the Q C group is the entering of scrap parts on the system from the QC Manager mode This function is vital to the integrity of the Copyright 2002 MATTEC 1 9 710 0092 ProHelp Millennium system Scrap is one factor of production that is usually not derived from the machine The responsibilities of the Quality Control Department are 1 Record all scrap part reasons and quantities via the PC into ProHelp Millennium Assign the scrap to the proper shift of production that made the part 2 Review the real time screens throughout the day to assure that parts are being made within the cycle time limits and process parameter limits that you require 3 Reallocate parts scrapped by operators via MIUs to good parts if they were reworked or are determined to be acceptable as is 4 Establish and follow all procedures for Statistical Process Control as required Make sure that you utilize the ProStat package to save time and effort 1 2 10 Maintenance Manager The Maintenanc
144. Sample Enable Enter Y es to enable attribute data sampling Reference Section 5 6 7 for information on modifying attribute related SPC fields 5 6 2 ProLim Automatic and Manual Limits To modify the control and specification limits for a job automatic and manual data follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F6 ProLim The SPC Process Parameters screen will be displayed Use the spacebar for picklist of options Use arrow keys to move from field to field Copyright 2002 MATTEC 5 15 710 0092 ProHelp Millennium Tob top10 SPC PROCESS PARAMETERS Figure 5 4 SPC Process Parameters The following fields are then available for modification The machine parameters which can be collected as the set of process parameters are as follows Copyright 2002 MATTEC 5 16 710 0092 Analog signal 5 value Analog 5 Channel 5 Analog signal 6 value Analog 6 Channel 6 Analog signal 6 value Hydraulic injection pressure Analog signal 7 value Hydraulic second stage pressure Analog signal 8 value Hydraulic back pressure The set of three hydraulic pressures are measured using a single hydraulic pressure sensor connected to analog channel 6 and four additional digital signal inp
145. Scrap e Help Log e Job Description e Mach Maintenance Log e Mach Schedule e Operator Efficiency History e Operation Tracking History e Parameter Record History e Part Descriptor e SPC History e Tool Run History e Tool Maintenance Log 3 10 General Pick Lists Where ever possible picklists are available for the selection of e Machines e Jobs e Parts e Tools e Materials To produce a picklist for the above selections Press spacebar Tool and Materials lists are manually maintained while the other lists are based on existing definitions Individual Tools and Materials may be added or deleted through functions available to the System Manager Copyright 2002 MATTEC 3 55 710 0092 Service programs are provided for the initial creation of the new lists These programs are executed from the command line and scan the entire set of Part Descriptors and active Job Descriptors S_mk_tool_def adds all referenced Tools and Tool Bases to the Tool List S_mk_matl_def adds all referenced Materials to the Material List The full list is always produced for e Machines e Parts e Tools e Materials Modified lists are produced in certain situations for e Jobs For example when modifying Daily History only the appropriate subset is presented The affected functions are e QC Entry e QC Edit e Cost Entry MODE only running jobs are presented only jobs which ran on the selected day and shift are presented
146. Section 5 7 for additional information To select the parameter data type to chart Press spacebar The available choices include automatic manual and variable data To generate a chart for attribute data reference Section 5 7 6 Position the cursor to the proper choice Press Enter To generate a Moving Range and Chart of Individuals set the Moving Range field to Y es The OBSERV RANGE field defines the number of observations grouped together for the moving range chart or the size of the moving range Range sizes between two and nine can be entered The default range size is two The MRx chart displays the moving range chart where x is the range size If selected the range chart does not start until the first range size of observations has been collected A value on the range chart represents the range of range size observations at and before the point The OBSERV SAMPLE field is for display purposes only and displays the number of observations per sample used when the SPC data was collected Press F1 Done The selected chart s will be displayed Scaling Functions The user has the ability to specify the scaling limits before generating the chart If you are trying to compare charts from different time frames it is very easy to specify the same scaling limits so as to make easy comparisons for the data Move the cursor to the appropriate high or low limit boundary to be specified Enter the numeric value for the li
147. TEC 4 35 710 0092 FIELD DESCRIPTION Type This column contains the name of the parameter There are 2 types of inputs used to monitor machine parameters Timed inputs are switches and relays opening and closing on the machine Analog inputs are sensors that relate temperatures pressures and positions The first 5 types are the timed inputs the remainder are the analog inputs Only those parameters present on a system are named and displayed The names given to machine parameters is the responsibility of the System Manager The names of the processes monitored can be different for each machine However any process being monitored in a machine may be turned off by setting its high and low limits to zero High and Low The HIGH and LOW values are used to set the limits of acceptable performance for each parameter Values of zero have the effect of disabling the parameter monitoring for this job Delay The delay value is a time delay from the beginning of the cycle to the time of reading the sensor This is very useful on injection molding machines when monitoring the pressure cycle values of injection hold and back pressure 4 3 2 Create a New Part Descriptor To create a new part descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F4 NewPt If the standards from an existing part are to be copied to your new part Press F1 CpyPt Enter the old part number to copy Press
148. TEC 4 9 710 0092 FIELD DESCRIPTION In the lower right hand corner of the dark blue area of job descriptor is the job s status RUN means this job is now running on a machine and job data is now being recorded PEND means the job descriptor has not been RUN yet but it is scheduled and or pending to run SUSP means the job is suspended and the job data is stored Machine repair tool repair etc can be valid reasons to suspend a job When the job is restarted the production totals start off where they ended COMP means the job is complete All data is stored for historical purposes and the job will not be rerun again BUSY occurs when editing a job descriptor while another user is also modifying the job 4 1 3 Job Standards To edit a job descriptor s standards fields follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Select Standard Press OK The right hand side of the job descriptor contains different pages of engineering standards and performance data Refer to Figure 4 3 Job Descriptor Standards The engineering and production control department should set these standards The first section of the standards screen provides scheduling information FIELD DESCRIPTION Select either schedule from start or end To select a
149. To clear all breaks for the displayed shift Press F8 Clear To exit to the Shift Configuration screen Press Escape The Breaks key may be used to define Shift Breaks for other shifts in the selected department Copyright 2002 MATTEC 7 13 710 0092 When the Escape key is pressed to leave the shift configuration screen the Shift Break entries are scanned to verify that they all occur within the designated shift Any erroneous shift break definitions are eliminated and a warning message is displayed 7 5 Miscellaneous System Options The ProHelp Millennium miscellaneous configuration is used to set the configuration of many of the optional and standard features of the system Such things as end of job warning and alerts help and downtime logs schedule format start or end date scheduling etc are set or enabled on this screen To set the miscellaneous options in the ProHelp Millennium system follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F4 Misc To Set Misc Options Figure 7 10 Miscellaneous Option Screen will be displayed SS ProHelp Millennium Bisi x Figure 7 10 Miscellaneous Option Screen Copyright 2002 MATTEC 7 14 710 0092 Following is an explanation of each field FIELD DESCRIPTION Yld Low Lim The value entered here is the low limit the system uses to determine color changes on all real time Yield Efficiency fields A value below this limit causes the backgroun
150. To save your changes Press Esc 4 2 6 Profile Graphs The optional Profile Graphs feature allows the user to view profile graphs for the last cycle s injection pressure velocity and distance profiles A standard profile graph may be saved for each of the graph types To view a profile graph follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight Profiles Click OK If the Profile Enab flag in the job descriptor is set to N the error message Operation not permitted will be displayed Once Profiles is selected the following selections are then available FUNCTION KEY DESCRIPTION F4 InjStd Press to view the standard injection pressure profile graph F5 VelStd Press to view the standard velocity profile graph F6 PosStd Press to view the standard position profile graph Copyright 2002 MATTEC 4 28 710 0092 injection pressure profile graph velocity profile graph F9 PosCur Press to collect the next cycle s profile graph data and display the position profile graph F10 SavStd Press to save the current profile graph data as the standard profile graph s Standard Profile Graphs The last cycle s profile graph may be saved as the standard graph s from the MIU from a user in the Job Manager mode
151. Tool To create a master QC setup Press F3 OC Enter the new sheet number you intend to create Copyright 2002 MATTEC 7 31 710 0092 Press Enter This is a 12 character alphanumeric field ProHelp Millennium 0f x Figure 7 17 Master Setup Sheet Most of the master field names should be entered while in the protected mode This means that other people who are viewing the data sheets or that are entering new machine values cannot destroy your original named fields Toggle the F3 Protect Unprot key so that it shows the protected mode on the top line of the screen Any fields entered in protected mode may not be deleted when the setup sheet is copied to a job or part descriptor All name fields entered while in the protected mode have a light blue background Use the cursor keys to position the cursor to the area in which you wish to make an entry Enter your field name Press Enter Toggle the F4 OvlOn OvlOff Overlay on Overlay off to display the area of the setup sheet that can be displayed at the MIU Move your cursor keys to position to the next field Continue typing the names for each master field by using the position of the cursor keys The field names may be as long as you desire This is a free format style After entering one complete screen of information of format data you may create a second page by pressing the PgDn key Type in Y es to create another page Press any other key to continue without creatin
152. U uses Because the TIU does not connect to a machine the machine parameter information is unnecessary The IU type for the TIU is 9 Enter either a 9 or Press spacebar Copyright 2002 MATTEC 7 61 710 0092 A picklist will be displayed Pick Transaction Unit and the machine parameters are cleared from the screen ProHelp Millennium Figure 7 29 IU Configuration Screen Refer to Section 0 for a description of channel and IU number settings Configure the TIU as appropriate To save your changes Press Esc You must reboot all nodes on the ProHelp Millennium network for your changes to take effect 7 13 Language Editor ProHelp Millennium has the ability to support up to two different languages simultaneously per node This gives the user the ability to display different languages at a node and any X Server or X terminal that connects to this node Two of the languages that are displayed are usually ordered and shipped with the system A third translation is called User Defined This gives the user the ability to create a completely new translation or to copy and modify any of the languages shipped with the system Multiple language support and the language editor are options to the ProHelp Millennium system 7 13 1 Edit a Language To edit the User Define language follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Copyright 2002 MATTEC 7 62 710 0092 To edit a sta
153. able to reschedule a job which was mistakenly ended To suspend a running job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F3 Suspnd Enter the machine number on which the job is running Press Enter The suspended job will be placed as the first job in the machine s schedule A job s status may be changed from ended to suspended if the job is to be rerun Production totals will accumulate where they left off To suspend a job which has been ended change the job s status from end to suspend follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F3 Suspnd At the machine number prompt Press Enter When prompted for a job number enter the job number to suspend Press Enter 4 5 4 Start the Next Job The Next function ends the currently running job on the selected machine and starts the next job in the machine s schedule This is very similar to the End of Job function at the Machine Interface Unit The Next function stops the current job and starts the next job immediately The End of Job function at the MIU may be disabled or have constraints placed upon it e g lot size check before it works reference Section 7 12 To perform a next job change for a machine follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F4 Next Enter the machine number to perform the next
154. above max cause An attempt was made to enter a figure that had more decimal places than allowable remedy The valid number of decimal places is 0 through 3 Error Machine schedule not found cause An attempt to view a machine schedule but no schedule exist remedy Create a schedule for the specific machine desired Error Machine will not fit on plant layout screen cause An attempt was made to place a machine that did not fit on the grid layout screen remedy Delete some of the items that were selected for each machine Error Machine will overlap an existing machine on the plant layout screen cause An attempt was made to add a machine to the plant layout screen when there was not enough room for another machine remedy A machine must be deleted from the plant layout screen in order for the desired machine to be added Error Maximum active sons is greater than maximum cause The maximum number of active sons was greater than the maximum allowable remedy The maximum number of active sons must be 10 or fewer Error Maximum active sons is zero must be non zero cause An attempt was made to escape from a family job description with the maximum sons set to zero remedy A non zero number must be selected the maximum number of sons is 10 Error Nonproduction limit above maximum Copyright 2002 MATTEC 15 13 710 0092 cause While establishing job standards the non production limit field was set greater
155. achine Schedule Forecasted and Desired Figure 3 40 Future Requirements Field Choices Each of the Value selections Material Direct Labor Mach Hours Tool Hours Setup Hours and Setup Labor may be associated with individual machines In addition a Value selection of Material may be associated with individual Material Codes and a Value selection of Tool Hours may be associated with individual Tool Identifiers This means that for each Interval it is possible to show distinct values for each machine and for some selections to divide the machine based values into individual components or to show those components without regard to machine numbers The Detail selection specifies the level of detail reported Its definition depends on the Value selection and Figure 3 41 shows all of the possible combinations Combined Individual Indiv Mach Material Interval Material within Material within Mach within Interval Mach within Interval Interval Interval Interval Interval Interval within Interval Interval Interval Interval Interval Interval Figure 3 41 Detail and Value Relationships A Schedule selection of Forecasted will produce estimates based on the production schedule forecasted by ProHelp Millennium A Schedule selection of Desired will produce estimates based directly on entered desired dates without regard to feasibility Estimates produced based on the Forecasted schedule are used for planning material purchase
156. achine for a running job The cost standards fields are listed on the right hand side of the job descriptor Copyright 2002 MATTEC 10 1 710 0092 ProHelp Millennium Iof x Figure 10 1 Job Cost Standards Use the cursor keys to position to the desired field Enter the new standard value Press Enter Repeat these steps as required The definition of the data fields are IELD DEFINITION Mtl Cost Lb Material cost per pound The cost per pound listed in the first column is the quoted cost per pound The value in the job column is the actual value paid for the material Dir Labor Hr_ The average standard rate for direct labor in dollars per hour Ind Rew Hr The average standard rate for indirect or rework labor per hour in dollars per hour Mach Cost The accounting cost of the machine per hour This is the burden rate assigned to that particular machine It usually includes utility expenses and the purchase cost expense per hour Mach Sell The selling price per hour of machine run time that you expect to receive in order to generate a profit Dir 1000 Parts The direct labor hour standard needed to produce 1000 parts for a Z R 1000 Parts The indirect and rework labor hour standard needed to produce Deeg oom mise a cra neei o pratas job Copyright 2002 MATTEC 10 2 710 0092 10 2 Modify Standard Cost Data Part Descriptor To create or edit standard cost data for a job follow these steps Pr
157. achine only they may not be inserted via the ProStat edit function Note The SQC Directory lists all jobs in which one type of sampling is enabled on the sample day An error message will inform you if a requested type is not enabled Automatic manual and variable data are shown a sample at a time with all characteristics shown Attribute data is presented with multiple samples The sample data may be paged through using the Home End PgUp and PgDn keys Once in edit or view mode the following selections are available UNCTION KEY DESCRIPTION F1 Sample The F1 Sample menu key allows the user to position to a known sample by entering the date and time stamp of the desired sample F2 Specs The F2 Specs menu key displays the specification data eg control limits and engineering specifications and calculated Xbar and Range or P Ubar values for the job Press the Esc key to return to the sample data view edit screen Changes made to specifications data apply only to the specified data subset i e job shift date data type and characteristic if applicable that were displayed Additionally if changes are made to specifications data for a job which is currently running and the sample date is equal to the current ProHelp Millennium shift date those changes will become active in the job descriptor See the Calculating Limits note below for additional information F3 Insert When editing variable or attribute da
158. achine s maintenance history file Use to modify the last time PM was performed on this machine Reference Section 9 4 for additional information Moves the screen to the next machine Use the cursor keys to move the highlighted field User Enter to move from field to field within the highlighted range Changes can be made in the following fields only Labor Hours Parts Cost Description Use PgUp and PgDn to scroll through all activities Copyright 2002 MATTEC 9 9 710 0092 Enter in the labor hours spent on the maintenance activity This is a three digit field with one decimal point Press Enter Enter in the parts cost associated with this activity This is a five digit field with two decimal places Press Enter Enter in a descriptive value concerning the maintenance you performed This is a 35 character alphanumeric field Press Enter Use the cursor keys to return to any field to modify it Enter in the proper data Press Enter To save your changes Press Esc To modify the tool maintenance activity logged at the MIU follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F2 Tool Press F1 Histry Enter the tool number Press Enter Any codes that do not fall within the 1 100 range will be displayed with the following message Warning Code out of range press Y to add anyway any other key to abort Modify the tool history as described above To sav
159. added Adding an MIU requires that a machine name be entered Adding an AIU requires an AIU number 2 through 16 to be entered F2 Delete Press F2 Delete to delete the currently selected MIU or AIU When deleting an MIU you must first delete all jobs in the machine s schedule F3 IU F4 Copy Used to copy the configuration of an existing MIU to the screen This saves time when configuring many MIUs of the same configuration F5 CurVal Displays the current value of machine process parameters Used when setting gains and offsets Press Esc to exit F6 Update F8 PrvAIU Displays the previous AIU for current MIU Present only if MIU supports AIUs F9 NxtAIU Displays the next AIU for current MIU Present only if MIU supports AIUs F10 Remote Used to remotely calibrate MIUs Copyright 2002 MATTEC 7 48 710 0092 ProHelp Millennium 1 mrktog i INJECT 1 000 Figure 7 23 MIU Installation Screen Copyright 2002 MATTEC 7 49 710 0092 The following is an explanation of the fields on the MIU Installation screen DESCRIPTION IU Name The name entered in this field will appear as the machine number throughout the system This number is used to place all machines in alphanumeric order on the real time screen The node monitoring this machine is entered here Channel The number in this field is the ProHelp Millennium computer communication channel cable monitoring the MIU Each monitoring node can
160. ailable fields is listed below in the left to right order The order may not be changed but any item beyond the first five may be omitted Production Cycles Primary Scrap Counts 26 45 Primary Down Times To setup a template for a specific department before entering the Manual Production Entry Screen Press F4 Sysman Figure 3 1 Copyright Screen Press F8 Install Press F10 more Press F3 ManEnt The following screen will display Copyright 2002 MATTEC 4 61 710 0092 es BA Millennium es BA E A Delete Wi Figure 4 9 Manual Production Entry Template Screen In the Enable column Enter Y es or N o based on whether this information should appear in the final Manual Production Entry Screen To access the Manual Production Entry Screen feature Press F2 Job Man Figure 3 1 Copyright Screen OR Press F3 QC Man Figure 3 1 Copyright Screen Press F10 ManEnt An interactive screen is presented which permits selection of a department and field configuration Copyright 2002 MATTEC 4 62 710 0092 ProHelp Millennium Tenplate DIEE Dept BLOW Figure 4 10 Manual Production Entry Setup Screen Pressing the F1 Done key causes the user to be prompted for a e Date e Shift Tag picklist appears e Job Number hit spacebar for picklist Enter the appropriate information and the following screen will appear ProHelp Millennium Bisi x Manual Production Entry DATE SH RUN HR _ GOOD
161. al may connect to this node to access ProHelp Millennium 1 3 2 Serial Communications Board Communication between the machines MIUs and the ProHelp Millennium Host is enabled by a smart serial communications board i e RocketPort Board This board typically consists of four or eight RS 485 channels Four channels 16 MIUs per channel may be used to communicate with the MIUs maximum 64 per each node One additional serial channel is typically used to connect a phone modem for use by the MATTEC Customer Service Department Copyright 2002 MATTEC 1 12 710 0092 1 3 3 VGA Monitor and Color Graphics Board A VGA color monitor with a color graphics driver board is required for the ProHelp Millennium system Typically any monitor and driver board will work for a ProHelp Millennium Open Unix node although the ATI Ultra card is known to require additional drivers and is typically avoided You may use the Open Unix screen BLANKER to help prolong the life of the monitor but you should not use a screen saver e g spinning lines If your monitor does fail after a period of time other monitors can be used in place of the supplied monitor but should be approved by MATTEC first 1 3 4 Printer Port and Printer The ProHelp Millennium system is set up with a printer port in the Host computer The printer cable plugs into the 25 pin female connector at the back of the computer Your ProHelp Millennium system probably in
162. al number mom remedy If a space is desired use an underline symbol Machine parameter number of decimal places above maximum cause The number of decimal places specified for the SPC machine parameter is greater than 4 remedy Change the number of decimal places to a value between 0 to 4 Machine unreachable at this time cause An attempt to pull an MIU that could not be accessed remedy Try again when there is less traffic Maintenance history has been purged and or no data has been recorded cause No maintenance history exists remedy Enter maintenance data from the MIU or keyboard Maintenance schedule not found cause An attempt to obtain P M data was performed but failed because there was no schedule file for the desired date Copyright 2002 MATTEC 15 26 710 0092 remedy Have the System Manager create the schedule file Master QC control sheets do not exist cause An attempt was made to view a QC control sheet that did not exist remedy Either create a new QC control sheet or key in a valid QC control sheet number Master setup sheets do not exist cause An attempt was made to view a Setup sheet that did not exist remedy Either create a new Setup sheet or key in a valid Setup sheet number Maximum definitions have been defined Cannot save as named cause An attempt was made to add another real time screen definition after the maximum number of screens was already defined remedy Either abort the opera
163. alculated values or utilize calculated values in some form of analysis At the heart of most of these calculations are simple averages and percentages but these may be combined in fairly complex ways to produce the final numbers and they are often affected by user specified switches and limits This section defines some of the more common values presented by ProHelp Millennium in terms of the calculations behind them To help with the explanations an example is given of each calculated value and these examples use a common set of collected data and user settings Collected Data Run Time 2 00 hours Down Time 0 50 hours Production Cycles 250 Good Parts Made 850 Scrap Parts Made 150 Configuration Scrap Pred Lim 20 Cyc Tm Pred Lim 10 Job Standards Standard Scrap 10 Standard Cycle Time 30 seconds Lot Size 20000 Standard Utilization 90 Standard Setup Time 1 50 hours Standard Operators 0 5 Standard Cavities 6 Actual Cavities 4 Figure 14 1 Assumed Values for Examples Total Parts Made Good Parts Made Scrap Parts Made 1000 850 150 Actual Utilization Run Time Run Time Down Time 80 0 50 hours 2 00 0 50 Average Cycle Time Run Time Production Cycles 28 8 seconds 7200 seconds 250 cycles Cycle Time Efficiency Standard Cycle Time Average Cycle Time Copyright 2002 MATTEC 14 1 710 0092 10
164. ame To save Press Esc Reference the ProHelp Voice Install Manual 720 0055 for more details 7 10 1 Voice Option Configuration The ProHelp Voice option allows for the use of recorded voice messages in wav format to be voiced at the host using a sound card with speakers or PA system within a plant for various reasons such as down reasons help call reasons and violations of parameters limits Copyright 2002 MATTEC 7 36 710 0092 There are two parts to setting up voice configuration and using the voice option in ProHelp The first is to create the recorded messages using Microsoft s sound recorder or some program that allows for the recording of voice and save in wav format The second part is to setup ProHelp Millennium voice option configuration pages under SysMan Before voice will function properly two lines must be uncommented in the file etc rc2 d S99phm_start As root vi the file S99phm_start on line 94 and line 140 remove the from the front of the line Save the changes and then do a phm_stop phm_start To ensure the changes took effect do a ps ef grep voice There should be mat_voice and voice_srv which have been started Configuring ProHelp Voice Option To start setup Press F4 SysMan Press F2 Voice There are three places where the voice configuration must be setup Help Reasons Help F1 Down Reasons Down F2 Process Parameters Parms F3 A E E Copyright
165. an change schedule priorities The Production Control Manager should assure that job changeovers are performed as quickly as possible and that ProHelp Millennium is always up to date with the actual tool numbers and job numbers that are running on the machines Included with this is the responsibility to assure that the next tool and material are ready when the new job is ready to run The MOST IMPORTANT function that the Production Control Manager has to do is to appoint a knowledgeable person as the MATTEC System Manager The System Manager usually performs the data backup tasks and the basic system configuration tasks 1 2 5 Shop Foremen Foremen are the people who have to respond to production problems The Foremen must be able to interface with upper management Q C maintenance material control setup people and the machine operators The Foreman is one of the most active people on the ProHelp Millennium system from a monitoring standpoint This person must know every aspect of the MIU Machine Interface Unit The Foreman must know how the machine operator should use the MIU The Foreman may also be required to reschedule jobs to different machines This person must know how to interpret real time screens and react to out of tolerance conditions To summarize the Shop Foreman should have a general knowledge of the ProHelp Millennium system as a whole The more familiar the Foreman is with the MIU and View and PrdMan featur
166. an group the MIUs into classes and use the Class filter for reports schedules and real time screens NOTE The job and part descriptor displays reflect the MIU settings of rates or cycles A system wide setting of Deflt Speed Units can be reversed by an individual job or part if the machine number field specifies a different type of machine rate cycle 7 17 Configuration Summary Report The Configuration Summary Report is a report showing the current set up of the system It includes a print out of the System Manager miscellaneous screens all system names and department names all active and standby file locations all node network configurations and all MIU set up configuration information We recommend every time you change the system setup that you print out a hard copy of your configuration and store this in a safe place for future reference To generate a summary of your ProHelp Millennium installation follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F10 More Press F2 Summry Fill in the interactive screen as appropriate Press F1 Done Copyright 2002 MATTEC 7 75 710 0092 The Configuration Summary Report will be generated Copyright 2002 MATTEC 7 76 710 0092 8 Production Manager The Production Manager mode of operation allows the foreman the flexibility to change machine schedules actual cavities for a job regrind for a job and the amount of setup m
167. and single bachelor jobs may be scheduled Copyright 2002 MATTEC 4 52 710 0092 Once a family is running it is possible to end and start individual son jobs without changing the status of the family itself When a status change e g suspend end is made to the family however the change applies to all members of the family The job history maintained for son jobs is the same as that maintained for bachelor jobs The job history maintained for family jobs is a subset of this history and includes no part related data All time related data however is maintained for the family job A single set of process parameters e g standard cycle time high and low limits etc applies to an entire family On running jobs this information comes from the family job descriptor For forecasted end dates and material use and needs predictors to work correctly for the component son jobs however it is necessary that the correct cycle time standard number of cavities shot weight and part weight be entered in each component job descriptor Changes to historical data affect only the job through which the changes are made An exception to this is the fact that reallocation of downtime for the current shift affects all running component jobs regardless of the job number used in making the changes On the standard MATTEC real time screen or any custom screen that contains the machine number and job number fields a machine which is running a family job
168. and the family job is ready to be scheduled and started Family jobs are scheduled in the same manner as bachelor jobs Family jobs are also started and suspended in the same manner as bachelor jobs reference Section 4 2 and 4 5 4 6 2 Copy a Family Job To create a new family job descriptor by copying an existing family job descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Copyright 2002 MATTEC 4 55 710 0092 Press F2 JbDesc Press F4 NewJb Press F2 Family Press F4 CpyFam Enter the job number of the family to be copied Press Enter Enter the new family identifier This is a suffix of up to six characters that is added to the family job number being copied e g The family job number being copied is 5950 The new identifier entered is A The new family job number is 5950A This identifier suffix is also added to all component jobs being copied The new family will be displayed with all component son jobs and standards copied from the old family job 4 6 3 Edit an Existing Family Job Any family job that is not running on a machine may be edited Running family jobs must be suspended before they may be edited To edit an existing family job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job Enter the job number to edit Press Enter The system will display the family job descriptor for editing If an improper job nu
169. andards Except machines that are running but not within the specified Limits machines that have no job scheduled NonRun or machines that are nearing job completion LotSiz F3 Voice Each department may have a total of twenty one parameter related phrases Separate phrases may exist for each of the twenty Primary Process Parameters plus one additional for the auxiliary parameters as a group F7 Class Press F7 Class to view a particular machine class only Machine classes are assigned to each machine by the System Manager F8 Custom Press F8 Custom to view a custom made screen To return to the standard MATTEC real time screen Press F8 Custom and Press F9 Std This function provides a method to view any of the user created real time screens that have been placed in the custom menu The F10 Other menu key in this function displays a summary list of all custom screens created by the System Manager Press F9 Std to return to the standard MATTEC real time screen F9 Dept To view a particular department only Press F9 Dept and select the appropriate department To view all departments select AH To turn the department feature off and view machines in their alphanumeric order select Off With departments turned Off the real time screen is similar to that in ProHelp Release 3 2 Each MIU is assigned to a department by the System Manager F10 AutoPg Press F10 AutoPg to select automatic paging This
170. area Figure 12 4 ProSched Startup While ProSched can be used to display machine schedules for all machines in a ProHelp system it is suspected that users will find it convenient to select a sub set of machines for processing Input fields will allow selection via machine class Class Filter or machine department Department Filter If both class selection criteria and department selection criteria are entered they will be applied to the selection criteria to produce the set of machines used in the current ProSched session Selection in the Class Filter and Department Filter windows can be accessed by clicking on the arrow next to their respective sections This will activate a pop up window for selection of criteria Figure 12 5 Class Filter PopUp Make your selection and press APPLY Copyright 2002 MATTEC 12 4 710 0092 Selection Figure 12 5 Class Filter PopUp The control area of the initial ProSched dialog will contain an input field labeled Number of days to consider The value entered into this field will determine the number of days displayed in the Gantt area However ProSched will provide accurate calculations of dates for any dates in a 10 year range centered on the current date Any job whose forecast start or end date does not fall within this 10 year range will be displayed in yellow in the Gantt chart since ProSched will not know if the job is completed on time If a desired start or desired end date
171. art of scrap or downtime for the current shift or Scrap or Downtime the entire job F4 JobPar or F5 ShfPar To exit this mode Press Esc several times to return to the copyright screen 4 2 2 Standard Operator Requirements Both Part and Job Descriptors contain an Operators Required field and a Setup Persons Required field These allow entry of the standard number of operators required during normal operation and during setup for use in estimating future labor requirements The Operators Required field is also used in determining the Earned Labor Hours stored in Condensed Production Data This field contains four digits with two decimal places 4 2 3 Edit Existing Jobs To edit an existing job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Move the cursor to the data field to edit Enter the new value Press Enter Copyright 2002 MATTEC 4 24 710 0092 To save your changes Press Esc 4 2 4 Job Descriptor Summary Report The summary function allows you to generate a summary report of all job descriptors in the system This summary includes a list of all jobs scheduled to machines and those jobs that have been created and are active in the system but are not yet in a particular machine s schedule Jobs that are currently scheduled will have a Y under the SCHED colu
172. at require operator intervention for part removal and secondary operations must have a non production limit great enough to allow the recording of cycles times that vary as the result Set the non production limit to the cycle time plus 5 or 10 seconds for cycle completion before downtime is recorded Slow inefficient cycles should not be recorded as machine downtime but leaving the machine idle or stopped is true downtime The maximum non production limit is 3 276 seconds Hi Res systems allow a non production limit of 327 6 seconds Profile Enable Set to Y es to allow use of the optional profile graph storage for this job Parm Record Freq The parameter recording frequency is set to a value of 0 9999 This value tells the system how frequently to collect the process parameter data from the machine and record the data in the history files If the value is set to 1 then each cycle is collected If 5 then every 5th cycle is collected All process samples are time and date stamped A report is available that lists all sample data or these sample values may be used to generate a graph Caution Activate parameter recording only when necessary Reset the PARM RECORD FREQ to 0 to deactivate the recording of parameter history data as soon as your parameter study is complete Careless use of this feature can result in a large number of parameter history files that waste space on the disk Unneeded parameter recordings are considered a wast
173. ate of the shift to be edited Press Enter Enter the job number Press Enter Press F4 DownTm A picklist will appear Highlight the downtime reason Click OK Enter the quantity of downtime for the selected reason Press Enter Repeat this process as many times as required Negative numbers can be entered A negative number has the effect of reducing the downtime for the selected reason To edit another shift of production Press F1 ChgRec Enter the desired shift date and job number Press Enter Note The total of all downtime entries may never exceed the shift and job totals accumulated by the system A value entry greater than an acceptable total is simply ignored 5 4 Pareto Charts Downtime and Scrap Pareto charts for downtime and scrap may be generated for the present shift or for previous shifts To generate a Pareto chart for a shift follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QC Ent Press F1 Active enter the machine number of a running job OR Press F2 Prev enter the shift date and job number Press F3 Pareto A picklist will appear Highlight the type of chart Click OK The appropriate Pareto chart will be returned To print the Pareto chart Click File Select Print Copyright 2002 MATTEC 5 5 710 0092 To exit the Pareto chart Click File Select Close 5 5 Modify Hold Parts If your system was initialized by the Sys
174. aterial used for a job The standard value for cavities may not be edited nor can any other standard The Production Manager mode of operation is a small subset of the Job Manager mode of operation All functions available in the Production Manager mode of operation are also available in the Job Manager mode of operation Many times throughout the day the proper tool is not available to run even though the production control department schedules it to run The foreman must have the ability to tell the system which job is really running on the machine regardless of what the schedule says The Production Manager mode provides this capability More detailed information on scheduling and job control may be found in the Job Manager section of this manual Sections 4 6 8 1 Change Cavities of a Job To change cavities for a running job follow these steps Press F6 PrdMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the appropriate job number OR Press F2 Mach enter the appropriate machine number The job descriptor is now displayed The cursor is positioned at the cavity field Enter the new quantity of cavities Press Enter To return to the prior menu and save your changes Press Esc Note The quantity of cavities entered may not be greater than the standard number of cavities 8 2 Change Material Setup of Job To change the material setup for a running job follow these steps Press F6
175. atic data versus variable data In regression analysis the user first identifies a characteristic that is to be considered independent in the relationship A second characteristic is then chosen and is considered to be dependent in the relationship These two selected data types may then be subjected to a precise and complicated data analysis process in which it may be determined to what degree changes in the first independent characteristic affect changes in the second dependent characteristic Matching data sample points recorded during the specified start and end dates are constructed for the specified characteristics Copyright 2002 MATTEC 5 46 710 0092 Once the data sets have been collected they are then processed and a graphical display is generated showing a scatter diagram the least squares regression equation the number of points defining the relationship the Xbar and Sigma of each characteristic the Pearson product moment correlation coefficient and a measure of significance of the correlation The scatter diagram least squares regression equation correlation coefficient and correlation significance must be interpreted by the user Various statistical texts contain the background for interpretation The Statistical QUALITY CONTROL Handbook published by AT amp T Select Code 700 444 contains information on interpretation of all of the calculated values To perform linear regression analysis for a job follow these
176. ative quantity to subtract from the material used F6 DLabor Press F6 DLabor to specify the direct labor hours used if different from the hours listed by operators logging on and off the MIU Enter the actual hours and press Enter Enter a negative quantity to subtract from the direct labor hours note be sure to use the negative sign when entering a number F7 Ind Rw Press F7 Ind Rw to specify the indirect labor and rework hours used Enter the actual hours and press Enter Enter a negative quantity to subtract from the indirect labor and rework hours note be sure to use the negative sign when entering a number Some numbers will not be accepted by the system since they are in conflict with the overall values The system will redisplay the screen and ignore the prior entry To save your changes Press Esc 10 4 The Cost and Contribution Report The Cost and Contribution Report is by shift or by day All jobs run during the requested shift are listed on the report This report is a wide carriage report and requires 132 column paper Use the PgUp Pg Down right and left cursor keys to browse the report To generate the Cost and Contribution Report follow these steps Copyright 2002 MATTEC 10 4 710 0092 Press F8 CstMan Figure 3 1 Copyright Screen Press F3 Contrb Fill in the interactive screen as appropriate For picklist screen Press Spacebar Use cursor keys to move from field to field
177. become familiar with all Modes of the ProHelp Millennium system to the extent that he will be able to delegate the various duties to the appropriate people Please notice that the word delegate is used Although full responsibility for the system is often assumed by the Production Control Manager that fact does not mean that all duties should be assumed by any one person All related departments should have their representative s actively involved in the daily duties associated with the system A good starting place for the Production Control Manager would be learning to view all displays After this the Production Control Manager will see what kind of information is required by ProHelp Millennium and which reports can be generated by the system A Copyright 2002 MATTEC 1 5 710 0092 good objective is to learn how to read the real time screen and to generate production reports The Production Control Manager must know what is required for job descriptors and must establish the standards that measure production performance This person must learn how these standards are derived and what effect s they will have on the reports generated by the system The Production Control Manager should study the Quality Control Manager function to realize the effect that scrap part entry and downtime have on the integrity of the system The Production Control Manager should also study the Production Manager functions to know how the foremen c
178. ber of seconds the system waits for the machine to cycle If the machine does not cycle in that time then the machine is classified as down and downtime hours start to accumulate The value that is used here is important to the accuracy of the downtime records for the job Non production limits must be chosen carefully When a machine cycles automatically and is repetitive within 1 second then the non production limit should be set to the cycle time high limit Manual jobs that require operator intervention for part removal and secondary operations must have a non production limit great enough to allow the recording of cycles times that vary as the result Set the non production limit to the cycle time plus 5 or 10 seconds for cycle completion before downtime is recorded Slow inefficient cycles should not be recorded as machine downtime but leaving the machine idle or stopped is true downtime The maximum non productive limit for low resolution systems is 3 276 seconds or 327 6 seconds for high resolution systems These are two lines of 30 characters each that can be used to relate useful information to production personnel You may list packing instructions Q C information To display the part descriptor s machine process parameters once in the part descriptor Press F4 Disply A picklist will appear Highlight Machine Parameters Click OK This information includes the following fields Copyright 2002 MAT
179. ber that displays Good Prod the number of good parts produced on this shift When the number is actually greater than 999 999 only the last 6 digits are shown Copyright 2002 MATTEC 3 10 710 0092 Parts To Go The parts to go field is a seven digit number that displays Good Pr To Go the number of parts left to be produced for this job When the number is greater than 9 999 999 only the last 7 digits are shown This field may be enabled by the System Manager to change colors to act as an end of job warning yellow and end of job alert red Hours To Go The hours to go field displays the remaining hours left to run the job if the machine continues to cycle at the current average rate with the current average scrap percentage This field may be enabled by the System Manager to change colors to act as an end of job warning yellow and end of job alert red The actual cycle time is a real time value updated with each cycle of the machine and with each real time screen update There are three background colors Red means the cycle time is longer than the high limit White means that the cycle time is faster than the low limit Green means that the cycle time is within the limits The yield efficiency percentage is the ratio of good parts made per run hours this shift compared to the standard that should have been made This field has 3 background colors Yellow means the yield efficiency is less than the low limit White means the yi
180. causes machines to be displayed on the screen for approximately 10 seconds then automatically displays the next set of machines for the same amount of time This action continues until F10 is pressed again or until the RealTm function is stopped When you select F10 AutoPg the function key menu selection changes to F10 SnglPg Single Paging to indicate that if you Press F10 again you will stop automatic paging and select the single page display Copyright 2002 MATTEC 3 6 710 0092 The filters available for viewing under F1 Filter are further described below F1 FILTER DESCRIPTION This function is the heart of most monitoring activities because it provides an overview of every machine The Production Control Manager and others use this screen to evaluate the overall performance of the plant Personnel must respond to red situations and recognize that red flags indicate lost time and money Through prudent responses to correct the reds productivity increases The plant must be managed to keep the All screen as green as possible Complacent attitudes toward reds always result in lost productivity This function displays only those machines which have called for help from the MIU The help call reason is shown in the right hand column of the display This screen is useful to foremen and dispatchers to locate and expedite personnel to needy machines Only the last call for help reason from an MIU is shown Help call
181. cess parameters The original Mattec MIUs provided 13 process parameters including cycle time and this is the basis for the layout of this screen area portion Some newer model MIUs 10X and TS MIUs allow the number of process parameters to be increased by adding AIUs AIUs are similar to MIUs with the distinction that they do not communicate directly to the host computer but to an MIU that communicates to the host computer In terms of process parameters AIUs are virtually identical to MIUs and they are configured in an identical manner The process parameters of each AIU are displayed in the same area and with the same layout of the parameters of the primary MIU Digital signals may be assigned a unique number from 1 to 3 inclusive to identify auxiliary counters These can be located under the heading Cour A zero indicates an unused count Assigning a digital signal to an auxiliary counter does not require that it also be assigned a non zero process parameter number More flexible formatting is supported by a decimal point DP and sign SN field on each parameter However for the derived analog signals and the timers these fields are only valid when the values are supplied by a PLC When the MIU AIU configuration screen is displayed additional function key selections are offered FUNCTION KEY DESCRIPTION F1 Add Press F1 Add to create a new MIU AIU If the current MIU supports AIUs you will be prompted to chose which is being
182. cess the Select Down Time Reason screen Press F1 View Figure 3 1 Copyright Screen Press F8 MchDTm ProHelp Millennium OE x Select down time reason Figure 7 3 Select Down Time Screen To access the Select choices ProHelp Millennium iol x Press F2 Select Items SC WAIT MAT MACHINE MOLD The following picklist will display QUALITY MOLD SET UNSCHED i ji 8 r NO OPER This picklist consists of pre determined Down 9 down reasons as well as undetermined down reasons OK Cancel Help 7 4 Set Shift Configuration and System Exception Periods Shift configuration is important in providing time divisions for the recording of history Production and SPC data are stored to a job number according to the shift tag and date Copyright 2002 MATTEC 7 5 710 0092 ProHelp Millennium has the ability to set unique shift schedules for each department defined by the system The shift schedule describes a repeating arrangement of shifts which identify how long the shift is how often it repeats and whether work is normally planned for that shift Each department can support 4 unique shift numbers per day Shift numbers have a maximum repeat factor of 112 shifts ProHelp Millennium also offers users the ability to schedule 20 exception periods to the weekly shift array for three areas of the system Exceptions may be scheduled for the plant each department and each machine Non working periods for the plan
183. chedule remedy Suspend or end the job if appropriate The job may then be deleted from the schedule Cannot force end to non suspended job cause An attempt was made to end a job whose status is PENDING The system only allows End operations on jobs which are RUNNING or SUSPENDED remedy Verify the entered job number and its status Cannot generate report sample size is one cause An attempt was made to make a report with an insufficient amount of data remedy Wait until another sample is taken Copyright 2002 MATTEC 15 4 710 0092 Cannot operate on individual family member cause A start job function was attempted specifying a member son of a family job remedy Start job operations are permitted only on the family job itself or on single jobs If you really intended to start or stop the family then retry the operation using the number of the family job itself If you really do want to start the individual member then you must first remove it from the family or perform a Next Job function Cannot produce Pareto chart for P attribute data cause An attempt was made to view a Pareto chart for P attribute data remedy Pareto charts are only valid for U attribute data types Cannot re activate non completed job cause An attempt was made to suspend a job whose status is PENDING The system only allows Suspend operations on jobs which are RUNNING or COMPLETE remedy Verify the entered job number and
184. chine A dual cycle time job must have a minimum of two sons specified and the maximum active sons must equal two When viewed on the real time screen a dual cycle time father job will not show an actual cycle time The first son job will display the actual cycle time The second son job will display the value of Pulse 2 Signal 3 This value is for display purposes only and is not used in calculations Although two cycle times are actually shown all part counts and downtime are driven by the standard actual cycle time only Scrap entry and next son job functions are permitted For display purposes all odd numbered son jobs Figure 4 8 Family Job Descriptor as specified in the father job display the actual cycle time All even numbered son jobs as specified in the father job display the value of Pulse 2 Signal 3 as their cycle time 4 7 Operator Tracking Two types of operator histories are maintained an operator efficiency history and an operator tracking history In order for either type of history to be recorded operators must login and logout at the MIU by entering a unique identifying number Copyright 2002 MATTEC 4 57 710 0092 Efficiency history is kept for up to five operators per machine There is no per machine limit on the number of operators for which tracking history may be kept An efficiency report and a tracking report are available The efficiency report shows who logged in and how many parts they made Avera
185. cified a job number containing an invalid character or a job number that does not exist remedy Change the job number to remove the invalid character A job number may contain only alphabetic characters numeric digits or the special characters underline or period Invalid length for this item cause An invalid length was entered for an item on the real time display generator remedy Validate the length and reenter Invalid machine cause The machine number entered does not exist remedy Verify and reenter the machine number Invalid machine name cause The machine name entered does not exist or is invalid remedy Enter a valid machine name Invalid machine number cause An invalid machine number was entered remedy Enter in a valid machine number Invalid maximum simultaneous sons cause An attempt was made to run more than 10 sons from one family job remedy Change the maximum simultaneous sons to be less than or equal to 10 Copyright 2002 MATTEC 15 21 710 0092 Invalid Operating System release cause The Operating System release is not the one required to run ProHelp Millennium remedy Contact MATTEC for assistance Invalid record type cause An incorrect record type was entered while using the report generator remedy Enter in a valid record type the choices are DR GR T1 T2 T9 Invalid shift identifier Must be 1 2 and 3 in any sequence cause An invalid shift number was entered Valid values
186. cludes an Epson compatible printer which is connected to the Host This printer is intended to be used to print reports and summaries or do a Print Screen at any time throughout ProHelp Millennium Due to the variety of printers available for use with ProHelp Millennium MATTEC provides you with a user manual with each printer You should familiarize yourself with ribbon and paper replacement and general operation and care of the unit MATTEC supports Epson compatible parallel printers HP LaserJet printers most PostScript printers and the HP DeskJet 1200C color printer 1 3 5 Disk Drive and Controller Board The ProHelp Millennium system requires that the primary node include a 3 5 floppy disk drive a hard disk drive and a tape drive Normal configuration for the central computer is a minimum 540 MB hard disk Care should be exercised to help prevent problems with the disk drive units The floppy drive should be cleaned periodically with a floppy disk cleaning kit Once every six months is a general guideline but if the Host is located in an environment with a lot of dirt or smoke you may have to clean the floppy drive more often If you are not familiar with the different kits available or how to use them call MATTEC or your local computer supply store for assistance The hard drive requires no routine maintenance however there is a word of caution about this unit It is very susceptible to damage which can be caused by rough o
187. creen Press F8 Instal Press F2 MIU Press F1 Add The following message will appear Select IU type to create A picklist will appear Highlight the choice Press OK The following message will appear Enter the AIU number 2 16 Make your selection Press OK Copyright 2002 MATTEC 7 57 710 0092 NOTE You cannot use imbedded spaces in an IU name If a space is required in your oo 99 naming convention use the underline __ character or a period Fill in the fields on the MIU installation screen as required To save your changes Press Esc You must reboot all nodes on the ProHelp Millennium Network for your changes to take effect To delete an MIU or AIU follow these steps Delete all jobs from the machine s schedule then Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU Select the MIU you wish to delete Press F2 Delete To delete the MIU Enter Y es You must reboot all nodes on the ProHelp Millennium Network for your changes to take effect 7 12 4 PLC Configuration Machine Interface Units MIU and Auxiliary Interface Units AIU may be equipped with optional hardware and software that allows the ProHelp Millennium system to read values of selected machine processes directly from the Programmable Logic Controller PLC that is controlling the machine Values read from the PLC are subject to the same type of monitoring an
188. cuetasens 1 8 12 8 Machine Operators eene Ae 1 8 1 2 9 Quality Control Klestadt EE 1 9 1 22 10 Maintenance Ee 1 10 V2 1 System Manager sien geridde E Ea 1 11 L3 System CG OmpPONe Eeer 1 12 1 31 Ve 1 12 1 3 2 Serial Communications ET 1 12 1 3 3 VGA Monitor and Color Graphics Board 1 13 134 Ee POP and Prnter sasien Es 1 13 1 3 5 Disk Drive and Controller Eemere deed Eege due 1 13 1 3 6 Machine Interface Unit OMIU 1 14 1 3 7 Auxiliary Interface Unit AIO s2 ccccgs ccssvesade cassaccsucsedsactsusadevestecats nastdecsantiadnaesdanns 1 17 2 General ere E EE 2 1 Del POWer CIE REECH eet EE dE 2 2 2 2 Ma Server and X Terminal EE 2 3 23 gt Mouse SUpport ane serieen eaoin rai E AERE aA A EEA O E N R 2 3 edt Real Time SOT EE 2 4 2 3 2 Eelere EE 2 7 DA RANE SOR Ae IS SY IAD EE 2 7 3 View Mode ssi casvids dic cavusica vi e Ze0eEN eet dE ASSA EEN anne 3 1 SN D TEE 3 1 3 2 View Mode Men Selections EE 3 3 3 34 Real Time Displays EE 3 4 NOnR N TEE 3 8 Socks Real E a e E E nde Rene a E OS 3 8 3 3 2 Standard MATTEC Real KEE 3 10 3 3 3 View Custom EE 3 13 3 3 4 Elapsed Downtime RESEC j2cc 5ciecssescadanads sccssnasaaes edd dei EE Edge dE ENEE 3 13 33 3 Real Time PM Notification oseere e e a E TRR 3 13 SAL Job DESCriptOt Sa eene tie esteso Eu eegent 3 14 Copyright 2002 MATTEC i 710 0092 34T ER KEE 3 15 3 4 1 1 Machine Signal leger ee eege 3 16 3 4 2 Job Downtime and Scrap sicicascngicccsseassdsvass saccisnt
189. curred on system power up in initializing the ACU dual port memory remedy Contact MATTEC for assistance Asynchronous Communications Unit INSUFFICIENT RAM cause An error has occurred on system power up in initializing the ACU dual port memory remedy Contact MATTEC for assistance Asynchronous Communications Unit not responding cause An error has occurred on system power up in initializing the ACU board remedy Contact MATTEC for assistance Asynchronous Communications Unit not responding to mount command cause An error has occurred on system power up in initializing the ACU board This normally indicated a hardware failure remedy Contact MATTEC for assistance Copyright 2002 MATTEC 15 3 710 0092 Attribute names have not been specified cause An attempt was made to escape out of the attribute SPC setup screen without specifying names for attribute data remedy Specify at least one name for an attribute before trying to leave this screen Attributes are not enabled cause An attempt was made to collect an SPC attribute sample when the attribute sampling option was not activated remedy Activate the attribute sampling option in the job descriptor Cannot chart sample size is one cause An attempt was made to make a chart with an insufficient amount of data to plot points remedy Wait until another sample is taken Cannot delete running job cause An attempt was made to delete a running job from a s
190. cycle time efficiency standard is always 100 In the minds of truly productive people nothing else makes sense There may be moments when it is required to run a machine at less than 100 of standard cycle but this cannot be the norm Running the machine faster than standard may be good increased productivity but it may also be bad scrap The standard set by engineering is always the best for the part This value shows you the bottom line of profit or loss At any time during or after the job run this value displays the overall job success Included in the calculations are cycle time actual parts cycle and scrap Just as in CYC TIME EFF the standard is always 100 Yield efficiency is the ratio of good parts made per run time versus the standard for the good parts that should have been made per the actual Each machine produces a number of parts each cycle In ProHelp Millennium that number is shown by the CAVITIES field The cavities standard value is set when the part is created The number of standard hours to allow for machine setup of this part The number of operators required during setup This field contains four digits with two decimal places The standard number of operators required during normal operation This is used in estimating future labor requirements and in determining the Earned Labor Hours stored in Condensed Production Data This field contains four digits with two decimal places Scrap percentage is used to fac
191. d SPC sampling that are applied to discrete sensors in a regular MIU To accomplish this several conditions must be met e The PLC must have communications capability or be able to be retrofitted with this capacity e The interface must be developed and supported by MATTEC or be contracted to be developed Contact MATTEC for the current list of interfaces or for information on developing new interfaces e The MATTEC MIU can collect only those machine parameters that the PLC manufacturer makes available for reading This list of parameters varies from manufacturer to manufacturer so check to be sure values you wish to monitor are available for reading Copyright 2002 MATTEC 7 58 710 0092 NOTE The list of supported PLC interfaces is always growing Please contact MATTEC for the current supported PLC interfaces To configure an MIU with a PLC interface follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU Use the IU key or PgUp or PgDn keys to position to the desired MIU To display the PLC choices go to PLC field Press spacebar Use the arrow keys to make a selection Press Enter After you select the PLC type the F7 PLC key will appear ProHelp Millennium Supported Programmable Logic Controller Interfaces e Moog Mopac 22 e Cincinnati Milacron CAMAC XTA XTC VLC VEL e Klockner FMT e Barber Coleman MACO 8000 e Engel EC88 CC90 e Van Dorn CRTC e Siemens
192. d color on the yield fields to turn red Yld High Lim The value entered here is the high limit the system uses to determine color changes on all real time Yield Efficiency fields A value above this limit causes the background color or the yield fields to turn white EOJ Warning End of Job Warning is enabled by entering a time in minutes in this field When the run time of a job is less than the time entered here the Parts To Go and Hours To Go fields on all real time screens will turn yellow The jobs with run times falling within this limit will also appear on the Lot Size exception screen A value of 999 turns off this feature EOJ Alert End of Job Alert is enabled by entering a time in minutes in this field When the run time of a job is less than this value the Parts To Go and Hours To Go fields on all real time screens will turn red End of Job Alert is active only if the End of Job Warning is also enabled Jobs with run times falling within this limit will also appear on the Lot Size exception screen A value of 999 turns off this feature MIU Password Enter a NUMERIC value to use as a password to gain access to protected areas of the system for all MIU s Reference the MJU Operator s Manual for additional information Copy SPC Set to Y es to allow SPC Enable fields in the part descriptor to be Enables copied to the job descriptor PM Warning This value is in minutes and is similar to the EO
193. dard piece weight should be considered in this selection as the number of decimal places selected reduces the number of whole numbers in the weight selection Default Cyc Res Cycle time is measured to a maximum of 5 digits This is the default cycle time resolution used in job and part descriptors until a machine number is specified Each machine can specify its own cycle time resolution 0 1 Sec One decimal place will be displayed in the cycle time standards The maximum allowable entry is 3276 0 sec 54 6 minutes 0 01 Sec Two decimal places will be displayed in the cycle time standards The maximum allowable entry is 327 60 sec 5 46 minutes per cycle Scrap Resolution 0 Dec PI standard scrap is displayed with no decimal places The maximum scrap value that may be displayed is 99 1 Dec Pl displays the scrap with one decimal place The maximum scrap value that may be displayed is 99 9 SPC DIN Table This specifies whether you will use the SPC table of constants that is standard in some European countries Copyright 2002 MATTEC 7 41 710 0092 FIELD Y es cost calculations use Run Time Downtime N o cost calculations use Run Time Setup Time This feature is used to turn on or off the keypads on the system s MIUs This is universal throughout the system MIUs may not have the keypads disabled on an individual basis MIU Cav Enab Allows the operator to change the number of ACTUAL CAV
194. davecaanes 7 28 7 7 2 Allocate Custom Screen Names to Function Keys 7 29 7 1 3 Set the Real Time Default Displayivncityeiegseds ehesagucs tes saeseeaalers ani aeiasee osama 7 29 7 8 Preventative Maintenance ee 7 30 7 9 _ Master Set p Sheets seccssccxscastacacdesdan i deed EEN oaavad exdegsaceh cuanas Sedeodauvemmeealinn 7 30 LLI Create EE e SE 7 31 7 9 2 Insert an Image File into the Setup Sheets ic sccsccasccsesdercddesccdavastaecbaconateaeedeeanunsedacns 7 33 7 9 3 Delete an Image File from a Setup Sheet EE 7 33 7 9 4 Delete Master Setup Sheets vivccciscsissccversscavsscissiva says avedsasossaeeessaveausdavsvaceesdagedenssdeaaeee 7 33 Dales BETINE SEUAD EE 7 34 AAO MOISE COMO EE 7 35 7 10 1 Voice eege 7 36 7 11 Miscellaneous Installation Parameters cecscceesceceseeeceecceceeeeeceeeeeceeeecseeeeeneeeenaeees 7 39 ZE MIVAIU Installation Parameters ergeet deer 7 47 TAZA Signal TYPES CS OULCES sise tiie e ge ates ies egal Eet 7 54 7 12 2 Parameter Types Primary and Auxiliary ccscceseccessceeenteeceesscecenseccetteceessees 7 56 7A23 Create Delete an MIU ATU xna nininini iinitan 7 57 TAZA SPCC Ono atl Oc ce tae eal a alee ae a ca dando eae dea es 7 58 7 12 5 Remote Analog Calibration Mode 7 60 SE E Terre 7 61 TAD Language TEE 7 62 Pol el cht okee ees 7 62 7 13 2 Copy a Language to User Dene pcxissegtoeeduccssacsdercdavontsceadeaybessaveshesnahasdensecsquadterets 7 64 7 13 3 Switching e RE 7 65 TAA SELSYSCEM
195. ding months into the future Day or shift based reports for the next one or two weeks could reveal overloads with enough time to respond For future requirements in text form all combinations of Value Interval and Detail are feasible even though the practical value of certain combinations may not be immediately obvious This is not the case with charts As previously described it is possible to request the requirements for a specific material or tool for each machine for each interval of a specified time period however showing this on a chart is not reasonable It is clearly desirable to show the required amount of the selected Value on one of a charts two dimensions That leaves up to three candidates interval machine individual for the remaining dimension Figure 3 42 shows how that second chart dimension is selected N N Interval invalid for Individual Individual Machine invalid for Pace est Pe e Aen EU Aer ect Interval invalid for Seen See Machine invalid for Material Material Y Y mengt Interval Interval Machine Figure 3 42 Second Requirements Chart Dimension The reason certain combinations are marked invalid for material is that combining Auxiliary material quantities which may be in units such as boxes with other material quantities is not practical These selections are permitted with either Primary or Additive specified as a Material filter Even though this can lead to the combining of vastly differe
196. displays the preventive maintenance schedule for all of the tool code numbers One entry is made per each code number The cursor is shown highlighting a field Use the cursor keys to move the cursor to the proper field to be changed The field for cycles is nine digits Enter the new schedule for cycles Press Enter Continue to move the cursor to the fields to be changed To modify the schedule for another tool Press F1 Tool Enter in the new number Press Enter To save your changes when you are complete Press Esc The schedule definition for each maintenance operation may contain a standard elapsed time value This field is for reference only and appears in no reports or other displays Three function keys are added to the Tool Maintenance Schedule function NxtTol moves to the next tool in alphanumeric sequence for which a schedule exists moves to the previous schedule deletes the schedule for the currently displayed tool In addition the identifier of the first tool with a maintenance schedule is displayed on entry to the function so that schedules can be maintained without knowledge of every tool identifier The Cycles to PM column on the schedule report may now show negative numbers for overdue items There is no attempt to determine exactly when the item became overdue but the negative cycle count does give an indication of how late the maintenance is Press F7 MntMan Figure 3 1 Copyright Screen
197. ds White means the value is above the standards Green means the value is within the standard limits Copyright 2002 MATTEC 4 11 710 0092 FIELD DESCRIPTION Cycle Time The display of a cycle time or rate is normally 4 digits to the left of the decimal place and 1 digit to the right This supports monitoring of machines that cycle in 0 2 seconds or greater up to 3276 0 seconds or approximately 54 6 minutes Another mode of display known as Hi Res Mode is available for the system High resolution effectively shifts the decimal place to the left resulting in 3 digits to the left and 2 digits to the right of the decimal place In Hi Res mode the monitoring range is 0 02 seconds to 327 60 seconds or 5 46 minutes The mode of the system is configured by the System Manager and may vary for each MIU The cycle time standard is entered on the job when created The SHIFT and JOB average values are calculated in real time using Cycle Time Shift Cycle Time Shift Run Hours Shift Machine Cycles Shift Cycle Time Job Cycle Time Job Run Hours Job Machine Cycles Job Cycle Time Efficiency The cycle time efficiency standard is always 100 In the minds of truly productive people nothing else makes sense There may be moments when it is required to run a machine at less than 100 of standard cycle but this cannot be the norm Running the machine faster than standard may be good increased productivity but it may also be bad scrap Th
198. ds max size of 8 characters cause More than 8 characters were entered as a DOS filename remedy Enter a valid DOS filename and retry the procedure Copyright 2002 MATTEC 15 8 710 0092 Download aborted no data cause The download option was halted because the requested downloading file contains no data remedy Check the download file for data Duplicate data cause A record already exists which corresponds to the data you are trying to enter remedy Alter the existing data or enter different data Duplicate IU name cause An attempt was made to use a previously defined interface unit name remedy Choose another suitable IU name or delete the existing name End date precedes start date dates out of sequence or dates overlap cause Start date and end date do not fall in chronological order remedy Enter a valid date range and retry the operation Error actual number of cavities greater than standard cause An attempt was made to change the current number of cavities to a number that was greater than the standard remedy A valid choice for cavities is equal to the standard or less than the standard Error Actual number of cavities is zero must be non zero cause While establishing job parameters the cavity field was left equal to zero remedy The cavity field must be filled with a number other than zero Error attempt to add family job as member of family cause An attempt was made to enter the fath
199. e An attempt was made to generate a job cost report for a father job Copyright 2002 MATTEC 15 18 710 0092 remedy Generate reports for the individual sons of the requested job First character of DOS file name root must be nonblank cause The first character of the root name entered is blank remedy Correct the root name to have an alphanumeric first character Function Aborted cause The function currently being executed at the console or terminal could not complete normally remedy Reactivate the function if necessary The most common cause for this message is a job or shift change occurring while a job descriptor for a running job is being edited When this happens the system simply aborts the edit function in order to safely modify the descriptor Help log has been reset and or no data has been recorded cause No help log data is present in the system remedy Wait until MIU operators have made help requests Help log in use please try again later cause An MIU operator has just made a help request remedy Have the user release the help log or try the request at a later time HIGH boundary must be greater than LOW boundary cause An attempt was made to enter in a high boundary that was lower than the low boundary remedy Enter a value for high boundary that is greater than the value for low boundary Incorrect length for machine number cause A machine number with too many characters was entered remedy
200. e The RSU s address the same way as MIU s F2 Delete Manipulates the RSU Active status F3 Summry You may summarize the RSU Configurations for print or browse F10 Status You may display the active communications status of all units To define the RSU set the RSU Active field to Y es Enter the machine names for the 10 machines that correspond to the 10 positions on the rotary switch The same name should be repeated in all 10 positions for units that are assigned to single machines A repetitive pattern should be used for locations that assign less than 10 machines Note that positions that are left blank will display a blank on the RSU s and act as a do nothing position Figure 7 2 RSU Configuration Screen shows the machine name locations as they correspond to the RSU s rotary switch Note that each machine name is limited to 6 characters and must match a previously defined MIU name machine number An error message will be displayed upon leaving the RSU configuration if an invalid name is entered ProHelp Millennium Iof x Figure 7 2 RSU Configuration Screen To save your changes Copyright 2002 MATTEC 7 4 710 0092 Press Esc 7 3 Remote from MIU Down Reason Selection If supported by the MIU a machine s down time reason may be selected from a computer console Both Job Manager and Production Manager have access to this function This is available with 10X and 5XS MIUs and the PCMIU To ac
201. e if you used the cpio copy utility described in Section 6 1 to the hard disk directory usr prohelp mat_backup follow these steps Open an xterminal by Click Terminal icon on the desktop Enter the following to copy the backup data on the tape to the hard disk cd usr prohelp mat_backup cpio icBdumlv I dev rmt cOsOr Where dev rmt cOsOr is the actual device name of the tape drive as described in System Device Names To restore backup data on the hard disk into ProHelp Millennium follow these steps Open an xterminal window by clicking on the Terminal icon on the desktop Enter the following to restore the backup data Copyright 2002 MATTEC 6 17 710 0092 phm_stop phm_start2 mrestore Directory Name You must specify the proper directory name that the backup was copied to on the hard disk For simplicity the directory usr prohelp mat_backup has been created for you to copy the backup to the hard disk To begin the restore Press F1 Done You must contact the MATTEC Customer Service Department for assistance and guidance BEFORE beginning this procedure After the restore you must restart ProHelp Millennium To do this follow these steps Open an xterminal window by Click Terminal icon on the desktop Enter the following to restore the backup data phm_stop phm_start 6 10 Edit Shift Production Data ProHelp Millennium provides direct access to shift history data files and provides t
202. e standard set by engineering is always the best for the machine and the job The calculations for SHIFT and JOB are Cycle Time Efficiency Shift Cycle Time Standard Cycle Time Shift Cycle Time Efficiency Job Cycle Time Standard Cycle Time Job Yield Efficiency This value shows you the bottom line of profit or loss At any time during or after the job run this value displays the overall job success Included in the calculations are cycle time actual parts cycle and scrap Just as in CYC TIME EFF the standard is always 100 Yield efficiency is the ratio of good parts made per run time versus the standard for the good parts that should have been made per the actual run time Each machine produces a number of parts each cycle In ProHelp Millennium that number is shown by the CAVITIES field The cavities standard value is set when the job is created The job s cavities value can be modified throughout the job run to reflect the true number of parts being made each cycle The actual cavity value may be changed at the MIU or from the computer in the Job Manager or Production Manager modes Note The accuracy of the parts made count is only as accurate as the value of the cavities field throughout the job run Make sure it is correct all the time The number of hours to allow for setup of this job or machine Actual values are collected and displayed when the MIU is set in the setup mode Copyright 2002 MATTEC 4
203. e 4 Parameter 1 Analog 1 Parameter 2 Analog 2 Parameter 3 Analog 3 Parameter 4 Analog 4 Parameter 5 Analog 5 Parameter 6 Analog 6 Parameter 7 Analog 7 Parameter 8 Analog 8 The MACHINE PARAMETER flags on the real time screen are overwritten with a brown downtime status message when the machine stops cycling The downtime reason text and the accumulated time for this occurrence are displayed on a yellow background Downtime reasons are defined by the System Manager for each department A Machine Down Log is available The following are typical downtime reasons 1 Unknown 2 Idle 11 thru 20 For 3 Machine Problem Extended 4 Tool Problem 5 Wait Material 6 Wait Supervisor 7 Wait Q C 8 Wait Operator 9 Miscellaneous 10 Setup 3 12 710 0092 The MACHINE PARAMETER flags are overlaid with the help call reason when viewing the F1 Help real time screen The real time screen is one of the most powerful tools in the ProHelp Millennium system and when used properly always results in productivity improvements Green is good Think green 3 3 3 View Custom Made Screens Customized real time screens may be created by the System Manager and the Job Manager Refer to Sections 7 6 and 7 7 for additional information To view any custom real time screen follow these steps Press F1 View Figure 3 1 Copyright Screen Press F1 RealTm Press F8 Custom To select a custom
204. e EAEEAERE Edge 9 4 Figure 9 3 Machine Maintenance Schedule gi oceeigenisee Santee pecaieeech he DA aged eed gece Bee 9 5 Figure 9 4 Preventive Maintenance Screen eeneg denge 9 6 Figure 9 5 Tool Maintenance Eelere dees aS 9 8 Copyright 2002 MATTEC ili 710 0092 Figure 9 6 Machine Maintenance History Ee 9 9 Figure 9 7 Maintenance History Report GE 9 15 Figure 9 8 Preventive Maintenance Due Report 9 16 Figure 10 1 Job Cost Standards EE 10 2 Figure 10 2 Cost Manager Job Descriptor Screen 10 3 Figure 11 1 Manual Production Entry Template Screen e cc eeecceeeseeeeeeeeeseeecseeeecseeecsteeeenaeers 11 2 Figure 11 2 Manual Production Entry Setup Screen eee ceessceesseceeseceeseeeenaeeeenaeeeenaeeeaees 11 3 Figure 11 3 Manual Entry Production Screen 00 0 eesecsseceseeeseeesscesseeseeeesaeecsaeceseesseecaeenseensees 11 3 Figure 12 1 Copyright Screen sanscacaadancsasadeeedeeay e Eae E T A mesma tees 12 2 Figure 12 2 Production Manager Screen 2043426 eG ae As a es 12 3 ert UE EE 12 3 Pipure 124 ProSched Ee EE 12 4 Figure 1225 Class Filter POpU Poi hesr geess clan edu i ae acii rae rikas 12 5 Fig re 12 6 e RE EE 12 6 Fipure 12 7 ProSched Main Screen xcs as jetta eased Edge 12 7 Figur 12 8 Menu Bat a acts ea ch ee ean ae ese ice lala 12 8 te He Pile Pele Oy te ste cnc Sat ten face a acne ce te et Mot nes Adie ck eh ee ees iii dace et 12 8 Figure 12 10 Commit Results eeneg erageet 12 9 Figure 12 1 e E 12 10 Figure 12 1
205. e Manager is the person who seems to end up with the responsibility for repair and maintenance of any equipment that makes its way into the plant With the acquisition of the ProHelp Millennium system this person will probably be called upon to help troubleshoot many problems associated with this new system With that in mind it can be very beneficial for the maintenance group to study the entire section on system components Section 1 3 Learn about each component in the system and how it operates Also be aware of the warranty periods and the procedures for getting warranty work performed on the various hardware components Exercise caution when attempting to solve reported problems so as to not destroy any production data The responsibilities of the Maintenance Manager are 1 Train the maintenance person to log the maintenance activity at the MIU This will allow ProHelp Millennium to track who did what and when they did it 2 Review weekly the P M schedule to determine if tools or machines are due for preventive maintenance work 3 Login details of maintenance activities via the PC 4 Learn what the purple code means on the real time screen If there is a constant purple on any MIU contact the MATTEC Customer Service Department for guidance and if necessary arrange to send the MIU to MATTEC for repair Copyright 2002 MATTEC 1 10 710 0092 If the system computer or MIUs fail think about the actions that made them fail
206. e Pareto E 5 46 Figure 5 17 Linear Regression Analysis eseeeeeeseeseesesssesressessrestessesstsstestesseesrestreeseeseeseeeseeseee 5 48 Figur 5 18 U e E 5 50 Figure 5 19 Composite SPC Report Screen TEE 5 52 Preure 5 2 OMI Setup E 5 57 Copyright 2002 MATTEC li 710 0092 art e 6 6 at RN ONE 6 7 Figure 6 3 File Backup 0jc 2iteaint ended netted idee 6 10 eege 6 4 Backup bog Report huge heat Giulia iota ee aes 6 12 Figure 6 5 Automatic Archive Purge and Backup Commande 6 13 Figure 6 6 Automatic Archive Purge and Backup Option 6 14 Figure 7 1 User Configuration Screen si s sciscescsssdsessaccestatvencacednceceus seavsanisducnevadeoccduasessubecasndcceuaseases 7 2 Fig r 7 2 RSU Configuration Screen ee Bae ed ee Re ea ace Bes 7 4 Figure 7 4 Select Down Time Screen EE 7 5 Figure 7 4 Shift EE 10a Gah a ee ee REG ei ee GSS ie 7 6 Figure 7 5 Shift Config ratioN sino snusen EES Zeta 7 8 Figure 7 6 Shitt Confira on scat eae Ea AE a E Eai E E RS e 7 8 Figure 7 7 Plant Ee 7 9 Figure 7 8 Shift Configuration Screen eege ege eege egene geg 7 12 Figure 7 9 Shift Breaks Interactive Screen eeseseeeeeseereeressersresressersresresstessestesreeseesesreesreseee 7 13 Figure 7 10 Miscellaneous Option reen deed deg 7 14 Figure 7 11 Department Configuration Screen eeesseeseeseesersresreesersesresreesessresreeseesesreeseseee 7 17 Figure 7 12 Real Time Screen Template for Std MATTEC Sereen A 7 19 POURS EE Gid Layout Sereen EE
207. e SPC setup for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK The SPC SQC Basic setup screen will be displayed The following selections are then available FUNCTION KEY DESCRIPTION to modify number of a running job Family to select another member of the current family job Allows you to enable automatic manual variable and attribute data sampling Reference Section 5 6 1 for additional information Copyright 2002 MATTEC 5 10 710 0092 F6 ProLim Allows for modification of automatic and manual process parameter control and specification limits Reference Section 5 6 2 for additional information F7 ProEna Allows for modification of which process parameters automatic and manual are collected alarm conditions and part qualification conditions Reference Sections Error Reference source not found and 5 9 for additional information Allows for modification of variable control and specification limits Reference Section 5 6 4 for additional information Allows for modification of the alarm conditions for SQC variable data Reference Section 5 6 5 for additional information Allows for modification of attribute related SPC fields Reference Section 5 6 6 for additional information
208. e copyright screen you are asked to select your user name Select your name and Press Enter You are then asked to enter your password Type it in and Press Enter Any character entered will be echoed on the screen as a small x The password SAM will echo Password xxx as it is being entered When all characters of the password have been input Press Enter If the password is 8 characters long the system will not require the Enter During password entry the only key that is not considered a character is the Enter key This means that you may not backspace over typing errors Function Keys The F1 through F10 keys on the keyboard are function keys When any one of these keys is pressed the mode associated with the key as shown on the bottom line of the display is activated Enter Key This is the large double size key on the right side of the keyboard An or the word Enter is usually printed on the key Enter must be pressed every time a new data Copyright 2002 MATTEC 2 8 710 0092 value is being stored or an old value is being edited Function keys do not require the use of Enter Delete Key Control Break in DOS The Delete key usually has the same effect that the Control Break key has in DOS it causes an immediate and abrupt end to the current program that is being executed The use of this key should be avoided and used as a last resort Positioning Much of the data displayed by Pro
209. e current session of ProSched The graphical presentation shall resemble the current Gantt chart feature of ProHelp Millennium In addition the user will be able to drag graphical representations of any job not actually running on a machine at the time ProSched started and drop it into any position except the position occupied by a running job on any of the machines displayed Further the user may request that the changes made to the Gantt chart be committed to the current running ProHelp environment 12 1 Installation Due to this module s intense use of graphics it is recommended that a Super VGA monitor and card be used with this module 12 2 Main Menu Items From the Copyright screen Figure 3 1 Copyright Screen there are three ways to start ProSched You will want to carefully consider your options before proceeding As you can see the first choice of each option determines the outcome Items two and three in each option are the same OPTION 1 Press F1 View Press F3 Sched Press F4 ProSch With Option 1 you a cannot commit new schedule b cannot modify jobs c cannot create new jobs OPTION 2 Press F2 Jobman Press F3 Sched Press F4 ProSch Copyright 2002 MATTEC 12 1 710 0092 With Option 2 you have full functionality of all features OPTION 3 Press F6 PrdMan Press F3 Sched Press F4 ProSch With Option 3 you a can only modify cavities in Modify Job b cannot create new jobs Press F1
210. e cursor to the location for the first machine on the layout Press F1 Insert Enter the machine number for this location Press Enter Position the cursor to another location Press F1 Insert Enter the machine number Continue the sequence of positioning the cursor to the desired location and enter as many machine blocks as desired for this display ProHelp Millennium Of x Row 13 Column 40 Real Time Grid Definition H 01 l IMach Damm ICycle Time Sr Icycle Time cul IPulse 1 Data Wiear g Figure 7 13 Grid Layout Screen When finished creating the layout Press Esc The real time display design screen is shown You must now save the new grid format Press F3 Files Press F1 Save Copyright 2002 MATTEC 7 24 710 0092 Enter the display name by which this new grid pattern and data is to be stored Press Enter This name may be a new name or it may be the same name as the real time display file If a grid is defined for a real time display then the grid is always used when the display is requested to be viewed If it is desired to see the custom display in both the detailed numeric format and is also desired to see a graphic display of the plant layout grid then two separate files must be saved One with a grid definition provided and the other without the grid definition To make changes to the plant layout Press F2 Delete OR Press F4 Clear If F4 Clear is pressed a message
211. e drive enter the following from the command line cpio icBtv I dev rmt c0sOr Copyright 2002 MATTEC 6 4 710 0092 where dev rmt cOsOr is the actual device name See System Device Names of the tape drive that you are using After verifying that the archive or backup was successfully copied to the tape drive it is important to delete the archive or backup files from the hard disk so these files aren t copied to the tape drive the next time you perform an archive or backup To delete the archive or backup files from the hard disk after copying these files to a tape enter the following from the command line rm usr prohelp mat_backup where usr prohelp mat_backup is the location of the archive or backup files 6 2 Archiving Data The archive function provides a means to copy completed historical work from the active and standby files on the hard drive to another device e g a tape for permanent record storage The historical work includes completed job information shift history files SPC files and parameter history files It is important to understand that an archive is not the same as a backup of the system An archive copies historical work to an external storage device so this data may be deleted but accessed at a later time for reporting purposes A backup copies all active system data that would be needed in the event of a hard disk failure Archiving ProHelp Millennium data is a two step process In the first s
212. e forecasted end date displayed in the scheduler and on schedule summaries As an example a value of 80 entered in this field would mean that the user expects at least 20 downtime during the job Therefore the forecasted end date will be increased by 20 Typically with this value a 60 minute run would be forecast as taking 72 minutes or 20 more time The calculated run time desired end start that is displayed in the job descriptor is based on a machine utilization of 100 regardless of the value entered in the Utilization field A value of 100 or 0 will disable this function Part Qual Enab The part qualification enable field is for display purposes only and has a value of Y es or N o When enabled all parts are automatically qualified as good or bad by ProHelp Millennium Refer to Section 5 9 for additional information Copyright 2002 MATTEC 4 13 710 0092 FIELD DESCRIPTION Non Prod Limit The non production limit is the number of seconds the system waits for the machine to cycle If the machine does not cycle in that time then the machine is classified as down and downtime hours start to accumulate Suggestions The value that is used here is important to the accuracy of the downtime records for the job Non production limits must be chosen carefully When a machine cycles automatically and is repetitive within 1 second then the non production limit should be set to the cycle time high limit Manual jobs th
213. e in order to effectively set these values To set the system in Remote Analog Calibration mode follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU Select the MIU to calibrate Press F10 Remote At the blinking message Are you sure that at least one operating MIU has a keypad Press Y es The system will display the following screen Copyright 2002 MATTEC 7 60 710 0092 ProHelp Millennium OF x Figure 7 28 Remote Analog Calibration Mode Screen Analog calibration can now be performed at the MIU Reference the MIU Operator s Manual for details on Analog Calibration The Remote Analog Calibration mode can be exited in two ways The first way is to press the HstESC key at the MIU The other option is to press the Esc key at the ProHelp Millennium node 7 12 6 TIU Installation The Transaction Interface Unit TIU is a hardware device used for indirect labor tracking of machine operators The TIU is similar in appearance to an LED MIU with the exception of the special operator logging keys and connect to ProHelp Millennium as if it were an MIU Unlike the MIU the TIU does not connect to a machine To install a TIU follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU Press F1 Add Enter the name of the TIU to create Press Enter The TIU uses the same configuration screen that the MI
214. e is equal to the ProHelp Millennium shift date the job descriptor limits are also updated 5 7 4 Cause Reasons for Sample Data ProStat offers the ability to mark a sample with a Cause reason A sample may be marked for information only or for exclusion from calculations Up to 50 cause reasons may be defined for each department or the department cause reasons may be copied to an individual job where they may be modified To mark a sample with a cause follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F 1 Edit Enter the date to modify Press Enter Enter the job number If you do not know the job number Press spacebar Move the cursor to the desired choice Press Enter To select the data set parameter choice Press spacebar Move the cursor to the proper choice The available choices include none automatic process data manual process data variable data or attribute data Copyright 2002 MATTEC 5 31 710 0092 Press F1 Done Position the cursor to the Cause field at the bottom of the desired observation To see a list of user defined cause reasons Press spacebar Select a reason Press Enter To exclude a sample from SPC calculations i e have the sample appear in charts but not be included in related calculations move the cursor next to the cause field and select EXCLUDE To include a sample in all calculations select INCLUDE Highligh
215. e of ignoring the current item in the undo list or ignoring the remaining items in the undo list Since Refresh is dependent upon the undo list if the undo list has been overflowed in the current session the Refresh button will be made unavailable COMMIT The Commit button will cause ProSched to attempt to download its current machine schedule to the ProHelp system The schedule download can result in three outcomes 1 All changes requested by the user are applied to the ProHelp system Some changes requested by the user are applied to the ProHelp system 3 No changes required by the user are applied to the ProHelp system failure to apply ProSched changes can result if a job which was not running at the time ProSched was started is now running and was involved in a schedule change by the ProSched operator In the event that all changes were successfully applied the ProSched program will display an information dialog reporting the success Figure 12 10 Commit Results Commit Results Ea The schedule was updated Figure 12 10 Commit Results In the event that any or all of the schedule changes cannot be applied to the ProHelp system a different information dialog will be displayed This dialog will display any text messages relevant to the failures of the schedule download The dialog will offer the user the choice of restart ProSched Figure 12 3 Scheduler or exit Figure 12 4 ProSched Startup PRINT WINDOW
216. e of valuable computer time They can generate so much data that nobody could read it 4 1 4 Machine Process Parameters To edit a job descriptor s machine process parameters follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Copyright 2002 MATTEC 4 14 710 0092 Press F3 Disply A picklist will appear Select Machine Parameters Press OK The engineering standards and the actual values for the last cycle are shown ProHelp Millennium of x 0 1164120 Figure 4 4 Machine Parameters DESCRIPTION This column contains the name of the parameter There are 2 types of inputs used to monitor machine parameters Timed inputs are switches and relays opening and closing on the machine Analog inputs are sensors that relate temperatures pressures and positions The first 5 types shown in Figure 4 4 Machine Parameters are the timed inputs the remainder are the analog inputs Only those parameters present on a system are named and displayed The names given to machine parameters is the responsibility of the System Manager The names of the processes monitored can be different for each machine However any process being monitored in a machine may be turned off by setting its high and low limit to zero The HIGH and LOW limit values are used to set the limits of acceptabl
217. e or less The schedule is full cause An attempt was made to add a job to a machine schedule that was already full remedy Either delete an existing job from the desired machine schedule or add the job to a different machine schedule The schedule is in use at another terminal cannot edit now cause The schedule file may be modified by only one user at a time The file is currently being used remedy Have the user release the file or retry the operation at a later time Copyright 2002 MATTEC 15 43 710 0092 The schedule is not empty cause An attempt was made to either delete an MIU or move an MIU to a different location remedy Empty the schedule for the MIU in question before deleting or moving it The selected code is out of range cause An attempt was made to key in either machine or tool maintenance from an MIU that was out of the code number range remedy Valid numbers for machine maintenance are 300 through 310 valid numbers for tool maintenance are 320 through 339 The selected item may not be modified cause Certain items in the real time display writer have fixed lengths remedy Select another item or abort the operation The selected job is not a family job cause A family job operation was performed on a non family job remedy Abandon the family job operation or perform the operation on a valid family job The shift date of the sample must be in the past cause The shift date specified is in t
218. e part descriptor is displayed the following selections are then available UNCTION KEY DESCRIPTION F1 Part Press F1 Part to modify a different part descriptor F2 CpyJob Allows you to copy a job descriptor s general information to this part This function is useful for copying the SPC limits from a job to the part descriptor for permanent storage Refer to Section 4 4 3 for additional information F3 Delete Allows you to delete the part descriptor This is the only way to remove a part descriptor from the disk Refer to Section 4 4 4 for additional information F4 Disply Displays the engineering standards screen of the part descriptor Standard F4 Disply Displays the machine parameter limits for this part Machine Parameters F4 Disply Press to modify the material needs and usage setup for this part Materials List Reference Section 4 1 8 for additional information F4 Disply Allows you to enable SPC or part qualification for this part Reference SPC Setting Sections 5 6 and 5 9 for additional information F4 Disply Allows you to create or modify setup sheets and QC sheets for the part Machine Tool QC Document F4 Disply Displays the upper and lower specification limits and delay times for Auxiliary Parameters up to 76 auxiliary process parameters 4 3 1 Part Descriptor Field Definitions The following is a description of data fields in the part descriptor When a part descriptor is displayed on a screen
219. e performance for each parameter Values of zero have the affect of disabling the parameter monitoring for this job The delay value is a time delay from the beginning of the cycle to the time of reading the sensor This is very useful on injection molding machines when monitoring the pressure cycle values of injection hold and back pressure The actual value of the parameter as recorded for the last cycle The actual values are color coded based on their value compared with their standard values Red is used when the parameter value is higher than the HIGH limit Copyright 2002 MATTEC 4 15 710 0092 White is used when the value is lower than the LOW limit Green is used when the value is within limits 4 1 5 Last 50 Cycle Times To view a job descriptor s last 50 cycle times follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Select Last50 Cycle Times Press OK The individual time of each of the last 50 cycles will be displayed Using this information a foreman can watch the machine s history and react to trends that may be occurring The current cycle time comes on the bottom of the display and the 50th value rolls off the top of the display In addition to the 50 cycle times the standards high and low values and actual averag
220. e report screen as appropriate Press F1 Done The appropriate setup sheet will be returned To return to the copyright screen when finished Press Esc several times 7 10 Voice Option Voice recording is not provided within ProHelp Millennium System The user must record sound segments using MS WINDOWS and save them as WAV files These sound files are then placed in appropriate directories accessible to the node with sound card The Voice feature automatically plays prerecorded sound files Sound files can be configured to announce Help Calls Machine Down conditions and Machine Parameter out of limit conditions Sound files are not accessible by the ProHelp file system SFILE Each node with sound card must be able to access all sound files either locally or via mounted file system The following conditions are announced by the Voice feature Call For Help from MIU Eight help phrases can be defined for each department The phrase will be repeated at a predefined regular interval until the help code is canceled or the condition is acknowledged from the real time screen Machine Down Up to twenty down phrases one for each primary down reason can be defined for each department The phrase will be repeated at a predefined regular interval as long as the machine stays down or the condition is acknowledged from the real time screen Machine Parameter Out of Limits Each department may have a total of twenty one parame
221. e screen that shows among many other things Next Job information A Next Job screen is not shipped as standard with the system but is easily created by the user As a guideline a sample Next Job screen is shown Figure 7 14 Sample Next Job Real Time Screen with the choices that were used to create it Copyright 2002 MATTEC 7 26 710 0092 wii NXT MATL NED xT MOLD ot STAMP Shift 3 36 GE34233 fie 365 Gg 459008 Filter Bo Bvoice Class BCustom HES Figure 7 14 Sample Next Job Real Time Screen This screen shows current material and hours to go and then lists information about the Next Job Custom screens are created by the System Manager refer to Sections 7 5 and 7 6 or Job Manager The following Figure 7 15 Next Job Screen Configuration shows the choices that were used to create this Next Job screen X ProHelp Millennium Bisi x Real Time Display Design screen layout Columns Remaining 1 2 3 4 5 6 7 8 12345678901 2345678901 2345678901 2345678901 2345678901 2345678901 2345678901 234567890 MACH JOB H d STD ACT YLD STD ACT MACHINE NUMBER NUMBER P d 0 SPEED SPEED EFF CAV CAY PARAMETERS e Number u rrent Job s Shift Pre on Units Go Good Pre on Uni eed Current Job ft Figure 7 15 Next Job Screen Configuration Copyright 2002 MATTEC 7 27 710 0092 This screen is offered as an example of how a user could create a Next Job real time screen 7 7 Real Time Configuration for Users The configu
222. e to modify data that has been previously moved to the standby data directory Copyright 2002 MATTEC 15 7 710 0092 remedy Abort modification attempt because standby data cannot be modified Data in use at another terminal Press ESC to quit any other key to try again cause The selected data record may be modified by one and only one user at a time The file is currently being used remedy Have the user release the record or try the operation at a later time Data not found cause A report was requested for a date for which the required historical data is not on line and which was not found on the floppy diskette remedy Verify that the entered date is the desired one and that the proper archive diskette is mounted if required Data to be charted contains negative number cause One or more items of data is negative remedy A Pareto chart cannot be generated for a data set containing a negative number Inspect the data for correctness Data type not specified cause An attempt was made to specify a characteristic or activate a ProStat function and no data type was specified remedy Specify the data type Diskette is not formatted or is write protected Drive door may have been open cause An operation involving a diskette failed either because the drive door was open the diskette was not formatted or the diskette is currently write protected remedy Check the diskette and retry the procedure DOS filename excee
223. e your changes Press Esc 9 4 Modify the Last Time PM was Performed The history record for preventive maintenance is automatically updated whenever a PM code is entered at the MIU The last time the same code number was entered is recorded on a separate display The machine hours run since that PM activity was performed are accumulated If maintenance occurred on the machine and it was not logged at the MIU then it is necessary to make a manual entry adjusting the activity log and the hours run since the PM was performed Copyright 2002 MATTEC 9 10 710 0092 To manually adjust the number of hours since preventive maintenance was last performed on a machine follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F1 Mach Press F1 Histry Enter the machine number Press Enter Press F4 Hours A new display is shown which lists the 20 maintenance code numbers and the last time each one was performed Use the cursor keys to position to the proper field Enter the new date and time or the new hours run since maintenance was last performed Press Enter To save your changes Press Esc Note If you change the date and time fields or the run hour fields since the maintenance was last performed this data is not automatically changed on the maintenance activity event screen You should modify the history event screen with the same entries that you made for this machine To manually adjust
224. ead This value is used for inputting variable data at an MIU or computer terminal using an electronic gage When Nol double read is enabled In this mode any data entry with an electronic gage device must be entered twice before it is accepted the two entries must be identical The first entry is for display and verification The second entry is for sending the data into the system When Y es double read is disabled A single gage reading is considered correct and accepted into the system V A Sample Period This field specifies the fixed time interval in minutes in which variable or attribute SPC samples are to be taken at the MIU Once this period is reached the green light at the MIU will blink until a variable or an attribute sample is entered V A Samples Run This field is for display purposes only and displays the value of the Process SPC SAMPLES RUN field This is the number of data samples which define a run trend or shift Copyright 2002 MATTEC 5 14 710 0092 Valid choices are CHARACTERISTIC and OBSERVATION When CHARACTERISTIC is selected all observations for a characteristic are entered before stepping to the next characteristic i e all variable 1 entries are input before moving on to all variable 2 entries When OBSERVATION is selected all characteristics i e variable 1 through 10 for an observation are entered before stepping to the next observation ATTRIBUTES SQC FIELD DESCRIPTION Attribute
225. ed Start Desired End Prohelp Millennium ProSched File View PROD NUMBER NUMBER TO GO DESIRED START DESIRED Figure 12 25 Unscheduled Jobs In all of the above examples the third column in the Unscheduled Jobs Area is the column of change dependent upon your choices in the pull down menu Note the Machine Schedule area appears with a blue header versus the Unscheduled Jobs area which has a gray header Copyright 2002 MATTEC 12 21 710 0092 Prohelp Millennium ProSched of x OS 28 ts lll LR l cA JOB AR AVAIL NUMBER RUN HRS DESIRED START FOREC A JOB PART NUMBER NUMBER DESIRED START DESIRED END Figure 12 26 Adjusting the View Viewing By using the left button on your mouse place the cursor arrow on the small box E A above located on the right side of ProHelp Millennium ProSched screen Figure 12 26 Adjusting the View When the cursor arrow is placed on the box the arrow becomes a cross While holding the left mouse button down move the cross up or down depending upon the screen you want to view Split screen of Gantt Area Machine Schedule Area and Unscheduled Jobs Area is possible To escape from the screens Machine Schedule Area or Unscheduled Jobs Area go back to the pull down menu under View and press Off 12 2 2 2 Tool Bar The Tool Bar Figure 12 27 Tool Bar will be located directly below the menu bar The Tool Bar area consists entirely of push buttons Each p
226. ed date is entered for each individual job and a desired date determined for the family based on these Just as there is no desired date entered for the family there is no SCHED FROM selection The SCHED FROM setting of the first job placed in a family becomes the setting for the entire family After entering all the component jobs maximum 20 the cursor moves to the MAX ACTIVE COMPONENTS field This specifies the number of son jobs that will be placed in a running mode when the job is started and is limited to a maximum of 10 For example in the figure there are 20 component jobs SON_01 to SON_20 in the family and the MAX ACTIVE COMPONENTS is set at 10 The component jobs SON_01 to SON_10 will be placed in a run mode when the job is started The other 10 jobs will be scheduled component jobs that may be started during the family run however no more than 10 component jobs can be running at one time Refer to Section 4 5 for details on starting and stopping component jobs The standards field of a family job descriptor contains only machine related data such as cycle time non production limit etc Information such as shot and part weight cavities etc come from the component son job descriptors The remainder of the job descriptor fields are filled in in the same manner as any single job descriptor Reference Section 4 2 1 for additional information After all appropriate fields are entered Press Esc All information is saved
227. edule This enables the Job Manager to Copyright 2002 MATTEC 4 40 710 0092 see the effects of the changes immediately and to produce best fit planning for the monitored machines A job can be scheduled to a machine in several ways 1 Through the scheduling function in the Job Manager Mode 2 Through the scheduling function in the Production Manager Mode 3 Through the job descriptor in the Job Manager Mode It is possible to schedule idle time within the machine schedule If the desired start date of a pending job is later than the ending date of a previous job then an idle block of time will exist between the two but only if the DESIRED schedule method is selected by the System Manager The Gantt chart of the plant schedule will identify these holes in the schedule You may preprogram preventive maintenance time or scheduled idle time as you see fit by pushing back the desired starting time of the future jobs You may also schedule dummy jobs which appropriate longer machine set up hours These set up hours can then act as preventive maintenance time allocation for your equipment The SCHED METHOD option in the System Manager miscellaneous function defines the method with which scheduled job start dates will be calculated Refer to Section 7 4 If the SCHED METHOD FORECAST the forecasted method will be used The rule is as follows The END date of the previous job on the schedule becomes the START date for the next job on
228. edule will clearly identify holes or idle time in the schedule if the DESIRED method is used To delete a job from a machine the job must not be running on the machine presently If it is use the control mode to suspend or end the job If a job is ended using the control mode it will automatically be removed from the schedule To delete a job from a machine schedule follow these steps Press F2 JobMan Figure 3 1 Copyright Screen To select the schedule Press F3 Sched Press F1 Mach Enter the machine number Press Enter Press F3 Delete Select the job number to be deleted Press Enter Any non running job may be selected The job is now removed from the schedule but it is not deleted from the data files This job may be rescheduled to another machine or to the same machine When the job is deleted the schedules for all other jobs on the machine are recalculated To change priorities of a job within a schedule the job must be scheduled on the desired machine To change the order priority of jobs in a machine s schedule follow these steps Copyright 2002 MATTEC 4 44 710 0092 Press F2 JobMan Figure 3 1 Copyright Screen To select the schedule Press F3 Sched Press F1 Mach Enter the machine number Press Enter Press F4 Move Select the job number to be moved Press Enter Select where the job is to be moved Press Enter Any non running job may be selected When t
229. eeds the low limit high limit or both limits This feature is also used for part qualification to select processes that determine bad parts Refer to Section 5 8 for additional information A Y es in the Low column activates the relay when the corresponding signal exceeds the set low limit A Y es in the Hi column activates the relay when the corresponding signal exceeds the set high limit Any selection and combination of monitored signals is possible Alarm LED Low The four Led alarm lights on MIUs 1 2 amp 3 are enabled in this field Hr The LED number entered in these fields activate the light when the selected Low or Hi limit is exceeded ProHelp Millennium Fiel x ProHelp Millennium Oe x Items Linear C Temp J C Temp K F Temp J F Temp K Analog 1 Analog 2 Analog 3 Figure 7 24 Type picklist Figure 7 25 Type picklist continued 7 12 1 Signal Types Sources Each MIU and AIU has twelve sources for values Of these eight may be obtained from A D devices and therefore may have some sort of profile associated with them These will be referred to as Analog 1 through Analog 8 even though seven and eight are actually derived from the physical Analog 6 channel The other four are digital pulses whose on time leading edge to trailing edge is measured A thirteenth value Cycle Time is the time between leading edges of the first digital signal Originally values from these sources were directly associated with
230. een Press F4 Report A picklist will display Highlight Maintenance Highlight Tool PM Due The Tool PM Due Report can be selected to show one or all tools one or all departments and one or all maintenance code numbers Fill in the interactive screen as appropriate To generate the report Press F1 Done 9 9 Preventive Maintenance Enhancements The following enhancements have been made to the Preventive Maintenance feature Both Machine and Tool Preventive Maintenance Due reports incorporate current information about logged preventive maintenance operations and about machine cycling There are changes in the effect of preventive maintenance logging at the MIU but not in the logging procedure itself Both Machine and Tool preventive maintenance entries are applied at the time of logging rather than at beginning of shift The Hours screen in Machine Maintenance History entry and the Cycles screen in Tool Maintenance History entry are no longer directly editable Instead entry of a time or cycles value becomes part of the process of adding a line Pressing the Add Ln function key results in prompts for date time operation operator number and either run hours or cycles This last field is a decrement applied to Run Hours Since Last Performed or Cycles Since Last Performed Date and time fields entered as part of a new line are automatically placed in the associated Date Time Last Performed To aid in arriving at the prope
231. eing polled and collected data is being transmitted to the Host computer If you have additional computer terminals connected to your system someone at those terminals could be logged in and simultaneously running ProHelp Millennium If the current time corresponds to your predefined shift change time the system could also be summarizing the activities of the current shift and recording that data in history files on the hard disk Every minute the status of the jobs running on all the monitored machines is written to the disk This activity preserves the state of each machine until the next status record is written As you can see the fact that you are looking at a fairly inactive screen does not mean the system is not working The ability to perform many activities at one time is a characteristic of the ProHelp Millennium system and is called multi tasking The ability to serve more than one computer node or terminal simultaneously is called multi user Both are important characteristics of the ProHelp Millennium system ProHelp Millennium is designed to continue collecting data whenever possible The monitoring node and each MIU are independent computers Each MIU collects local data about the machine it is monitoring and transmits the data to the main computer when polled An MIU will continue collecting data without loss for up to 18 hours without being polled by the monitoring node The data collected are totals for cycle counts run
232. eld is greater than the high limit Blue indicates the current percentage is acceptable and lies within the limits set at configuration time The System Manager sets the limit refer to Section 7 This field differs from the others on the real time screen in that the changes in color do not directly affect the background color of the machine number or job number columns Changes in background color for yield efficiency are caused by changes in machine cycle speed cavity activation and scrap parts This field is a real measure of profit and loss per job Std Cav The standard cavities is a value specified in the job descriptor The actual cavities is the number of cavities now running in the machine Any reduction in actual cavities reduces the yield efficiency percentage Copyright 2002 MATTEC 3 11 710 0092 FIELD DESCRIPTION Machine Parameters Down Time Reason Copyright 2002 MATTEC These 12 flags reflect the current real time condition of the machine s process parameters Each flag changes background color independently in real time Each process parameter has a high and low limit range in the job descriptor that is used to determine color changes The machine parameters that are listed as ABCD 12345678 represent the digital and analog parameters as listed in the job descriptor file and as named by the System Manager Parameter A Pulse 1 Parameter B Pulse 2 Parameter C Pulse 3 Parameter D Puls
233. elp Millennium system to limit access to certain areas of the system Up to 100 users may be defined each with their own password Passwords are 8 alphanumeric characters They are used to protect all modes of operation from use by unauthorized people The System Manager can specify which modes of operation may be accessed by each user The master user name on the system is named mattec This user may never be deleted and has access to all functions It is recommended that the password periodically be changed To add a user to the system follow these steps Copyright 2002 MATTEC 7 1 710 0092 Press F4 Aye Man Figure 3 1 Copyright Screen Press F1 User The system will display the user configuration screen ProHelp Millennium Ioj x Add Delete Figure 7 1 User Configuration Screen To add a new user Press F1 Add Enter the new user name Press Enter Enter the passwords for the new user and enable each mode this user may access by setting that mode to Y es CAUTION If the Passwd field is set to Y es this user will have access to all other passwords on the system If the field is set to N o this user will have the ability to change their own password only Note The view user has been created to allow all people access to the view mode To disable the password enter in the password field This user should only have view enabled All other modes should be set to N o If you forg
234. elp Millennium that the current job should be ended and the next job should be started In special cases direct control is necessary and provided for in the Job Manager or Production Manager Control functions The control function allows for a job to be started ended or suspended Ended jobs will not be run again All history is saved and the job is deleted from the schedule Suspended jobs may be restarted in the future on the same machine or on another machine All production totals restart at the point they stopped To perform job control functions follow these steps Press F6 PrdMan Figure 3 1 Copyright Screen Press F4 Contrl A new menu is displayed with the following choices Copyright 2002 MATTEC 8 3 710 0092 FUNCTION KEY DESCRIPTION Select to start a specified job on a machine If a job is currently running on the machine it may be suspended or ended F1 Start F2 End Select to end the currently running job and remove it from the machine s schedule This function may also be used to end a job which was previously suspended F3 Suspnd F4 Next Select to suspend the currently running job and leave it as the first job in the machine s schedule This function may also be used to suspend a job which was previously ended Select to start the next scheduled job for a machine and automatically end the currently running job F5 NxtFam Select to start a component son job for a running family father
235. en a job is displayed on the screen the lower left hand portion of the standard job display shaded in dark blue contains production totals for the job Refer to Figure 4 2 Job Descriptor Production Data Fields Figure 4 2 Job Descriptor Production Data Fields The first column of data displays the current shift totals This column of data is zeroed at each shift change At any moment during the day you can see the tabulated production and scrap for the current shift Copyright 2002 MATTEC 4 6 710 0092 The second column of data displays job totals This column relates what has happened to the job since its actual start The third column of data displays the job to go values This displays how many pieces are left how much time is needed how much material is needed etc When production quantities are maintained with greater precision than displayed completed quantities are truncated and To Go quantities are displayed as the next higher value This derives from the view that a case or other collection of parts can only be counted when it is complete Rounding to the nearest displayable value my be more instinctive but is considered less realistic To illustrate the difference consider a job with a lot size of 10 cases of 10 parts per case At the point where 16 parts have been made rounding to nearest would show 2 cases made and 8 cases to go ProHelp Millennium shows 1 complete case made and 9 cases to go Copyr
236. ents Chart Dimension sssssssesessssseessrtssresseeeseesseeesseesseesseeeseee 3 42 Copyright 2002 MATTEC i 710 0092 Figure 3 43 Future Requirements Schedule Shift Reno 3 43 Figure 3 44 Future Requirements Schedule Daily Report 3 44 Figure 3 45 Future Requirements Schedule Weekly Report 3 44 Figure 3 46 Future Requirements Schedule Monthly Report 3 45 Figure 3 47 Future Requirements Monthly Chart AAA 3 46 Figure 3 48 Tool Conflict Report Picklist sscssssscsssssessssscsensccsssaccsenacsessecsecaccesnceseonsecs 3 47 Figure 3 49 Tool Conflict Report cccicisccssecavsceceassaveraceussaceceassevaatasousaccessaceadasdecssnadeonacvedadeceunsens 3 47 Figure 3 50 Tool Conflict Results Remote ed eee Bade 3 48 Figure 3 51 Parameter Graphing Selection Screen Gample ceceecesseesseceeeeeseeenseenseessees 3 49 Frgure 3 32 Parameter Crapo NEE 3 50 Figure 3 53 Parameter Graphing Selection Screen UL stCwcl 3 51 Figure 3 54 bast Cycle Picklist ecenin nied oe E EE eee ee ace eanies 3 51 Figure 3 35 Last Cycle Graph Al nigora es snout cts saa eege Ee 3 52 Figure 3 56 Last Cycle Graph Midi vidual TG 3 53 Figure 4 1 Job Descriptor General Information Fields 4 4 Figure 4 2 Job Descriptor Production Data Fields 4 6 Figure 4 3 Job Descriptor Ss tamGard Scie cces sas ssueg ee Eege edd 4 11 Figure 4 4 Machine Parameters scn ccce EENS 4 15 Fisur 4 5 NG Wed OD PICS Ott EE 4 22 Figure 4 6 Position
237. er in as one of the components of the family job Copyright 2002 MATTEC 15 9 710 0092 remedy A father job may not be entered as a component job Error Analog low limit above high spec limit cause While setting up upper and lower control limits an error occurred where the lower limit is greater than the upper limit remedy Adjust the control limits so that the lower limit is less than the upper limit Error Analog low spec limit out of range cause An attempt was made to enter an analog specification limit that was out of range remedy Either increase the specification limit or create pulse limit within range Error Cannot add machine The maximum has been reached cause The maximum number of machines have been exhausted remedy Contact MATTEC for assistance Error Cannot add running job to family cause An attempt was made to add a running job to a family job remedy In order to add a job to a family that job must be suspended or pending not running Error Cannot delete machine from floor layout improper cursor position cause An attempt was made to delete a machine from the floor layout remedy The cursor must be in the proper position in order to delete a machine from the floor layout Error Cannot delete selected sort field used by total record cause An attempt was made to delete a sort field that was used by a total record remedy Delete the total record before deleting the sort field Er
238. er the Suspnd or End key If a family job is running the operator is presented with a list of the currently running components as well as the family job itself If a component is selected the operator is presented with a list of the non running components If the family job is selected there is no running job or the running job is not a family job the operator is presented with a list of jobs scheduled on the machine The list of scheduled jobs also contains a None choice to allow a running job to be ended or suspended without starting another If the End key was selected the ended job is removed from the family job or from the schedule list Copyright 2002 MATTEC 4 51 710 0092 If the Suspnd was selected handling of the suspended job is dependent on a system wide configuration item Suspended job disposition may be selected as Remove The suspended job is removed from the family job or the schedule list just as with ended jobs First The suspended job remains in the family job or schedule list as the first non running job It remains in the list as the last job 4 6 Family Molding Family Molding is an optional program available in the ProHelp Millennium system that allows multiple jobs to be run and monitored simultaneously on the same machine These component son jobs in a family may be ended and started on an individual basis independent of the family father job Historical information is maintained for each
239. erators logout with this selection Reference the MIU Operator s Manual for additional information 4 7 2 Operator Tracking Reports Two reports are provided in connection with operator history e Operator Efficiency Report shows operator history with efficiencies e Operator Tracking Report shows operator history without efficiencies To view the Operator Efficiency Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4 Report Press F10 more Press F1 Opratr Press F1 Effncy Fill in the interactive screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Press F1 Done Copyright 2002 MATTEC 4 59 710 0092 The Operator Efficiency Report will be displayed The Operator Efficiency Report contains the following information The operator s identifying number The machine number The job number The shift number The start of the time period to which this line applies This may be the time the login occurred the time the job started or the time the shift started The end of the time period to which this line applies This may be the time the logout occurred the time the job ended or the time the shift ended The hours and minutes between the start and end of the time period The number of parts made during the time period Cycle efficiency during the time period Cycle efficiency is the ratio of actual average cycle time to
240. erence the MIU Operator s Manual for additional information After the predefined number of consecutive SPC samples have been taken new control limits will be calculated The new control limits will be automatically loaded at the Host and the MIU The MIU operator may not restart automatic SPC limits calculations unless the Job Manager resets the AUTO SPC LIM CALCULATE field in the job descriptor to Y es Copyright 2002 MATTEC 5 26 710 0092 5 7 ProStat Data Editing SPC data is collected by ProStat in four ways DATA TYPE DESCRIPTION Machine processes being monitored e g cycle time pulse time and analog values are automatically collected at random intervals specified by the user in the job descriptor No manual intervention is required during the collection of data Process parameter data is collected by the MIU and sent to the Host computer for processing and storage Process data from a specified number of consecutive machine cycles is collected upon command by the MIU operator When collected this data is time and date stamped and sent to the Host computer for processing and storage Variable and Attribute Variable and attribute part related data may be entered at an MIU via the keypad or serial channel using a serial gage interface or at a computer terminal via the keyboard and serial channel gage interface The data entered is derived from a sample of parts collected and inspected at the MIU or computer terminal
241. erences Bar Labels Copyright 2002 MATTEC 12 14 710 0092 SCHED DISP Another group in the control area composed of five 5 exclusive toggles is labeled Sched Disp ProSched Preferences x mme ae Sched Method ea Desired Start Desired End Desired Start Forecasted End Desired End Forecasted End Forecasted Start Forecasted End Use Sched Disp setting in Misc Options Apply Save CANCEL Figure 12 18 Preferences Sched Disp The first four 4 toggles are labeled with the standard ProHelp Millennium schedule display options i e Desired Start Desired End Desired Start Forecasted End Desired End Forecasted End Forecasted Start Forecasted End The last toggle is labeled Use Sched Disp setting in Misc Options This final toggle when active will cause the setting in the dynamic misc config file to be used in the machine schedule area By default the Use Sched Disp setting in Misc Options toggle will be active SCHED METHOD Another group in the control area consists of three 3 mutually exclusive toggle controls This group is labeled Sched Method Copyright 2002 MATTEC 12 15 710 0092 a gt lt Preferences j i i J n SS SS es x Forecast Scheduling Desired Date Scheduling Use Sched Method setting in Misc Options Apply Save CANCEL Figure 12 19 Preferences Sched Method The first control is labeled Forecast Scheduling When this co
242. ering and cost departments set as standard If the cycle times of the machines deviate from allowable standard alarm displays are shown on the computer monitors that are connected into the Host computer Your company may also want to monitor the temperatures and pressures on certain machines ProHelp Millennium has the ability to do this If the temperatures or pressures deviate from allowable standards alarm displays are shown on the terminals PCs throughout the plant The computer system is a typically network of IBM compatible personal computers dedicated entirely to production and process monitoring The computers have hard disks for permanent storage of production and SPC data Printers are available throughout the network for reports on production machine downtime material usage etc The company may have also purchased additional computers that can be mounted throughout the plant so that foremen quality control engineers and the maintenance department can see what is going on in the plant at any given time Data is collected off the machine with the use of a micro processor called a Machine Interface Unit MIU The MIU collects production and process data and provides information to personnel on the shop floor 1 2 Identification of Responsibility In a manufacturing plant there are a lot of departments responsible for production The ProHelp Millennium system offers a number of tools which will aid individuals within
243. ervice Department Open Unix treats floppy drives tape drives CD ROM drives CD RW drives and most other devices in a manner similar to directories For example in MS DOS you would reference a 3 5 floppy drive configured as drive 1 as the AT drive In Open Unix this drive would most likely be identified as dev rdsk f0q18dt This is known as the device name for the floppy drive Listed in the table below are the devices that you are most likely to encounter a typical device name and space for you to write in the actual device name on your system In the latest release of Open Unix we are now able to use a CD RW as a backup device Contact Mattec Technical Support to help in setting up this new feature SYSTEM DEVICE TYPICAL DEVICE ACTUAL DEVICE NAME NAME 3 5 Floppy Drive 1 dev rdsk fOgi8dt_ Z o S ee eee id dev rmt c1sOr Oe eee E Drive Copyright 2002 MATTEC 6 2 710 0092 System Device Names To format a floppy disk that is inserted in the 3 5 floppy drive that is configured as drive 1 follow these steps Open an xterminal window by Click Terminal icon on the desktop Become the super user by typing su Press Enter When prompted enter the super user password Press Enter The command line prompt will most likely change to the symbol Enter the following to format the floppy diskette format dev rdsk f0q18dt where dev rdsk f0q18dt is the actual device name See System D
244. es Standard Shot Weight J Actual Material Used Actual Material Cost Standard Direct Labor per Part Good Parts 1 Hours Standard Scrap Direct labor hours used Hours Standard Direct Labor Hours Direct Labor Rate Variance Actual Direct Labor Hours Direct Labor Rate Rework Hours Rework Cost Rate Good Parts 1 Standard Scrap Standard Cycle Hours Time Standard Cavities Setup Time I S Actual Machine Cost Actual Machine Hours Machine Cost Rate Machine Cost Variance tandard Machine Cost Actual Machine Cost Actual Indirect Labor Cost Actual Materials Cost Produced Sales Dollars Produced Good Parts Selling Price per part Manufacturing Profit Manufacturing Dollars Produced Total Cost Sales Profit Sales Dollars Produced Total Cost Note Optional Hours may be either Run Time Setup Time or Run Time all down time as configured by the System Manager F4 SysMan F8 Instal F1 Misc Within the miscellaneous configuration page change the field labeled Cost Total Time to Y to include all down time or to N to include only down time charged to set up Changing the Cost Total Time option will also affect the operation of the Contribution and Variance report Move through this screen by use of the cursor keys To exit Copyright 2002 MATTEC 10 7 710 0092 Press Esc Copyright 2002 MATTEC 10 8 710 0092 11 Manual Entry of Production The Manual Production function allo
245. es are also displayed Cycle times shown in Green are within the standard limits Red are higher than the high limit White are lower than the low limit 4 1 6 Downtime and Scrap To view a job descriptor s downtime and scrap follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Select either Scrap or Downtime Press OK Copyright 2002 MATTEC 4 16 710 0092 FIELD DESCRIPTION The system automatically accumulates the downtime of each machine When a job is running on a machine the downtime records become part of the job history The system maintains a count CNT of downtime occurrences and accumulates the time HRS against 10 downtime reasons Totals for the current shift and the overall job are shown The downtime reason is selected at the MIU If no downtime reason is selected the unknown category downtime reason one is used Downtime begins when the cycle time exceeds the non production limit and continues until the next cycle start signal is received Every occurrence exceeding the non production limit increases the downtime frequency by one Downtime may be edited from one category to another by the QC Manager mode Refer to Section 5 3 The system records the amounts of bad parts entered for ten scrap reasons and keeps
246. es for every MIU on the system regardless of which department it belongs to The system can also define 10 unique scrap reasons 10 downtime reasons and 8 help calls for each department defined by the system The method of allocating the proper signal scrap names downtime names or help calls to a job descriptor is by making an entry in the machine number field of the job descriptor 7 14 1 System Wide Default Names To set the system wide default names for machine signals scrap downtime and help calls follows these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F6 Names Copyright 2002 MATTEC 7 65 710 0092 Figure 7 31 System Names The number of Scrap and Downtime reasons is increased by doubling the number of primary reasons to twenty Ten sub categories or secondary reasons are also supported for each primary reason other than Unknown Downtime These can be utilized by Press F5 Scrap OR Press F6 DownTm This arrangement provides a total of 200 scrap reasons and 191 downtime reasons Because various operation and formats are altered by these features they may be independently disabled so that current operations can be maintained if desired These selections are made by department so that individual departments may be set up to operate as in the past 10 primary reasons and no secondary reasons with 20 primary reasons only with 100 reasons 10 primary reasons with 10 secondaries eac
247. es of the system the better this person will be able to respond to any questions or problems that may arise The responsibilities of the Shop Foreman are Copyright 2002 MATTEC 1 6 710 0092 Review the real time screen immediately at the beginning and throughout his work shift Determine which machines are running properly and which machines are running outside of limits From the review of the real time screen prioritize the machines that have problems and list the order in which they are to be fixed during this shift At the beginning of the shift review all the machines that are down not running Allocate maintenance and setup people to fix those machines according to the priorities set Print the schedule at the beginning of every shift See what tools are due for change this shift Assure that the new tools and new material will be on site in the time frame needed Throughout the day review the last 50 cycle times of all machines to determine if any machines have mechanical problems operator problems or setup problems Fix those problems when they occur Review the production report for your shift and previous shifts Are you meeting the production goals for all jobs Are other shifts outperforming you Did the proper amount of scrap parts get entered by the operator or by the Q C person Review the real time screen many times throughout the day Assure that all machines are running in the green If they are not make su
248. esired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist Select the parameter Select Attrib Press F1 Done If no samples have been entered on this date the error message No samples found will appear To clear the message and access the Attribute Edit screen Press Enter To insert a new sample or you may select an existing sample to edit Press F3 Insert Enter the appropriate data for P or U Attribute types Up to 7 sample entries may be displayed on one screen After data entry is complete you may Press Esc to exit this mode and save your changes OR Press F3 Insert to add another attribute sample for this job 5 8 ProStat Functions Copyright 2002 MATTEC 5 34 710 0092 Once SPC data has been entered into the system it is available for viewing in many different ways For example you can generate XbarR charts and perform linear regression analysis Each of the ProStat SPC functions are described in further detail in the following sections SPC by Part All SPC functions can be accessed by specifying a specific job number In addition to this the XbarR charts histograms Pareto charts linear regression analysis P U charts and the SPC composite report can be generated for a part number multiple job runs with the same part number The following screen is usually displayed at the top
249. ess F1 Mach To delete a master tool setup Press F2 Tool To delete a master QC setup Copyright 2002 MATTEC 7 33 710 0092 Press F3 OC Press Enter When the sheet is displayed Press F2 Delete When the system asks if you want to delete the master setup sheet Press Y es The setup sheet will be deleted 7 9 5 Print Setup Sheets To print a summary of all master setup sheets follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F7 Documt Press F2 Summry To display a master mach summary Press F1 Mach To display a master tool summary Press F2 Tool To display a master QC summary Press F3 OC OR Press F1 View Figure 3 1 Copyright Screen Press F4 Report Pick the appropriate report to print Make your selection from any of the labeled F keys Fill in the interactive screen as appropriate Press F1 Done A summary report of all master setup sheets active in the system will be generated To print or view a single job part or master setup sheet follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4 Report Press F10 more Press F5 Documt Press F1 Sheet Press F1 Job for a job setup sheet Copyright 2002 MATTEC 7 34 710 0092 OR Press F2 Part for a part setup sheet OR Press F3 Master for a master setup sheet Enter the proper setup sheet number Press Enter Fill in the interactiv
250. ess F8 CstMan Figure 3 1 Copyright Screen Press F1 CstEdt Press F2 PtDesc Enter the desired part number The cost standards fields are listed on the right hand side of the part descriptor ProHelp Millennium iol x 0 0 0 0 44 0 0 Figure 10 2 Cost Manager Job Descriptor Screen The field definitions are the same as those described in section 10 1 for the job descriptor 10 3 Edit Actual Hours and Material Usage Data entry for specifying actual values for labor hours and material pounds used needs to be made on a shift by shift basis To edit actual hours and material used for a job follow these steps Press F8 CstMan Figure 3 1 Copyright Screen Press F2 CstEnt For the active shift and enter a machine number Press F1 Active OR For a previous shift Press F2 Prev If the data to be entered is for a previous shift enter the department Copyright 2002 MATTEC 10 3 710 0092 Press Enter Enter the shift number Press Enter Enter the desired date Press Enter Enter the desired job number Press Enter UNCTION KEY DESCRIPTION F1 Job Press F1 Job to select another job to edit F2 Mach Press F2 Mach to select a running job to edit F5 MtlUse Press F5 MtlUse to edit the actual pounds of material used Select the material to edit by pressing spacebar and press OK Enter the quantity and press Enter A picklist appears Select and press OK Enter a neg
251. et of 10 primary down reasons Enable Aux DT Enables 10 subcategories of down time per primary down reason Enable Scrap 11 20 Enables the second set of 10 primary scrap reasons Enable Aux Scrap Enables 10 subcategories of scrap per primary scrap reason Hold Parts This parameter activates the Hold Parts mode of operation This mode places all production on hold neither good nor bad until placed in the good or scrap category by the QC Manager Packed Parts When set to Y es this parameter enables the entry and display of Packed Production Copyright 2002 MATTEC 7 46 710 0092 FIELD DESCRIPTION Auto Scrap Switch Together these four parameters determine the operation of the PRI Automatic Scrap feature The two Switch parameters identify a Auto Scrap Switch down reason and the two Reason parameters identify a scrap AUX reason Auto Scrap Reason PRD Auto Scrap Reason AUX If Auto Scrap Switch PRI is zero Automatic Scrap is disabled and the settings of the other three parameters are meaningless An Auto Scrap Switch PRI value of 1 through 19 identifies one of the nineteen possible primary down reasons the reasons labeled DT2 through DT20 in Figure 7 22 and an Auto Scrap Switch AUX value of 1 through 10 identifies one of the 10 possible auxiliary down reasons associated with the specified primary reason An Auto Scrap Switch AUX value of zero indicates that only the primary down reason is to be considered for a
252. et your passwords contact MATTEC s Customer Service Department for assistance You must be designated as the System Manager for MATTEC to assist you After creating a user you must define the user s default real time screen Reference Section 7 6 for additional information 7 2 Remote Scrap Unit RSU Copyright 2002 MATTEC 7 2 710 0092 The Remote Scrap Unit RSU gives ProHelp Millennium users the ability to enter scrap counts and reasons for one or more machines at locations remote from the machine itself Scrap entry is done through a special type of hardware called a Remote Scrap Unit RSU Each RSU can allow scrap input for up to 10 different machines Operators simply identify the machine and scrap quantity and then send this information to the ProHelp Millennium system This type of remote scrap entry acts in exactly the same manner as scrap input right at the machine i e part counts are updated and run time and end dates are adjusted accordingly The advantage of Remote Scrap Units is that they accept scrap entry at areas that are not near the machine and scrap can be input for up to 10 machines on each RSU Up to 32 RSU s may be configured on a single ProHelp Millennium node All 32 can be daisy chained on a single cable This feature allows placing RSU units at convenient locations throughout the plant The maximum cable run should be limited to approximately 4000 feet This communications cable is dedicated
253. ete contiguous samples from the beginning or end of the data set Schedule for this machine in use at another terminal cannot edit now cause An attempt has been made to modify a schedule list from two or more terminals simultaneously Only one person at a time may change a schedule remedy Wait until the user at the other terminal has completed his modifications and has ESCaped or paged off of the schedule page off yourself and then page back onto the schedule in question Schedule full cause The schedule list for this machine has no more room for additional jobs remedy Wait until one of the jobs already scheduled for this machine completes or delete a job before adding the current job Selected item is not available cause An attempt was made to insert an item into a real time display format that was not applicable to a given ProHelp Millennium system remedy Select another item or contact MATTEC for assistance SPC data busy cause An attempt was made to update SPC data while another user was modifying the SPC data file remedy Have the user release the data or retry the operation at a later time SPC not enabled cause An attempt was made to access an SPC feature that was not currently enabled remedy Enable the SPC flag for the specific type of sampling desired Copyright 2002 MATTEC 15 38 710 0092 Specified data not enabled for SPC sampling cause Attribute data was not enable in the job descriptor
254. evice Names of the floppy drive that you are using Copy Data from the Hard Disk to an External Device Copying a ProHelp Millennium archive or backup to an external storage device e g a tape is a two step process e The archive or backup must be copied to a directory on the hard disk The directories usr prohelp mat_archive archive and usr prohelp mat_backup backup have been created for this purpose You must use ProHelp Millennium to create the archive or backup on the hard disk Reference Sections 6 2 and 6 4 for additional information e The archive or backup must be copied from the hard disk to the external storage device e g a tape using standard Open Unix copy utilities For the sake of simplicity MATTEC uses the cpio command to perform this copy MATTEC strongly recommends that you use the cpio command to copy files from the hard disk to either a floppy or tape drive instead of other Open Unix copy utilities eg tar The cpio command will prompt you to insert additional floppies or tapes if required In addition in the event that you need to restore this data to your ProHelp Millennium system the MATTEC Customer Service Department will be able to assist you a great deal more if you have used cpio in the way it is described in this section The cpio command pronounced c p i o0 allows you to copy information from the hard disk to a floppy drive or tape drive The following cpio commands will be hel
255. first be deleted from the original schedule and then added to the new schedule Job cannot be moved to the same machine cause A job move was attempted but the job was repositioned at the same machine remedy Abort the procedure or move the job to a different machine Job currently running on Machine XX cause An attempt was made to add a running job to a schedule for a machine other than the machine on which the job is running remedy Suspend the running job if appropriate It may then be added to the desired schedule Job descriptor busy Cannot add cause An attempt was made to add a component to a family which is already in use at another terminal or by a system function remedy Have the other user release the record or retry the operation at a later time Job descriptor busy Cannot delete cause An attempt was made to modify a job which is already in use at another terminal or by a system function remedy Have the other user release the record or retry the operation at a later time Copyright 2002 MATTEC 15 23 710 0092 Job Descriptor SPC data busy try later cause Someone at another terminal is editing the job descriptor SPC data that you specified remedy Have the other user release the record or retry the operation at a later time Job Descriptor not found cause An operation was attempted that used a job descriptor that was not found remedy Verify the job descriptor entered and retry the ope
256. for easy access to the interior wiring terminal The MIU faceplate is the same as used on the Level 0 2 and 3 MIUs MIU 4 The Level 4 MIU is completely different in appearance than the Level 0 through 3 MIUs It has a large 16 x 40 character display and alphanumeric keypad This MIU displays Copyright 2002 MATTEC 1 15 710 0092 entire screens of real time information at the machine Selection and entry of information are made by menu key selections as compared to key code entries It can be equipped with all of the monitoring capabilities temperatures pressures RS 232 channel that are available on a Level 3 MIU MIU 5DP 6DP 7 and 8 These MIUs have a 16 X 40 character display and are completely menu key driven Entire screens of information are available at the machine Graphic displays such as X bar and R charts are also available in these MIUs In addition the Level 6DP and Level 8 MIUs have discrete analog channel inputs and additional digital inputs as well as a printer port MIU 7X 8X 5Xs and 10X The X type MIUs are similar in appearance and basic function to the SDP 6DP 7 and 8 however these units have considerably more processing power As a result new features are designed more frequently for X type MIUs than other MIUs MIU 9 The Level 9 MIU is a low cost MIU without operator warning lights It is similar in function to the Level 2 MIU MIU 0 XS The MIU O XS includes all the opera
257. g another page of setup data Use the cursor keys to position to the area in which you want to make an entry Copyright 2002 MATTEC 7 32 710 0092 When you are finished entering your master setup sheet press the Esc key several times to return to the main menu Your new setup sheet is stored automatically on hard disk and added to the setup sheet summary list 7 9 2 Insert an Image File into the Setup Sheet To insert an image file into the setup sheet follow these steps Position the cursor on the setup to the place where the image file should be inserted then Press F5 Image Enter the Image file name The inserted name will be displayed in the setup sheet To view the image file simply use the mouse and click on the inserted name and the image file will appear To close the image file simply double click on the upper left hand corner of the image file or use the escape key to exit from the setup sheet 7 9 3 Delete an Image File from a Setup Sheet Position the cursor to the first character in the image file name Press F5 Image A message will appear clear image file name Y N N Pressing a Y will clear the image 7 9 4 Delete Master Setup Sheets To delete a master setup sheet follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F7 Documt Press F1 Define Enter the name of the master setup sheet to be removed from the system To delete a master machine setup Pr
258. g the correct shift data Requested SPC data busy cause Someone else at another terminal is using ProStat on the same data remedy Have the user release the data or retry the operation at a later time Root portion of DOS file name must be alphanumeric cause Non alphanumeric characters were entered in the root name remedy Reenter the root name using the characters a through z A through Z and 0 through 9 RSU is marked Active but no Machines are listed cause The RSU was switched to active but no machines were configured for it remedy Configure at least one machine in the RSU configuration screen Sample data for specified Job and Date not available cause The specified ProStat data is not on line or on the mounted diskette remedy Select the appropriate date or mount the correct diskette Sample descriptor for specified Job and Date not found cause The specified ProStat data is not on line or on the mounted diskette remedy Select the appropriate date or mount the correct diskette Sample exists cause You have attempted to insert a sample which has the same date and time as one which already exists remedy Make sure you are not entering the same data again or change the time of the data you wish to enter by 1 minute and try again Sample frequency too high cause More data exists than can be charted Copyright 2002 MATTEC 15 37 710 0092 remedy Reduce the sample frequency and collect a new set of data or del
259. g to MATTEC Customer Service you should always mention your ProHelp Millennium Release level first All ProHelp Millennium releases contain three digits The first digit to the left of the decimal place denotes the major software release number The first digit to the right of the decimal place denotes the feature release number The third digit second to the right of the decimal place notes the maintenance release of the software level The third digit is mainly for MATTEC service personnel If you have special software the release number will be preceded by the letter S e g Rel 1 40 This is used to indicate a system that is non standard or special These systems contain some type of modification special reports internal calculations etc that take them out of the mainstream of ProHelp Millennium users Updates for these systems generally require extra engineering efforts to adapt them to new software releases The next to last line on the screen is the mode selection menu Refer to Figure 3 1 Copyright Screen An operating mode is chosen by pressing the corresponding function key F1 through F10 If your password is assigned to a selected mode then the system immediately grants access and displays another menu The copyright screen also displays which user is logged in at this terminal Copyright 2002 MATTEC 3 1 710 0092 ProHelp Millennium Ee i ew BobMan oc Man WsysMan BFilMan BPrdMan HMntMan Bcstman E D OI
260. g will offer the user the choice of aborting the current drag and drop operation or forgetting the oldest drag and drop operation If the user chooses to allow events to fall off the Undo list the Refresh button under File pull down Figure 12 9 File Pulldown will be disabled ATTENTION f There are no transactions to undo Figure 12 13 Exhausting the Undo List MODIFY JOB DESCRIPTOR When activated Modify Job Descriptor will determine if any job has been selected in the Gantt area If no job is currently selected a modal dialog Figure 12 14 Modify PopUp will appear that will allow the user to enter a job number or cancel the request If a job number is found Modify Job Descriptor will invoke the standard MATTEC Job Descriptor utility for that job Changes made to a job descriptor will not be displayed in the current session of ProSched unless a successful Refresh refer to Section 11 2 2 1 1 is performed Copyright 2002 MATTEC 12 11 710 0092 ProHelp Millennium Job Number Enter Job Number to Modify i CANCEL Figure 12 14 Modify PopUp VIEW JOB DESCRIPTOR The View Job Descriptor will function in a manner similar to Modify Job Descriptor except changes cannot be made to the Job Descriptor Upon entering a job number in the Job Number screen Figure 12 14 Modify PopUp the Job Descriptor selected will appear on the screen in a new window Figure 12 15 Job Descriptor Screen ProHelp Millennium 120
261. ge cycle time and yield is kept per operator The tracking report only shows who logged in or out at what time No parts production is kept Reference Section 6 for information on Archiving and Purging operator tracking information Reference the MIU Operator s Manual for information regarding operator ID entry 4 7 1 MIU Login and Logout MIU 0 1 2 and 3 Operator ID entry at the MIU varies slightly depending on the type of MIU being utilized in the system MIU Levels 0 1 2 and 3 require that entry begin with one of the Function keys The FI F2 and F3 keys are used to login and logout at the MIU 0 1 2 and 3 Use the F1 key to login when the recording of efficiency is desired F3 key to login when tracking only is desired F2 key to logout for either type of login Depressing the F1 key causes the MIU to display an IN prompt The indicates that the operator is logging in plus efficiencies F3 key causes the MIU to display an IN prompt The indicates that the operator is logging in minus efficiencies or in other words for tracking only After either prompt appears the operator must then enter his or her operator number followed by the Enter key The operator number may be up to 9 numeric characters in length An operator number of 0 is not allowed and is ignored if entered F2 key causes an OUT prompt to appear after which the operator enters his operator number followed by
262. h or the full 200 reasons A system may contain departments with these configurations in any mixture This will bring up the system wide default names Department System for signal scrap downtime and help If you do not specify a machine number in the job descriptor these are the names that will be displayed To change the names use the arrow key to move the cursor to the desired name type the new name Press Enter To save your changes Press Esc After changing any system wide names you must reboot the system All MIUs need to be reset by powering them off and turning them back on Copyright 2002 MATTEC 7 66 710 0092 For machine signal names 1 is always the cycle time and 2 is always the cycle time signal For downtime names 1 is always UNKNOWN The unknown reason is activated when the non production limit is reached or the machine goes down until another downtime reason is selected 7 14 2 Create or Delete a Department To create a department follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F6 Names Press F1 Add Type in the name of the new department you wish to create Press Enter This will bring up the scrap downtime and help names for the department you have just created Enter in the desired scrap downtime and help names You must reboot the system and reboot all MIUs for your changes to take effect To delete a department fol
263. h real time screen has its own field length of values associated with it It is possible to create screens with the same data field each having different lengths 7 6 6 Create a Graphic Layout Grid for the Display A real time custom display can be shown as a regular screen layout or as a grid layout The grid layout enables the data to be arranged within a graphic block The blocks are displayed on the screen in the order which typically represents the physical position of machines on the shop floor The user has total freedom in creating the contents of the blocks and the positions on the shop floor layout The size of the block is dependent on the number of items selected within the display and the length of the field characters of each item If five items were selected and the largest item was 15 characters in length then the block would be 5 X 15 If one item were selected and its length was three characters then the block would be 1 X 3 To create a real time plant layout grid follow these steps Press F4 Aye Man Figure 3 1 Copyright Screen Copyright 2002 MATTEC 7 23 710 0092 Press F5 RITmDf Press F3 Files Press F2 Load Select the file to load Press Enter Press F8 Grid A new display is shown with the cursor highlighted Move the cursor keys to position the highlighted block In the upper left hand corner of the display the position of the cursor is shown by row number and column position Position th
264. have up to four channels numbers 1 4 to 16 MIUs numbers 1 16 Department This field specifies which department this machine belongs to To place a machine in a department press the spacebar and select the department name IU Type This defines the type of Level of MIU being configured on this screen Press the spacebar for a list of valid MIU types If the MIU is equipped with a Programmable Logic Controller interface it must be defined in this field Set at Y es only if the MIU is equipped with the automatic downtime Downtime feature Digital downtime inputs Scrap PB This field identifies the class of machine that the MIU monitors This field becomes a filter field for reports schedules and real time displays Dual Cyc A Y es entry specifies that the machine processes two different parts with different cycle times simultaneously within one machine cycle However the standard cycle time is used for both job s part counts and downtime Reference Section 4 6 6 for additional information Speed Units The selections for this field are seconds per cycle cycles per hour cycles per minute or meters per minute This field causes a machine to be treated as a cyclic machine or a rate machine The meters per minute selection is used for extrusion machines Linear Mult This default value will be 1 000 unless the Speed Units field is set to meters per minute Then this field represents the length of product made each
265. he ability to modify the production performance records in the files in any way desired The system does not validate the data entered nor does it attempt to keep the overall job totals up to date with the changes made using this function This function is needed occasionally to correct errors in job descriptors for jobs not started at the right time incorrect values in actual cavities cycles counted against non productive cycles etc To edit shift production data follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F6 QCEdit Enter the desired shift Press Enter Enter the desired date Press Enter Enter the desired job number to be edited Press Enter The selected job descriptor will be displayed Use the cursor keys to position to the proper field Enter the new value s as appropriate Copyright 2002 MATTEC 6 18 710 0092 Press Enter To save your changes Press Esc Note The use of QCEdit and JDEdit functions should be limited Changes to the collections of data using these features requires considerable thought and possibly some calculations Any change to a shift history record using QCEdit could require a similar change to the job descriptor using JDEdit 6 11 Edit Job Production Data ProHelp Millennium provides direct access to job history data files and provides the ability to modify the production performance records in the files in any way desired The system does not val
266. he selected signals This alarm condition is only reported if process exception logging is enabled Parts Qualification These fields describe process parameters that have been Machine Parameters selected for part qualification Reference Section 5 9 for SPEC CNTRL additional information Parts Qualification This column is for display purposes only and displays the MIU signals that are enabled for part qualification as described in Section 5 9 1 5 6 4 VarLim Variable Limits To modify the control and specification limits for variable data for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Copyright 2002 MATTEC 5 19 710 0092 Press F8 VarLim The SQC Variables screen will be displayed Use the spacebar for picklist of options Use arrow keys to move from field to field ProHelp Millennium O E3 Tob top10 OC VARIABLES A Figure 5 6 SQC Variables The following fields are then available for modification This is the name of the variable that can be collected Up to 10 variable names may be specified Data may be collected for all non blank variable names At least one variable name must be specified if variable data sampling is enabled The average of Xbar This value
267. he cycle relative time at which the maximum value occurred Time of Minimum the cycle relative time at which the minimum value occurred Note Only 10X MIUs and TS MIUs support Area Under Curve Mean Value Time of Peak and Time of Minimum AIUs do not support Area Under The Curve or Mean Value but do support Time of Peak and Time of Minimum D P A N This field actually identifies the source of the parameter Originally it simply specified the type of sensor providing a signal but its meaning has been broadened so that it may specify an attached PLC or an already defined analog signal as the source The list of available choices is shown in Figure 7 24 Type picklist and Figure 7 25 Type picklist continued and this field is further discussed in 7 12 1 The number of decimal places in the signal value is entered here maximum value of three decimal places Any decimal place change will not take effect on any currently running jobs until they are restarted Y or N if a sign should be assigned to the value Copyright 2002 MATTEC 7 53 710 0092 FIELD DESCRIPTION Software Gain Gain and Offset are software values entered to correctly read the Offset analog values This procedure is outlined in the Hardware Installation Manual Alarm Output Any of the monitored signals may be used to activate an alarm relay Low Hi in the MIU when the signal goes OUT OF LIMITS A selected signal will activate the alarm when it exc
268. he future remedy Enter a valid shift date The software gain must be less than 10 cause An attempt to adjust the analog gain by more than 10 units was made remedy Constrain analog gain to less than 10 The software offset must be between 6550 and 6550 cause An attempt was made to key in an offset that was not between these two numbers Copyright 2002 MATTEC 15 44 710 0092 remedy Key in an offset value that is between 6550 and 6550 The STANDBY DATE entered is greater than the ACTIVE DATE cause The standby date cannot be later than the active date remedy Enter a valid standby date The start date cannot be in the past cause The desired start date is earlier than the current date remedy Enter a valid start date The start date cannot follow the end date cause An attempt was made to use a start date that chronologically follows the end date remedy Enter a valid start date The start date of the sample must be in the past cause The desired sample start date is earlier than the current date remedy Enter a valid start date The start of the time period may not be in the past cause The period of time for which a prediction applies must be a future period remedy Enter a valid start time The start of the time period must be in the past cause The date and time specified for a report or other function is required to be in the past and the entered date did not meet this requirement remedy Enter a val
269. he hard drive to a tape and delete the backup data that exists on the hard drive Copyright 2002 MATTEC 6 12 710 0092 Command Line Syntax To run the archive purge or backup programs from the command line follow this syntax command options Where command is the archive purge or backup command See Automatic Archive Purge and Backup Commands and options are archive purge or backup options See Automatic Archive Purge and Backup Options as appropriate Automatic Syntax The archive purge or backup command may be run automatically by creating a shell script that contains the following bin sh usr bin env sh command options additional_commands Where additional_commands can include the cpio commands necessary to copy the archive or backup from the hard disk to a tape then delete these files from the hard disk Reference Section 6 1 for additional information Once the above script has been created it must be made executable When this has been done you can use the standard Open Unix command cron to schedule the script to execute automatically at different times throughout the day and different days throughout the week month or year For additional information on how to create a shell script or execute cron reference the Open Unix documentation that came with your ProHelp Millennium system NOTE When scheduling the archive or backup commands to execute automatically it is the user s resp
270. he material is available for use at the machine The ProHelp Millennium system has material usage and material lot tracking capabilities The responsibilities of the Material Controller are 1 Review the material forecast report every day Assure that there is sufficient material on hand for all jobs today and for the rest of the week Place orders for materials not on hand 2 Assure that material for new jobs is to the machine site prior to the time of the new job changeover Review the schedule or next job real time screen for this data 3 Review the job history for long run jobs Determine if the material used is appropriate for the standards set If not determine why there is waste and where it is going 4 Work with the Scheduling Department and the Production Control Manager to make priority changes due to conflicts on material availability 1 2 8 Machine Operators Machine Operators will be involved in the ProHelp Millennium system to varying degrees depending on how the system is implemented in your particular plant In light of the fact that the MIU is at or close to the operator station i e on the machine study the MIU Operator s Manual In addition to learning how the MIU operates operators should have a general knowledge of how the system works by studying the View mode Learn what the real time screens mean Learn how to look at your last 50 cycle times Copyright 2002 MATTEC 1 8 710 0092 The responsibi
271. he move is complete the computer updates the schedule with recalculated start dates and end dates To display the parts to go hours to go or available hours between all jobs in the schedule follow these steps Press F2 JobMan Figure 3 1 Copyright Screen To select the schedule Press F3 Sched Press F1 Mach Enter the machine number Press Enter Press F5 ToGo Select the values you wish to display Press Enter The move machine instruction allows for a job scheduled on one machine to be moved to be another machine The job is deleted from the original machine automatically and added to the target machine To move a job from one machine s schedule to another follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F3 Sched Press F1 Mach Enter the machine number Press Enter Press F7 MovMch Select the job number to be moved Press Enter Enter the target machine number to which the job will be moved Press Enter Select the position in the schedule to schedule the job Copyright 2002 MATTEC 4 45 710 0092 Press Enter The computer will now automatically delete the job from the first machine and add it to the target machine One job at a time can be moved between machines Schedules are recalculated when the new job is added 4 4 3 Gantt Chart Schedule The ProHelp Millennium scheduler can generate a graphical Gantt chart of the entire plant s machi
272. he second signal in the list is enabled by placing a 2 here or disabled with a 0 For MIUs that do support full mapping this can be any number from 2 through 96 1 is reserved for cycle time and each number may only be used once per MIU Parameters 21 through 96 are secondary parameters and do not have all functions available to the first twenty See section 7 12 2 for a description of the specific differences A number from to 3 assigns the associated digital signal to one of the three auxiliary counters Copyright 2002 MATTEC 7 52 710 0092 DESCRIPTION The method by which a single numeric value is produced from a signal s readings Peak the system will monitor and record the maximum value of the signal Minimum the system will monitor and record the minimum value of the signal Single Point single point monitoring means that one reading of the signal will be taken at a specified point from the beginning of the cycle The delay entered in the job descriptor for the individual job is used to determine the sample time Area Under Curve the area represented by the signal s profile over the entire cycle period This is a two dimensional measurement using time in one direction and whatever units are associated with the signal in the other The result is unit minutes Mean Value the average value over the entire cycle In effect this is the sum of all readings divided by the number of readings Time of Peak t
273. hed ID Menu Bar File Edit View Tool Bar Gantt Area JOB PART PROD NUMBER NUMBER TO GO Machine Schedule Area JOB PART PROD Unscheduled Jobs Area NUMBER NUMBER TO GO Figure 12 7 ProSched Main Screen 12 2 2 1 Menu Bar At the top of the main window is a Motif style Figure 12 8 Menu Bar menu bar Several pull downs will be available from this top level menu bar The menu bar s pull downs will be labeled File Edit View Copyright 2002 MATTEC 12 7 710 0092 xN Prohelp Millennium ProSched Figure 12 8 Menu Bar 12 2 2 1 1 File The File pull down Figure 12 9 File Pulldown includes the following push buttons Refresh Commit Print Window Print Gantt Only Exit X Prohelp Millennium ProSched 96 08 18 96 08 30 96 09 12 96 09 24 96 01 00 13 00 01 00 13 00 Figure 12 9 File Pulldown Copyright 2002 MATTEC 12 8 710 0092 REFRESH The Refresh button will cause ProSched to reinitialize itself with the current state of the ProHelp environment As a result all data generated during the current session of ProSched will be lost except for the undo list Section 12 2 2 1 2 Once ProSched has acquired all the current data ProSched will then replay the undo list from the beginning If ProSched is unable to apply any action in the undo list for any reason the user will be presented with an information dialog that will give the user the choic
274. holds identified in the component Job Descriptors Either or both may be blank depending on the user s desires regarding Tool History and Preventive Maintenance The other type of operation also has one tool holding one or more others but with all held tools being identical Although Family Molding could be used to identify both tools it is cumbersome Instead the Tool Base field may be used for this purpose for non family jobs Non blank values in the Tool Base field of non family jobs are used to record Tool History and schedule and predict Preventive Maintenance in exactly the same manner as the Tool field The Tool Base field in family component jobs is not modifiable and displays the Tool field of the associated family job The Tool Base field is added as a display choice in ProSched and the Gantt Schedule To view the Tool Base field function Copyright 2002 MATTEC 3 22 710 0092 Click F6 PrdMan Figure 3 1 Copyright Screen or Click F2 JobMan Click F3 Sched Click F4 ProSch or Click F3 Gantt Fill in the appropriate information If the selection is F3 Gantt the following will display Click File ProHelp Millennium See f Gantt Sched Summry O7 01 97 O7 04 97 Print Close 16 17 16 19 20 11 Te 01 0z 03 04 05 06 07701797 07702797 077 03 97 Figure 3 7 Gantt Schedule Screen Select Preferences User Preferences X Job Name wv Show Full Labels Only
275. hould be ended and the next job should be started In special cases direct control is necessary and provided for in the Job Manager or Production Manager Control functions Copyright 2002 MATTEC 4 47 710 0092 The control function allows for a job to be started ended or suspended Ended jobs will not be run again All history is saved and the job is deleted from the schedule Suspended jobs may be restarted in the future on the same machine or on another machine All production totals restart at the point they stopped A job which is suspended is placed as the first job in the machine s schedule To perform job control functions follow these steps Select F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl A new menu is displayed with the following choices Select to start a specified job on a machine Ifa job is currently running on the machine it may be suspended or ended F2 End Select to end the currently running job and remove it from the machine s schedule This function may also be used to end a job which was previously suspended F3 Suspnd Select to suspend the currently running job and leave it as the first job in the machine s schedule This function may also be used to suspend a job which was previously ended end the currently running job F5 NxtFam Select to start a component son job for a running family father job and end a running son job This function applies only to systems with the optional
276. i ra a ened a ea eae a apes 4 16 AET Material LON esta sidan cease Mata ris a Ee 4 17 AUS Material Need and RE 4 18 4 1 9 Enable SPC and Part Qualification 0 cccccccccccccccessessssecececececessssecececeeeceensnseaeees 4 20 SE ER EE 4 20 4 2 1 EE 4 21 4 2 2 Standard Operator Requirements cs ccacsas Drees eege aed 4 24 4 2 3 Edit Existing JODS ia sicccacssvarccdestsseveasporcdsctsdsnevavsncnssasaginieaguasadeaseeesaseaesganadvenaavetaieceeess 4 24 424 Job Descriptor Summary Report eege ee Ae 4 25 4297 SEP ANECS ee ee Eegen 4 25 DG PROT GAAS ee gdh ta dla an see actu dE 4 28 427 Rabe SYSUCM EE 4 30 43 Part IIS SETI Heeler 4 31 Copyright 2002 MATTEC ii 710 0092 4 3 1 Part Descriptor Field Eiere jeeag ieassuds tans i onedsodeeceedemenwwens 4 32 4 3 2 Create a New Part Descript i deer 4 36 4 3 3 Edit Existing Part Descriptors wisicissesccdivessdacciensiane desesarasuseadcvanddeeds sodeeatedesdaceaseseaenens 4 37 4 3 4 Copy Job Standards to Part Descriptors iere Zuse erter Diere 4 37 4 3 5 Deleted PAL Kee 4 37 ADO SCHIP SHCCUS lee ett eege enee 4 38 4 3 7 Part Descriptor Summary Report isscccsssisacsscisvscatsassavcisasesesecassasvecsasvssaceassaseeenseevedeas 4 40 Seck rees 4 40 4 4 1 lt Display a Machine Schedule iccs cctsysccsagtueesucavduennatancsdedss svedacedetidaganteteseegsdnssaaneuccgenes 4 4 4 4 2 Modify a Machine E 4 43 44 3 Gantt Chart Seeche zeitessiue ege ege SEAN EE EE 4 46 AAA lt SChedule Summary
277. ic and Manual Limits 2 0 0 0 ccc ccccccccceesessssecececeeeeeessnseceeeeees 5 15 5 6 3 ProEna Automatic and Manual Enable ccccccccccccccccecenssseceeeceeeesessnseceeeeees 5 17 5 6 4 EE V aria ble TEE EE 5 19 5 6 5 VarEna Variable Alarm Enables 5 20 5 6 6 Attrib Attribute Setup scccscctcssicccatesstaatisacteasscesedaas sonsir iS 5 22 5 027 Process Exception Ose EE 5 23 Copyright 2002 MATTEC iii 710 0092 5 6 8 Automatic Limits Calculation 0 ccccsecececccccccssesssesccecccssssessseecceccsssusenseeceeess 5 25 Dar Prostat ata Wess tc oho sscies cone desas crested te alescincgivss easosayes a a arcu S 5 27 5 1 1 Starta Manual Sample x siceass tiysdasaseccsdevasjecdianadaee dossdacasuenddsvarddeets Edge ERC 5 27 5 7 2 Gage MPU EE EE 5 28 3 1 3 gt View Edit SPC Sample Date vcccisssccusescsuquadeges taavaqutsesantanadaea vanes a E ts 5 28 5 7 4 Cause Reasons for Sample Data sich sce Gace nce nace ous 5 31 5 1 5 Variable Data ENtry cidi y ivsasasescsccassastatascecedisassaneacea SEENEN ECHT 5 32 SLO Attib te Data EE 5 34 5 9 Prostat FUNCHONS E 5 34 SEN E od O E 01 1 A E E T EE E E 5 35 5 8 2 XbarR Chart Moving Range Chart Chart of Indvduals eeeeeesseeeesteeeeees 5 37 5 8 3 Prostat Histograms EE 5 39 5 94 SPCESUMMALY Report unenee ed DEE ie Goen Eeer 5 41 3 89 37 ACale u ato EE 5 42 5 8 6 Attribute Pareto Chart i0ciehcscliteweien ie Eege 5 45 5 8 7 Linear TEE 5 46 58 0 P U E EE 5 49 399 OPC CO Oste
278. id start date and time The start of the time period must precede the end of the time period cause A time period was specified for a report or other function whose end date preceded its start date Copyright 2002 MATTEC 15 45 710 0092 remedy Enter a valid start date and time This code is out of range for MACH Maintenance cannot add cause An invalid code number for machine maintenance history was entered remedy Enter a code number between 300 and 319 inclusive This code is out of range for Tool Maintenance cannot add cause An invalid code number for tool maintenance history was entered remedy Enter a code number between 320 and 339 inclusive This function available at system console only cause An attempt was made to access a function which is restricted to the system console remedy Request the desired function at the system console This function available at terminals only cause A function was performed at the console that is restricted to terminals only remedy Request the desired function at a remote terminal This function is not available at this terminal cause An attempt was made to perform a function that is not available at the current user terminal remedy Retry function from a terminal that has permission for the function Too many different languages specified cause An attempt was made to add another language to the set of usable languages at a node The maximum languages at a node i
279. idate the data entered nor does it attempt to keep the overall shift totals up to date with the changes made using this function This function is needed occasionally to correct errors in job descriptors for jobs not started at the right time incorrect values in actual cavities cycles counted against non productive cycles etc To edit job production data follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F7 JDEdit Enter the job number to be edited Press Enter The selected job descriptor will be displayed Use the cursor keys to position to the proper field Enter the new value s as appropriate Press Enter To save your changes Press Esc In order to edit all fields the job must not be running Note The use of QCEdit and JDEdit functions should be limited Changes to the collections of data using these features requires considerable thought and possibly some calculations Any change to the job descriptor using JDEdit could require a similar change to the shift history record using QCEdit The Machine History Report is based on information current at the time it is generated However Machine History Reset continues to operate on shift boundaries Regardless of when a Machine History Reset is performed it will appear as if it had occurred precisely at the beginning of the shift it is performed in Copyright 2002 MATTEC 6 19 710 0092 The Machine History Report is used to provide various info
280. ify a part To select machine processes for part qualification follow these steps Copyright 2002 MATTEC 5 56 710 0092 Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU The MIU Setup screen Figure 5 20 MIU Setup will be displayed ProHelp Millennium oj x 1 mrkt09 i INTECT 1 000 Figure 5 20 MIU Setup Select the appropriate MIU to configure When you have accessed the correct machine to configure for part qualification move the cursor to the Alarm Output Low Hi column Entering a Y es in the Low and or Hi field means the MIU will use these parameters to close its contact and possibly send a bad part message to the ProHelp Millennium monitoring node Remember to select only those process limits that you have proven will produce a bad part when they are exceeded To save your changes Press Esc You must reboot the system for your changes to take effect You have now set the MIU hardware to qualify parts on jobs where part qualification has been turned on 5 9 2 Enable Part Qualification for a Job Part qualification is enabled and modified on a job by job basis To enable part qualification for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Copyright 2002 MATTEC 5 57 710 0092 Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will a
281. ight 2002 MATTEC 4 7 710 0092 The values that are typically displayed are FIELD DESCRIPTION Total Parts The total parts field contains the theoretical numbers of parts made We use the term theoretical because if you multiply the actual cavities times the number of cycles you should compute the number of parts you ve made If you count those actual parts the number counted is usually different from the theoretical value Parts tend to bounce away or are lost due to handling shift x cavities in use for that cycle job x cavities in use for that cycle The total parts to go is based on calculations that differ if the job is running or not running 1 Non running jobs without hold parts Total parts to go Good parts to go good parts to go x standard scrap percentage 2 Non running jobs with hold parts Total parts to go Good parts to go good parts to go x standard scrap percentage hold parts x 1 standard scrap percent 3 Running jobs without hold parts Total parts to go Good parts to go good parts to go x standard scrap percentage or actual scrap whichever is greater 4 Running jobs with hold parts Total parts to go Good parts to go good parts to go x standard scrap percentage or actual scrap percentage whichever is greater ProHelp Millennium uses this scheme to give the best information available There will be times that this scheme fails to produce accurate value
282. ile by entering operator efficiency data Operator tracking history file not found cause An operation was attempted that needed the operator tracking file but it was not found remedy Check for the existence of the file or create the file by entering operator tracking data Part already exists cause A NewPt operation was attempted which specified a part number for which a part descriptor already exists remedy Verify the entered part number If is correct the existing descriptor must be deleted or it may be edited to create the desired descriptor Part descriptor not found cause An operation was attempted for a part descriptor that does not exist remedy Check the spelling of the desired part or create the part if it does not exist Part not found cause The part number entered does not exist remedy Verify the entered part number Part weight exceeds shot weight cause Incorrect part weight is specified in the job standards remedy Set the part weight to be less than or equal to the shot weight The value must take into consideration the number of parts made per cycle Cavities times the part weight must be less than or equal to the shot weight PLC permission must be removed before signal can be disabled cause An attempt was made to disable a signal that had PLC permission Copyright 2002 MATTEC 15 34 710 0092 remedy Disable PLC permission before disabling actual signal PLC process parameter defin
283. ill activate Once the computer has booted and the graphical login screen is displayed login as the user mattec with the password prohelp The graphical desktop will be displayed You may execute ProHelp Millennium by double clicking on the ProHelp icon You will be prompted to select a user and enter your password When you have done this you will be at the copyright screen showing you the release number and initial menu selection at the bottom You will only be able to access the functions allowed by your password ProHelp Millennium 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 shutdown Step 1 Step 2 Step 3 Step 4 Announce to all users that you will be taking the system down Have all users escape to the copyright screen and exit ProHelp Millennium Assure that no ProHelp Millennium job changes are under way Assure that a shift change is not in progress Go To the Unix CDE front panel and click on the SCOAdmin icon Click the System Folder then the System Shutdown Manager Select Reboot after Shutdown is desired then select Shutdown from the top Copyright 2002 MATTEC 2 2 710 0092 menu then Begin Shutdown This will automatically stop ProHelp and shut the system down Step 5 The system will now be shut down Ensure that all secondary nodes are shutdown first before stopping the prima
284. imits calculations function A value of N o indicates that automatic SPC limits calculations is not enabled for the job A value of Y es indicates that automatic SPC limits calculations is enabled The value Done displayed next to a N o indicates that consecutive SPC samples have already been taken for this job and the new control limits are being used Automatic SPC limits calculations can be restarted by changing this value to Y es This field describes the number of consecutive observations to be taken after automatic limits calculations has been initiated at the MIU The number of consecutive observations are grouped into samples as described by the CYCLE SAMPLE field Any incomplete sample is ignored For example if the number of consecutive observations is set to 57 and CYCLES SAMPLE is 5 then 57 consecutive observations will be taken which will be divided into 55 5 11 full samples The two remaining observations will be discarded and ignored Valid values for this field are from 0 to 99 default For a sample size of one the moving range method is used for calculating control limits You should avoid changing the automatic SPC limits calculations parameters for a running job during the time when consecutive SPC sampling is in progress The automatic SPC limits calculations fields may be set in a similar manner for part descriptors The automatic SPC limits calculations are initiated at the MIU by the MIU operator Ref
285. intenance History Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4 Report Highlight Maintenance Highlight Tool History The Tool Maintenance History Report can be shown for one or all tools one or all maintenance codes and for all history or for a history within a certain time frame Fill in the interactive screen as appropriate Press F1 Done The Tool Maintenance History Report will be displayed 9 8 Preventative Maintenance Due Report Maintenance due forecasts are generated based on the maintenance history of a machine or tool the preventive maintenance schedule and the job schedule These forecasts provide estimated due dates for preventive maintenance and may be requested for a particular machine or tool or for a particular maintenance code number Each maintenance due forecast covers a period beginning with the point in time at which the forecast is requested and extending for the specified time in the future Any maintenance which should have already occurred when the forecast is generated but Copyright 2002 MATTEC 9 15 710 0092 which maintenance history indicates has not occurred is also included in the forecast this situation is flagged with an asterisk in the OD overdue column of the forecast The ProHelp Millennium job schedule provides information concerning the number of run hours and cycles that are scheduled to occur in the future This information is used in
286. into the remaining columns Copyright 2002 MATTEC 15 32 710 0092 remedy Select an item that will fit or shorten the item that would not fit if possible Nothing to save cause An attempt was made to save a custom real time format when no format had been defined remedy Define a format or abort the operation Number entered does not correspond to supported PLC type cause An attempt was made to use a PLC that is not supported by ProHelp Millennium remedy Check the desired PLC number for typographical errors or contact the MATTEC Customer Service Department for information regarding PLC s supported by the ProHelp Millennium system Number of active IU s exceeds maximum permitted cause The number of interface units that are active exceeds the number allowed remedy Contact MATTEC for assistance Number of Observations 0 cause The number of observations in the specified data set is zero remedy Inspect and correct the appropriate field in the job descriptor Operation not permitted cause An operation was attempted that is not allowed by ProHelp Millennium remedy Consult the ProHelp Millennium Operator s Manual for an explanation of the procedure Operator efficiency history file not found cause An operation was attempted that needed the operator efficiency history file but it was not present Copyright 2002 MATTEC 15 33 710 0092 remedy Check for the existence of the file or create the f
287. ion Type The following picklist will display ProHelp Millennium ioj x Items MIU Simulated RSU DIU OK Cancel Help 7 14 6 2 Variable Speed MIU Communication The speed of Monitoring Node to MIU serial communication may be specified on a per channel basis Speeds of 4800 9600 and 19200 baud are supported Only 10X MIUs allow the baud to be configured and support the higher speeds Of course all MIUs on a channel must be configured with the same speed and that speed must match that specified at the Monitoring Node 7 14 7 SPC Cause Reasons To define SPC Cause reasons for the system and individual departments follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F10 more Press F1 SPC Select the desired department to configure To move through all of the cause reasons for the selected departments Press PgUp PgDn Home and End keys Up to 50 cause reasons each 60 alphanumeric characters long may be defined for each department When editing SPC data from a computer any of these cause reasons may be associated with a specific sample The selected cause number will then appear on reports or graphs as appropriate Reference Section 5 7 4 for additional information Copyright 2002 MATTEC 7 72 710 0092 7 15 Location of Data Files Data that is collected by the system must be sorted and classified based on a number of characteristics Data is first
288. iptor QC sheets are active on the system as long as the part descriptor they are associated with remains on the disk 4 3 7 Part Descriptor Summary Report To generate a summary report of all existing part descriptors follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F3 Summry Fill in the interactive report screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Press F1 Done The Part Descriptor Summary Report will be generated The part number part name tool number primary material code standard yield standard cycle time or machine speed shot weight and part weight are displayed 4 4 Machine Schedules The ability to manage production requires good scheduling abilities Personnel materials tools etc must all be available when needed in order to produce the products in the time required The ProHelp Millennium schedules are constructed by the Job Manager and provide forecasted start or end dates for all jobs in the schedules The end dates show the production personnel when to stage the next tool for setup when to make the needed material available when to assign personnel and when current jobs will complete The schedule function enables the Job Manager to add jobs move jobs and delete jobs from machine schedules Each time a change is made to a schedule the system recalculates all end dates and redisplays the sch
289. is 0 remedy Set the cycle time to anon 0 number Cycle times less than 0 5 seconds should be verified with MATTEC to assure that the unit can be physically monitored Standard scrap above maximum cause The job standards value for the standard scrap percentage is greater than 100 remedy Set the scrap percentage equal to a value between and 100 For high resolution systems the maximum value is 10 0 Start date may not be in the future cause An attempt was made to use a start date that was in the future remedy Adjust the desired start date so that the date is not in the future System Error cause The system has encountered some error which should not occur during normal operation It may indicate damage to hardware or to the system s file structure remedy Note the exact text of the message and contact MATTEC for assistance Copyright 2002 MATTEC 15 41 710 0092 System miscellaneous configuration not defined cause An operation was performed that required the system miscellaneous configuration to be initialized remedy Have the System Manager create the miscellaneous configuration Target schedule is full cannot move job cause An attempt was made to move a job to another machine where the schedule was already full remedy Delete an existing job from the desired machine or move the job to another machine The ACTIVE DATE entered is a future date cause The active date cannot be later tha
290. is displayed begins with the first process values collected on the requested date for the selected job ProHelp Millennium File Graph Figure 3 52 Parameter Graph To print the graph Click File Select Print To exit the graph Click File Select Close 3 6 2 4 2 Most Recent Cycles automatic This allows the graphing of process parameter values from the most recent cycles There are two possible sources for these values Some MIUs retain at the MIU the values for the most recent 100 cycles and the host retains values for the most recent 50 cycles regardless of the type of MIU To access this function follow these steps Press F1 View Figure 3 1 Copyright Screen Press F7 Pgraph Press F2 LstCyc The system will display the selection screen shown in Figure 3 53 Copyright 2002 MATTEC 3 50 710 0092 ES ProHelp Millennium OF E Figure 3 53 Parameter Graphing Selection Screen LstCyc The Parameter choices include all individual signals and an All selection When All is selected a chart is produced containing the last 50 host retained values of all Primary Machine Signals available for the selected machine Once the chart is displayed a control list is available which allows signals to be included or excluded on an individual basis This list is shown in Figure 3 54 and a sample chart is shown in Figure 3 55 Graph Selection x i Cycle Tm PARSHTM J BLOWTIME m COOLTIME
291. isaccsdvassovctasadsnetesaveiisageacnassasaceasecesuctaveaceuscecesentpanaduetanveness 6 20 Te System IN ATV AST gic ea lg ele i iat tae ws ose cae acl ah eo reg We Laon 7 1 ZE Define ProHelp Millennium Users 4 c d50 scccs acgasseissaaadneegeced de hue peaduosdadwansesecsteews 7 1 T2 Remote e Umit CRW EE 7 2 7 3 Remote from MIU Down Reason Sclecnon cccccccsesseccececeesessnseceeeceesesessnseceeeeees 7 5 7 4 Set Shift Configuration and System Exception Penode AAA 7 5 Copyright 2002 MATTEC iv 710 0092 7 4 1 Weekly Schedule Cont suratiom EE 7 6 DA2S Schedule TIRES EE 7 9 TAS SUN Breaks EE 7 11 7 Miscellaneous Syst m Opons axon caciaietiontnoey eege 7 14 TG Creating Real Lungen deeg enge det 7 17 FOT Create Real Time Dis play sisi cescceiesinucese eron e E made aeaeesomeee cee 7 19 7 6 2 Add or Delete Items from a Display s ciisicccicscvcssacasssceccassavastiscesadeessnecedeaseanaccesecceeeass 7 21 T03 Dele tean Entre Display nret ee AE ee 7 22 7 6 4 Create a New Display from an Existing Display 7 22 7 6 5 Change the Lengths of the Data EE 7 23 7 6 6 Create a Graphic Layout Grid for the Display eee eeeseceeseeeenteceeseeeeaeeeenes 7 23 ROT Ni w C st m DSP EE 7 26 TO NextJ b Real Time S Cree EE 7 26 7 7 Real Time Configuration for WSers seasescccsesortoticcdent sesdodeaseeeaeinacsaeecaineeaoneeaies 7 28 7 71 1 Display the Configuration Screenvss ccccssivicssissacacdassavalsasevsaccasstevavaswesaceatedece
292. itions busy cannot edit cause An attempt was made to access the PLC process parameter definition while another user was accessing it remedy Have the user release the record or retry the operation at a later time Pulse low spec limit above high spec limit cause The job standard value for the machine parameter pulse for the low limit is wrong remedy Set the pulse limit less than the high spec limit R Upper Control Limit and R Lower Control Limit are equal cause The current upper and lower control limits are equal remedy Use the SPC editor to enter valid control limits for this data set R Upper Control Limit less than R Lower Control Limit cause The current upper control limit is less than the lower control limit remedy Use the SPC editor to enter valid control limits for this data set Record busy Cannot delete cause An attempt was made to delete a record already in use at another terminal or by a system function remedy Have the other user release the record or retry the operation at a later time Record in use cannot add at this time cause An attempt was made to add a record while another user was accessing the record remedy Have the user release the record or retry the operation at a later time Record in use Cannot delete at this time Copyright 2002 MATTEC 15 35 710 0092 cause An attempt was made to delete a record while another user was accessing it remedy Have the user release the rec
293. its status Cannot read help reasons establishing defaults cause On initial startup of system help reasons were not defined Cannot read help reasons using defaults cause On initial startup of system help reasons were not defined Cannot save PLC process parameter definitions cause An attempt was made to save the process parameter definition and an error occurred remedy Check all process parameter definitions there is more than likely incorrect data entered Copyright 2002 MATTEC 15 5 710 0092 Characteristic not specified cause An attempt was made to activate a ProStat function and no characteristic was specified remedy Specify a characteristic Command can only be selected from the console cause An attempt to use a console based command was made remedy Perform the command at the console Communications Error BCC error at console cause A communication error has occurred which is not normal under normal operations remedy Contact MATTEC for assistance Communications Error ETX expected at the console but not received cause A communication error has occurred which is not normal under normal operations remedy Contact MATTEC for assistance Communications Error SOH expected at console but not received cause A communication error has occurred which is not normal under normal operations remedy Contact MATTEC for assistance Communications Error STX expected at console but not received
294. ive maintenance actions should occur on a particular machine or tool For each maintenance code number which the user adds to a machine or tool maintenance schedule the user also indicates the time period which should elapse between occurrences of the activity associated with that maintenance code number For Copyright 2002 MATTEC 9 4 710 0092 machine maintenance this maintenance period may be specified in calendar days run hours or both whichever occurs first For tool maintenance the maintenance period is specified in machine cycles The history reports update at the beginning of the shift Therefore the run hours since the last PM and the cycles since the last PM will be accurate to the last start of shift Specifying the maintenance period as 0 days and 0 run hours for machine maintenance or 0 cycles for tool maintenance has the affect of descheduling the activity indicated by the associated maintenance code number A descheduled maintenance code number will not appear in the maintenance due forecast for the machine or tool in question To schedule machine maintenance follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F1 Mach Press F2 Sched Enter the machine number Press Enter The computer displays the preventive maintenance schedule for all of the machine code numbers One entry is made per each code number The cursor is shown highlighting a field Use the cursor keys to m
295. job function on Press Enter Copyright 2002 MATTEC 4 50 710 0092 The currently running job will be ended and the next job in the machine schedule will be started If no job is currently running the system starts the first job in the machine s schedule If no jobs are scheduled monitoring for the machine goes against a null job 4 5 5 Start the Next Son Job The Next Family function is used to end and start component son jobs independently without changing the status of the family father job This function applies only to systems with the optional Family Molding program To start the next son job and end one son job for a family follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F5 NxtFam Enter the machine number currently running the family job Press Enter A list is displayed showing the currently running component son jobs Select the job to be ended Press Enter Select the component son job to start Press Enter The system will now end the specified job and remove it from the family job descriptor and start the selected component job 4 5 6 Job Selection at MIU Job selection is available from 10X Mis 5XS MIUs TS MIUs and the PCMIU Ifa job is currently running it may be either ended or suspended If a family job is running one of its members may be either suspended or ended When a job change operation is initiated the operator selects eith
296. l move the active field to the first row End key Pressing once will move the active field to the end of line Pressing twice will move the active field to the first field of the last row F1 Send Causes Data Import Records to be produced for all rows containing data Press F1 Send The following message will appear if successful Operation completed successfully to invoke the Data Import function with the delrecnoerr option described in ProHelp Millennium Data Exchange Manual 710 0085 If no errors are encountered a message is displayed informing the user that the import was successful and the Manual Entry feature exits when the message is acknowledged If errors are encountered a report is produced and just as with any Data Import operation the user can browse and or print the report When the user is finished with the error report the system offers the user the option of discarding the remaining import data If the data is discarded the Manual Entry feature exits Otherwise the spreadsheet interface is again presented with only the rows which contained errors Copyright 2002 MATTEC 11 4 710 0092 12 ProSched The ProSched will provide the user with a graphical representation of the current machine schedule for selected machines The ProSched will take a snapshot of the current running ProHelp system when ProSched is first invoked Changes made to the current running ProHelp system will not be tracked by th
297. l of 96 process parameters This includes Cycle Time but does not include the three auxiliary counters All capabilities previously provided for thirteen process parameters are available for twenty of these 96 The remaining 76 have a subset of those capabilities available The twenty parameters with full capabilities are called primary process parameters and the others are called auxiliary process parameters Copyright 2002 MATTEC 5 7 710 0092 Auxiliary Process Parameters DESCRIPTION Specification Limits These limits are available on a job by job basis They are modifiable in both the Part Descriptor and in the Job Descriptor Specification Limit Limit checking is performed by the MIU Out of limit conditions are Checking and enunciated at the MIU via red green and white lights At the host Alarming out of limit conditions are indicated by color coding of process parameter fields on the Real Time Display Exception Logging and All specification limit violations are written to the host s Exception Distribution Chart at The Distribution Chart based on the last 100 readings for a e Consecutive Cycle This chart is available from the MIU and host menus Additionally Chart Last 100 it is available at the host by mouse clicking on a process parameter field of the Real Time Display Primary Process Parameters Any 20 from the total of 96 are eligible as primaries For each machine 20 are selected at system configuration ti
298. l shift off of the right end of the field to make room for them Each press of the Insert key toggles the mode so that pressing it while characters are being inserted will return to the type over mode e The Delete key may NOT be used to erase the characters Use the Backspace key to erase the character preceding the cursor e Pressing Esc during field entry ends field entry and returns the original value of the field Since multiple choice and Yes No fields do not really have an entry phase where characters are being entered Esc cannot return the original value The various types of data fields and their specific rules are Text In general text fields may contain any alphabetic or numeric alphanumeric characters plus most of the punctuation characters However some fields e g job numbers are more restrictive in the characters accepted Typing any legal character into a text field blanks the field and places the typed character at the beginning The remainder of the field may now be entered Numeric Numeric fields only accept the numbers 0 through 9 and in some cases a sign or and decimal point If a sign is entered it must be the first character Copyright 2002 MATTEC 2 10 710 0092 Date Dates consist of three numbers separated by slashes The sequence of the numbers is selected by the System Manager and may be either mm dd yy or dd mm yy When entering a date field a or space may be used t
299. le above the maximum allowable value was entered remedy Values for cycles per sample or observations per sample must be 2 through 9 Error SQC cycle per sample or observations per sample below minimum cause A value for cycle per sample or observations per sample below the maximum allowable value was entered remedy Values for cycles per sample or observations per sample must be 2 through 9 Error SQC Mach Parm low ctrl limit above high ctrl limit cause While setting up upper and lower control limits an error occurred where the lower control limit is greater than the upper control limit remedy Adjust the control limits so that the lower limit is less than the upper limit Error SQC machine parameter average is outside control limits cause An attempt was made to manually key in values for the SQC limits remedy When manually keying in values the average must fall within the control limits Error SQC samples per run above maximum cause An attempt was made to key in a number for samples per run that was above the maximum allowable remedy The maximum allowable value for samples per run is 9 Error SQC variable average is outside control limits cause An attempt was made to manually key in SPC control limits for variables remedy When manually keying in control limits the average must fall within the control limits that are set Error SQC Variable low ctrl limit above high ctrl limit Copyright
300. le and Attribute Variable and attribute part related data may be entered at an MIU via the keypad or serial channel using a serial gage interface or at a computer terminal via the keyboard or serial channel gage interface The data entered is derived from a sample of parts collected and inspected at the MIU or computer terminal Variable and or attribute data may be entered for any job where SPC has been enabled in the job descriptor It is possible to enter variable and or attribute data that corresponds exactly with the machine process parameters by collecting parts immediately after starting a manual sample at an MIU After entry variable and or attribute data is sent to the proper node for storage and processing If a shift or trend is detected or if any variable or attribute data is out of limits a message is displayed at the MIU and alerts appear on all real time screens Reference the MIU Operator s Manual for information on the SPC functions available at the MIU General Operating Procedures Before you venture any further in the ProStat section of the manual keep these two things in mind 1 Standards are entered and sampling is enabled under the Job Manager mode in individual job descriptors 2 The ProStat function selections under View and QC Manager allow the user to apply statistical methods of examination to the collected samples e g XbarR charts histograms linear regression analysis etc The QC Manager mode
301. lection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To generate the chart for a part number multiple job runs with the same part number reference Section 5 7 for additional information To select the parameter data type Press spacebar The available choices include none automatic process parameters manual process parameters or variable data Use the cursor keys to position to the desired choice Press Enter Enter a number 1 to 30 in the Number of Cells field Press Enter NOTE When 0 is entered the system automatically calculates the cell size Reference line choices are displayed by pressing the spacebar Use the cursor to select Spec Sigma Individual Sigma Estimate Spec Sigma Individual or Spec Sigma Estimate Press Enter If you selected Sigma Individual you can specify a Sigma Multiplier Any number from 0 1 to 9 9 is allowable A histogram reflecting 3 sigma is generated by entering a sigma multiplier of 3 0 Enter your selection Press Enter Press F1 Done The histogram will be displayed Copyright 2002 MATTEC 5 40 710 0092 ProHelp Millennium File Graph LT Figure 5 13 Histogram Graph The histogram display consists of a histogram on the left hand side of the screen with a block of data on the right hand side of the screen To print the histogram Click File Select Print T
302. lities for the operator are 1 Login your employee number at the MIU at the beginning of each shift and after returning from breaks Logoff your employee number at the MIU whenever leaving the machine 2 Know the standard cycle time that is required for the job you are running Keep your machine running within limits Display each actual cycle time on the MIU so that you know how you are running compared to standards 3 Enter rejected part quantities and reasons at the MIU Do this every time rejects are detected not just once a shift 4 Call for help whenever necessary Use the call for help selector switch or menu selection at the MIU 5 Ifyou are involved with Statistical Process Control SPC learn how to take samples Learn what the display prompts and warning lights mean 6 Most importantly make sure that the job you are running is the same one ProHelp Millennium thinks you are running Use the MIU display to show what job is running 7 Watch the job complete light Know when your job is complete and inform your supervisor You may then determine if an overrun is necessary due to possible scrap parts 8 Allocate machine downtime to the proper reason Use the selector switch or menu selection on the MIU to determine why the machine will be down for long periods of time 9 When you are running production make sure the downtime switch is to the in production position 1 2 9 Quality Control Department The
303. low these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F6 Names Select the department to delete by pressing the spacebar in the department field Use the arrow keys to select the department Press Enter To delete the department Press F2 Delete To delete the displayed department definition Enter Y es To save your changes Press Esc In order to delete a department all machine schedules in that department must be empty All MIUs in that department must be deleted After doing this you must reboot the system To change the name of a department create a new department then change the department name of all affected MIUs in the MIU installation screen Now delete the old department and reboot the system Copyright 2002 MATTEC 7 67 710 0092 7 14 3 Department Scrap Downtime and Help Names To set scrap downtime and help names by department follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F6 Names Move the cursor to the department field Press spacebar Select the desired department Press Enter Move the cursor to the desired name field and enter the new name To save your changes Press Esc Any changes made to the department scrap downtime and help names require that the system be rebooted All affected MIUs must be rebooted 7 14 4 Individual Machine Signal Names To set individual machine MIU
304. ly 3 6 2 1 Annual Comparison Report Multiple years of production can be compared using Charts and matrix style Reports or it can be written to an ASCII file All items presently in the Condensed Production History file are available see Section 6 4 as well as the following calculated items Utilization Figure 3 31 Annual Comparison Report Calculated Fields To access the Annual Comparison Report Press F1 View Figure 3 1 Copyright Screen Press F4 Report Highlight Production The following picklist will display Copyright 2002 MATTEC 3 34 710 0092 ProHelp Millennium of x Items Annual Comparison Downtime Auxiliary Downtime Daily Downtime Period Event Log Material Used Operator Efficiency Operator Tracking Highlight Annual Comparison Click OK The following screen will display A Figure 3 32 Annual Comparison Report Screen Yearly quarterly or monthly detail is available for one to five years A single department may be selected or all departments combined Most of the fields shown in Figure 3 32 are common to many reports and should be familiar Period and Item are specific to the Future Requirements Report and define the report produced Choices for each of these are shown in Figure 3 33 and Figure 3 34 Copyright 2002 MATTEC 3 35 710 0092 K ProHelp Millennium Iof x gt lt ProHelp Millennium Figure 3 33 Period Picklist Figure 3 34 Item Picklist
305. m ProSched File Edit View OMe S25 ie doll RX JOE PART f NUMBER NUMBER DESIRED START DESIRED END Figure 12 30 Unscheduled Jobs 12 2 3 Selecting a Job To make any job the 1 current job the user will click the left mouse button in the bar that represents that job in the Gantt area There may only be one current job Clicking inside of another job s bar will cause that job to become the current job The current job is used by ProSched when the push buttons for View Job Descriptor and Modify Job Descriptor are selected Figure 12 12 Edit Pull down If the Machine Schedule Area has been enabled and a job is selected the machine schedule will be scrolled so that the job selected in the Gantt chart is displayed as the first job in the Machine Schedule text area Visually the bar representing the current selected job will be drawn with a 3 D pushed in effect No other special treatment will be provided for the current selected job 12 2 4 Drag and Drop Operation Copyright 2002 MATTEC 12 26 710 0092 A Drag and Drop Operation consists of two steps Step 1 The user identifies the drag source to the Drag and Drop Job Scheduler ProSched The user specifies the drag source by pressing and holding the left mouse button over the visual representation of the job Since for the Gantt area this is the same operation as selecting a job the user must move the mouse some non trivial amount before the drag source will be recog
306. ma Multiplier Sigma of the Individuals D and D Tabular Constants SPC CALCULATIONS CONTROL CHARTS continued C ESTIMATED SIGMA UCL GE e d 5 em x Jn UCL e DE LCL X e e vn LCL d D R R R Copyright 2002 MATTEC 5 54 710 0092 NOTE 0 Sigma Multiplier da Estimated Sigma D3 and D 4 Tabular Constants 3 SPC CALCULATIONS HISTOGRAMS USL X Z upper X LSL oO Z lower Z min the smaller of Z upper Z lower Zmin CPK 3 Cn USL LSL P 66 Cr 1 cp Cell Count if 0 is selected 1 is the minimum number of cells and 30 is the maximum number of cells E Skewness gt n ial Kurtosis 3 n 2 a fe Chi Square Jr e Where fa The actual frequency the actual cell count fe The theoretical frequency the theoretical cell count Copyright 2002 MATTEC 5 55 710 0092 Test for normality If chi square is less than or equal to the tabular chi square value indexed by the degrees of freedom then the distribution is normal NOTE The degrees of freedom is the number of cells minus three 5 9 Part Qualification The ProHelp Millennium system has the capability of 100 qualification of parts during production based on the SPC or Engineering limits of any machine process being monitored by an MIU When a part is produced during a cycle where any process exceeds its limit the system can automatically
307. mary Report of jobs in the standby data directory will be displayed Copyright 2002 MATTEC 6 16 710 0092 6 8 Retrieve Old ProHelp 1000 and ProHelp Archived Data If you upgraded to ProHelp Millennium from ProHelp 1000 or ProHelp it is very possible that you already have a great deal of archived ProHelp data This data needs to be converted to the ProHelp Millennium format before it may be used on the system If you want to restore old ProHelp 1000 or ProHelp data so that it may be used by ProHelp Millennium you must contact the MATTEC Customer Service Department for assistance 6 9 Restore Backup Data In the event of a hard disk failure the backup that you have created will be used to restore your ProHelp Millennium system You must contact the MATTEC Customer Service Department for assistance with restoring your ProHelp Millennium system BEFORE beginning this procedure NOTE If your most recent system backup was from six months ago for example you WILL lose the last six month of data This is why the backup function should be performed daily or every week at a minimum Restoring backed up ProHelp Millennium data is a two step process In the first step the user must manually copy the backup data from the storage device e g a tape to the hard disk using standard Open Unix copy utilities In the second step the backup data must be read into ProHelp Millennium To copy the backup data from a tap
308. mber was entered or the job number is no longer active in the system the error message Job not found will be displayed 4 6 4 Display the Schedule of Component Son jobs Individual component son jobs of a family job descriptor may be viewed in a schedule with desired and forecast end dates predicted To display the schedule of component son jobs follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F3 Sched Press F1 Mach Enter the machine number Press Enter Press F8 Family Select the family to be viewed Copyright 2002 MATTEC 4 56 710 0092 Press Enter A new schedule screen will be displayed showing only the component son jobs of the requested family job Each component job is shown with its current status and a forecast end date To return to the machine s schedule screen Press Esc 4 6 5 Enter Scrap at an MIU for Family Jobs The method of entering scrap for family jobs at the MIU depends upon the type of MIU in use at the machine MIUs Level 0 1 2 and 3 require code entries associated with the index number of component jobs MIUs Level 4 5 6 7 and 8 provide an LCD screen that displays the job number of the component son jobs currently running Reference the MIU Operator s Manual for information regarding scrap entry for family jobs 4 6 6 Dual Cycle Time Monitoring A dual cycle time job is a special type of family job that is scheduled on a dual cycle time ma
309. me A different set of 20 may be selected for each machine and the 20 selected for a particular machine can be altered Naturally any reconfiguration of a machine or its parameters should be done with care This is especially true if any sense is to be made of data collected both before and after a change In addition to the capabilities described for auxiliary parameters primary parameters possess the following capabilities Process Parameter This is the ProHelp Systems traditional Parameter Graph and recording reporting Parameter report and charting SPC recording All normal SPC functions are present including reporting and charting e Control Limits calculation and checking SPC Trending SPC Composite Chart Xbar R Chart Histogram X MR Chart SPC data is collected by ProStat in four ways DATA TYPE DESCRIPTION Copyright 2002 MATTEC 5 8 710 0092 Machine processes being monitored e g cycle time pulse time and analog values are automatically collected at random intervals specified by the user in the job descriptor No manual intervention is required during the collection of data Process parameter data is collected by the MIU and sent to the Host computer for processing and storage Process data from a specified number of consecutive machine cycles is collected upon command by the MIU operator When collected this data is time and date stamped and sent to the Host computer for processing and storage Variab
310. meters min 0 001 0 0001 Default Display resolution for the following values Production 0 Quantity 0 1 0 01 For parts meters cases rolls parts m 0 001 7 6 Creating Real Time Screens The real time display writer allows a user to develop up to 100 custom real time screens in addition to the standard MATTEC real time screen The format of these real time screens is dependent upon the choices that the user makes There are many values from the master data base that can be selected to be viewed on the real time screen When Copyright 2002 MATTEC 7 17 710 0092 these values are placed on the screen they will change colors from red green white yellow etc as they would normally do on the standard MATTEC real time screen It is very important to remember that once a real time screen format is created it must be saved to the hard disk Then this disk can be recalled at any time through the function keys in the view mode The standard MATTEC real time screen utilizes many data fields which have a fixed length The data fields that you select for your real time screens can have different lengths than the standard Each real time screen can have the same data field but a different length Each data field that is to be displayed as a column on the real time screen has two line headings that can be created Each line of the heading is the exact field length as the data field itself For example if the part number field is 22 character
311. mit Press Enter Copyright 2002 MATTEC 5 38 710 0092 Move the cursor to the next appropriate field and make entries for all of your limits If no limits are specified ProStat will scale the graph in proportion to the values of the data samples ProHelp Millennium File Graph Figure 5 12 XBar Chart To see additional points not displayed on this screen click on the scroll bar and drag it in the direction of the additional points To print the chart Click File Select Print To exit the chart Click File Select Close 5 8 3 ProStat Histogram Chart Histograms may be generated for automatic manual and variable SPC data The user may specify through menu selections that the histogram be generated based on the specification limits or on specified Sigma limits The number of cells i e classes for the histogram may be modified by the user from to 30 When 0 is selected the system automatically calculates the cell size Copyright 2002 MATTEC 5 39 710 0092 To generate a histogram follow these steps Press F1 View or F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F3 Histo Enter the start and end dates Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The se
312. mn To generate the Job Descriptor Summary Report follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F3 Summry Fill in the interactive screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Press F1 Done The Job Descriptor Summary Report will be returned The Job Descriptor Summary Report lists the job number part number tool number machine number good production scrap parts cycle and yield efficiency standard and actual machine speed or cycle times utilization and schedule status To generate the Job Descriptor Summary Report of jobs in the standby directory follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F5 SummSB Fill in the interactive screen as appropriate Press F1 Done The Job Descriptor Summary Report of jobs in the standby data directory will be returned 4 2 5 Setup Sheets To create or modify a job s setup sheet follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply Copyright 2002 MATTEC 4 25 710 0092 A picklist will appear Highlight the type of Document There are three choices Machine Tool or QC Click OK If you have copied a setup sheet with the job or part when crea
313. modification DESCRIPTION SPC Enable A Y es indicates that the individual process parameter is enabled This field is only available if either automatic or manual sampling is turned on Only enabled process parameters are collected and stored Alarm These fields define the alarm conditions to be tested after an SPC Samples SPC sample is taken They are available for modification CNTRL RUN only if the SPC enable flag for the individual process parameter has been enabled to Y es The alarm condition is displayed on the SQC status screen and on real time screens For Control alarms valid choices are none XLimits RLimits and XRLimits default An alarm occurs if the SPC sample exceeds any of the selected control limits For run alarms valid choices are none XRuns RRuns and XRRuns default An alarm occurs if the SPC sample causes a number of consecutive samples as defined by SAMPLES RUN to indicate a Trend or Shift for any of the selected run conditions Alarm These fields define the alarm conditions to be tested after Machine Parameters every machine cycle Both options are available regardless of SPEC CNTRL the value of the SPC enable flag For SPEC alarms an alarm occurs if the machine process parameters exceed the specification limits for any of the selected signals The alarm is displayed on real time screens For CNTRL alarms an alarm occurs if the machine process parameters exceed the SPC control limits for any of t
314. more accurate and current numbers being presented there are changes in the recording of preventive maintenance operations and in the Real Time Display 9 1 Maintenance Code Numbers Both Machine and Tool Maintenance Codes are expanded to a total of 100 Tool Codes are system wide but Machine Codes are defined by department In addition Purge and Archive operations deal with the maintenance logs in a manner similar to Job Descriptors Departments cannot be set up for the previous style of operation with PM Codes 300 339 All departments operate with the new codes 1 100 Old style MIUs will continue to function with PM Codes 300 through 319 being converted to Machine PM Codes 1 20 and PM Codes 320 through 339 being converted to Tool PM codes 1 20 Copyright 2002 MATTEC 9 1 710 0092 All PM Code definitions screens allow entry of 100 maintenance operation descriptions Machine Maintenance code definition allows selection of a department Tool Maintenance code definition does not Each set of definitions is identified by numbers 1 through 100 instead of the 301 320 and 321 340 previously used Each set is presented in five pages of 20 codes each The PgUp and PgDn keys may be used to move through the pages Maintenance code numbers identify a particular preventive maintenance activity There are twenty such maintenance code numbers allocated for preventive machine maintenance and an additional twenty allocated for preventive tool maintenance
315. n set to N o this value is reset only when the machine re enters production This allows the user to determine whether this number represents the amount of time since the machine has been in production or the amount of time since the current reason selection was made Import Run Comp This parameter determines how data import relates to running or completed jobs Specifically JB and JF records see 710 0085 Data Exchange Manual are affected Choices are Allow Imported data applies to jobs regardless of status Error If an import record references a running or completed job the changes are not applied and an error is reported Ignore If an import record references a running or completed job the changes are not applied but no error s reported This gives the user control of situations that may arise since the preparation of import files cannot be tightly synchronized with actual production A realistic situation would be an imported lot size increase for a job that has just ended It may be desired to have the situation flagged by having an error reported Other users may prefer that the data simply be ignored MIU Lang Sel Some of the text displayed at MIUs is provided by the host and this parameter determines what language is used for that text The parameter is set from a pick list of all available languages Copyright 2002 MATTEC 7 44 710 0092 Table 7 1 Miscellaneous Installation Parameters System
316. n 10 every time the MIU contact is closed If Part Qualification is set to Y es and SPC is enabled the MIU output contact will close during the next cycle if in the current cycle any signal with Hi set to Y es goes above the SPC control limit or any signal with Low set to Y es goes below the SPC control limit The system will count parts as scrap in scrap reason 10 every time the MIU contact is closed If Part Qualification is set to N o regardless if SPC is enabled or disabled the MIU output contact will close during the next cycle if in the current cycle any signal with Hi set to Y es goes above the specification limit or any signal with Low set to Y es goes below the specification limit The system will NOT count parts as scrap when the MIU contact is closed To set the entire system to operate under Release 1 3 part qualification rules follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F1 Misc Set the Enhanced Part Qual field to N o The system will now operate using Release 1 3 part qualification rules Copyright 2002 MATTEC 5 59 710 0092 To enable an individual job to follow Release 1 3 part qualification rules if you are using enhanced part qualification Release 1 4 rules follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job
317. n is the location where system exceptions are displayed The ProHelp Millennium system is constantly checking up on itself and when one of these self checks fails an exception message is displayed These are similar to System Errors in the sense that MATTEC personnel should be contacted for assistance and just like System Errors you should record the exact text of the message to help us diagnose the cause The following list contains most of the ProHelp Millennium error messages in alphabetical order along with a brief description of the most likely cause of the error and the remedy for it A family job is not running on this machine cause A family job operation was performed at a machine that does not have any family jobs running remedy Abort the operation or perform the operation on a machine running a family job A PLC type has not been specified cause An attempt to define a PLC was made before the actual type was specified remedy A type must be entered must be entered before giving the PLC a definition Copyright 2002 MATTEC 15 1 710 0092 A running job cannot be moved cause An attempt was made to move a job to another machine while the job was running on a machine remedy The job must first be suspended before a move can be done Actual number of cavities greater than standard cause The job descriptor standard for the actual number of cavities is greater than the standard value of cavities remedy Cha
318. n the current date remedy Enter a valid active date The date must be in the past cause The date specified for a report or other function is required to be in the past and the entered date did not meet this requirement remedy Enter a valid date The end date must be in the future cause An attempt was made to use an end date that was not in the future remedy Enter a valid end date The end date of the sample cannot be in the future cause The desired end date is later than the current date remedy Enter a valid end date The end of the time period cannot be in the future cause The desired end time is later than the current time remedy Enter a valid end time Copyright 2002 MATTEC 15 42 710 0092 The end of the time period must be now or in the past cause An attempt was made to perform a task using an end of time period that was in the future remedy Enter a valid end time The job has not ended cause An attempt was made to generate a Job Cost Report on a job that is not completed remedy Wait until the job has ended before requesting the report The MIU keypad is not enabled cause The MIU keypad flag was not properly enabled to perform the desired operation remedy Have the System Manager enable the MIU keypad flag The number of decimal places cannot exceed three cause The desired number of decimal places exceeds the maximum limit of three remedy Reduce the number of decimal places to thre
319. nce people should be trained to log activities at the MIUs when a machine repair or tool repair occurs The MIU time stamps the maintenance code number entered and sends it to the computer for storage Detailed data entry can be made at the computer terminals to explain the reason for the maintenance Performance histories of run times are kept on machines and tools PM preventive maintenance activities are based on actual use A Purge function is available which allows maintenance history for a particular machine or tool to be completely deleted or to have only those records removed whose time stamp indicates that the maintenance occurred prior to a particular date which the user specifies Typically machine and tool maintenance records are reset once a year Reference the MIU Operator s Manual for information on logging maintenance activities at the MIU In older versions the Preventive Maintenance feature operated under the assumption that all machine production cycles occurring during a shift occurred after any maintenance operations logged during that shift For preventive maintenance operations scheduled no more often than once a day this presented virtually no problem but is inadequate for more frequent maintenance operations In the current Release 3 x preventive maintenance displays and reports are based on machine production and maintenance entries which are current at the time the display or report is generated In addition to
320. nces contains five 5 index cards Action area There are four 4 push button controls in the action area The controls are labeled OK Apply Save CANCEL Activating the OK control will have the same effect as an activation of the Apply control followed by activation of the CANCEL control Copyright 2002 MATTEC 12 13 710 0092 Activating the Apply control will cause the changes made in the control area to be applied to the current session of ProSched Activating the CANCEL control will cause the ProSched Preferences to revert back to the ProHelp Millennium ProSched Control area The control area is composed of several groups of controls that can be used to change the appearance and operation of the current session of ProSched The following will briefly describe the 5 index cards in the ProSched Preferences screen BAR LABELS Bar Labels allow the user to select which job descriptor field is shown in each of the Gantt s bars This control group has six 6 toggles labeled Job Name Part Name Customer Name Tool Name Primary Matl Code None Only one of these controls can be active at a time These will be the only fields that can be displayed inside a Gantt bar By default the Job Name control will be active ProSched Preferences sl o a EE Mise Job Number Part Name Customer Name Tool Number Primary Matl Code None Apply save CANCEL Figure 12 17 Pref
321. ncountered a report is produced and just as with any Data Import operation the user can browse and or print the report When the user is finished with the error report the system offers the user the option of discarding the remaining import data If the data is discarded the Manual Entry feature exits Otherwise the spreadsheet interface is again presented with only the rows which contained errors Copyright 2002 MATTEC 4 64 710 0092 5 Quality Control Manager During normal operation of the ProHelp Millennium system scrap parts and reasons are entered at the MIU Machine downtime is accounted for by selecting the appropriate downtime category at the MIU when the machine stops cycling Occasionally it becomes necessary to modify scrap parts scrap reasons or machine downtime The QC Manager mode of operation provides the ability to edit these fields as well as perform SPC ProStat functions Reference the MIU Operator s Manual for information on logging scrap parts and machine downtime at the MIU 5 1 Edit Scrap Parts To edit scrap parts for the present shift of a running job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QC Ent Press F1 Active Enter the machine number of a running job Press F5 ScrapP A new menu is displayed The reason for the scrap parts must be selected and the quantity entered Figure 5 1 QC Scrap Entry Note For a running job scrap may also be entered at
322. nd time information displayed in Display the two right hand columns on the Sched Disp field is as follows e Desired Start Desired End e Desired Start Forecasted End e Desired End Forecasted End e Forecasted Start Forecasted End Report Header The name that will appear as the header on all printed ProHelp Millennium reports is entered in this field The name may be a maximum of 20 characters in length To set the downtime help exception logs and Kanban scheduling Press F1 Dept Use the spacebar for a picklist of Department names Default Machine Speeds and Default Production Quantities To save your changes Press Esc Copyright 2002 MATTEC 7 16 710 0092 prohelp Figure 7 11 Department Configuration Screen Following is an explanation of each field Help Log On These two logs may be turned on Y es or off N o When enabled Down Log On the Help Call and Downtime report are available under F1 View F4 Report Both reports list the occurrence and duration of every help and downtime message Because these reports use hard disk storage they should only be turned on if they will be used Exception Log Turns on exception log per department On Kanban When enabled it provides automatic Kanban Just In Time Scheduling scheduling functions within the ProHelp Millennium system Default Display resolution can be selected for the following values Machine Speed 0 1 0 01 For secs cyc cycs min cycs hour
323. ndard language Press F4 LangEd OR To edit special strings that have been created by MATTEC specifically for your installation Press F5 SplEdt The system will display the Language File Maintenance screen ProHelp Millennium Of x Language File Maintenance String Number 0 Length 18 Description TITLE CENTER WITH SPACES Figure 7 30 Language File Maintenance Screen The language maintenance screen is divided into the following four areas String Number In dark blue at the top are the String Number and Length fields String Number identifies the position of the phrase or word in the system translation There are literally thousands of strings in the system Use the PgUp and PgDn keys to access a string or you may use the F1 StrNum key to type in a particular string for translation Length tells how many characters may be used to translate or change the string String lengths may be less than but may not exceed the number of characters determined in the Length field English The yellow area shows the English translation of the word or phrase This is the English translation of the phrase as it appears on the standard ProHelp Millennium system Copyright 2002 MATTEC 7 63 710 0092 Description The third white area gives a brief description of the word or phrase as it is used in ProHelp Millennium In the figure the description of the phrase is TITLE CENTER WITH SPACES This indicates tha
324. ndow Press Esc to close this window Part Number or Part Name Click on the part number or part name fields and the first page of the job descriptor will be displayed in a new window Press Esc to close this window Scrap Percent Run Job or Shift Click on the scrap percent run job or shift field and the scrap page of the job descriptor will be displayed in a new window At this point a downtime or scrap Pareto chart can be graphed by pressing a function key Press FJ for current scrap F2 for current downtime F3 for job scrap or F4 for job downtime Press Esc to close this window Copyright 2002 MATTEC 2 6 710 0092 SPC Enable Flag Click on the SPC enable flag an for jobs running SPC and the following menu will be displayed This is the same menu that is displayed if you click on the machine or job number and select SPC ProStat View X Bar Charts Histograms Regression Analysis Pareto Charts Summary Reports P U Charts Combo Reports SOC Status Screen Exception Report Exception Chart Select the appropriate ProStat function that you wish to view 2 3 2 Graphics Mode When in graphics mode i e whenever a graph or Gantt chart is displayed a mouse is virtually required When in graphics mode the following rules generally apply e To exit the graph Click on the File Menu and select Close This can also be accomplished by pressing the hot keys Alt F and then C e To see addi
325. ne loading To display the Gantt chart schedule follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F3 Sched Press F3 Gantt Fill in the interactive screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Select the proper department and machine class Select the number of days the Gantt chart is to cover Any number from 1 to 365 may be specified Press F1 Done The Gantt chart schedule will be generated Periods for which no job is scheduled appear on the chart as a single gray colored line Scheduled jobs will appear in red or green Jobs which meet the desired end date are colored green Jobs which fail to meet the desired start or end date are colored red By default the Gantt chart will display in color with the job number displayed in the colored bar if it fits To display the part name customer ID or tool number or to modify other defaults Click File Select Preferences Make changes as required To make your changes take effect Click Apply Click Done To display job related information Click on any job with the mouse The machine number job number parts to go and related information will be displayed To view the entire job descriptor Click View Job Descriptor The job descriptor will be displayed in a new window Copyright 2002 MATTEC 4 46 710 0092 To display job related information for jobs that are too
326. nel to edit data and change standards Contact the MATTEC Customer Service Department to stay abreast of new software and hardware releases Copyright 2002 MATTEC 1 11 710 0092 1 3 System Components This Section describes the hardware used in the ProHelp Millennium system All users of the ProHelp Millennium system should have a general understanding of this hardware 1 3 1 Nodes Primary Node The main ProHelp Millennium computer is referred to as the primary node or Host computer This computer contains all of the configuration files and ProHelp Millennium software It can also contain various data files if desired This node is required to be booted and running for the ProHelp Millennium system to function Monitoring Node This is a node on the ProHelp Millennium network that is monitoring machines with the use of a serial board i e RocketPort Board Typically your primary node will also be a monitoring node Up to 64 machines may be monitored by each monitoring node Additional interactive users X Servers and X Terminals may connect to this node to access ProHelp Millennium Non Monitoring Node This node has most of the capabilities of a monitoring node but is not directly monitoring machines This is an active node on the network and can perform its own processing locally ProHelp Millennium software can be stored at a non monitoring node Usually one additional interactive user X Server or X Termin
327. ng Functions Copyright 2002 MATTEC 5 49 710 0092 The user has the ability to specify the scaling limits for chart before generating the chart If you are trying to compare charts from different time frames it is very easy to specify the same scaling limits so as to make easy comparisons for the data Move the cursor to the high or low limit boundary to be specified Enter the numeric value for the limit Press Enter Move the cursor to the next appropriate field and make entries for all of your limits If no limits are specified ProStat will scale the graph in proportion to the values of the data samples ProHelp Millennium File Graph Figure 5 18 U Chart To see additional points not displayed on this screen click on the scroll bar and drag it in the direction of the additional points To print the chart Click File Select Print To exit the chart Click File Select Close Copyright 2002 MATTEC 5 50 710 0092 5 8 9 SPC Composite Report The SPC Composite Report function allows the user to generate a report that includes various types of ProStat SPC data Any machine parameter or variable may be specified for the report and may be configured to display the following e XBar or P U Charts e Range Chart e Histogram e Capability Analysis e Sample Data To generate the SPC Composite Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F10 SPCRpt
328. nge the number to be less than or equal to the standard value Actual number of cavities is 0 must be non 0 cause The value for the cavities is 0 remedy Change the value to any number less than or equal to the standard value for cavities Adding to the schedule requires a valid machine number cause An attempt was made to add a job to a schedule and the job description with an incorrect machine number remedy You must enter a valid job number in the job description before you can schedule from the job description Analog checkpoint above cycle time high spec limit cause The checkpoint time value in the job descriptor is higher than the cycle time maximum limit remedy Lower the value to be under the cycle time maximum limit Analog low spec limit above high spec limit cause The low spec limit value must be less than the high spec limit value Remedy Change the value to be less than the high spec limit Async communications device not defined Copyright 2002 MATTEC 15 2 710 0092 cause The serial device to use for computer to computer communications has not been selected remedy Contact MATTEC for assistance Async communications device open error cause The serial device selected for computer to computer communications cannot be accessed The device may not be present or may have failed remedy Repair replace or install serial card Asynchronous Communications Unit DUAL PORT RAM cause An error has oc
329. ning at ProSched startup is never eligible as a drag source Once Commit is active you will see a screen indicating please wait processing data Upon tallying the results a screen will appear indicating completion You can either restart Figure 12 3 Scheduler or exit Figure 12 4 ProSched Startup 12 2 4 1 Brief Overview Copyright 2002 MATTEC 12 27 710 0092 Figure 12 31 ProSched Screen is a view of a ProSched Screen that will be used for this exercise File Edit Figure 12 31 ProSched Screen This screen will show the different jobs running on startup Notice red yellow and green bars Figure 12 21 Preferences Misc Copyright 2002 MATTEC 12 28 710 0092 lt gt SS Millennium ProSched JOB PART RO JOB f NUMBER NUMBER 0 GO STAT DESIRED START FORECAST END NUMBER JOB PART RO JOB NUMBER NUMBER 0 GO DESIRED START DESIRED END NUMBER Figure 12 32 ProSched Main Screen We will now move an Unscheduled Job located in the area with a gray header toa Scheduled Job located in the area with a blue header and have it show on the Gantt chart As you can see from this screen we have all different types of job scheduled unscheduled suspended etc We will take Job 02 in the Unscheduled Jobs and move it to the Machine Schedule area Copyright 2002 MATTEC 12 29 710 0092 X Prohelp Millennium ProSche a Se 3 2 oe ces ll x 08703796 08 03796 08 16 36 08 22 96 08 28
330. nized When ProSched has recognized the drag source the X cursor will be changed to indicate a Drag and Drop Operation is in progress The Drag and Drop Operation will continue as long as the user holds down the left mouse button Step 2 The final step of the Drag and Drop Operation will occur when the user releases the mouse button The point where the button is released is called the drop site The only valid drop sites are other representations of jobs in the ProSched session Once a valid drop site has been selected ProSched will remove the drag source from the machine it is scheduled on and add it to the schedule of the machine that has the drop site scheduled The job will be added after the drop site job There are two reasons why the ProSched process may not be completed 1 If the targeted machine of the drop already has 40 jobs scheduled 2 If the drop would effect a running job In either of these events a modal warning dialog will be presented to the user and no change will be made to the machine schedule Any job displayed in the Gantt Area the Machine Schedule Area or the Unscheduled Area is a valid drag source or drop site A drag source and drop site do not have to be from the same area It is illegal to drag a job from one session of ProSched into another It is important to note no schedule change is actually done in the ProHelp monitoring system until a Commit is issued by the user A job that is determined to be run
331. nt materials the units are at least some sort of weight measurement and judging whether or not the resultant values are meaningful is left to the user This is in lieu of blocking a potentially useful operation Note In all cases where the interval is not used as the second dimension all numbers represent the entire period of time requested The interactive request screen offers a number of options so that data can be presented in a manner appropriate for the audience purpose and situation Of course the precise Copyright 2002 MATTEC 3 42 710 0092 layout of a Report or Chart varies dependent on these options and not all permutations are reasonable In particular a Chart based on multiple materials is meaningless For that reason when the Value is Material and the Format is Chart a Material filter must be specified and the Detail choices are restricted to Individual and Indiv Mach 3 6 2 2 2 Examples MATERIAL NEEDS CLBS 0 00 LBS ABS BLACK 0 00 LBS POLYPRO 0 00 LD 1 Polypropylene 45 55678 0 00 LBS Total 0 00 ps 07 01 97 2 0 00 LS 3 2 1350 0 00 CLES 3 2 ABS BLACK 0 90 LBS Print Hcopy lovloff FndFst BrFndNxt Brndprv W trodt zt Figure 3 43 Future Requirements Schedule Shift Report The above screen Figure 3 43 was accessed by using Detail Individual Schedule Copyright 2002 MATTEC 3 43 710 0092 ProHelp Millennium DEPT INJECT
332. nt shift or for previous shifts To generate a Pareto chart follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Select Downtime or Scrap Press OK To generate an entire job Pareto Chart Press F4 JobPar To generate a shift Pareto Chart Press F5 ShfPar The downtime frequency and duration for the particular job will be displayed as well as the scrap quantities that were recorded this shift and the accumulative totals for the whole job The appropriate Pareto chart will be returned To print a Pareto chart Click File Press Print To exit the chart Click File Copyright 2002 MATTEC 3 18 710 0092 Select Close 3 4 4 Job Descriptor Summary Report To generate the Job Descriptor Summary Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F3 Summry Fill in the interactive report screen as appropriate Use the spacebar for picklist of options Use cursor keys to move from field to field Press F1 Done Jobs that are running jobs that are complete and new jobs scheduled to run will be displayed To generate the Job Descriptor Summary Report of jobs in the standby directory follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc
333. nter Specify Y es or N o for the Histogram chart Copyright 2002 MATTEC 5 52 710 0092 Enter a numeric value for the cells selection 1 30 When 0 is entered the system automatically calculates cell size Reference line choices are displayed by pressing the spacebar Use the cursor to select either Spec Sigma Individual Sigma Estimates Spec Sigma Individual or Spec Sigma Estimates Press Enter Press Enter again to move to the Sigma Multiplier field Any number from 0 1 to 9 9 is allowable A histogram reflecting 3 Sigma is generated by entering a Sigma Multiplier of 3 0 Enter the numeric value Press Enter To generate the Composite SPC Report Press F1 Done The report can not be browsed or copied to a file It may only be printed 5 8 10 ProStat SPC Calculations 1 SPC CALCULATIONS GENERAL G r x x n 1 6 R d NOTE o Sigma of the Individuals d Estimated Sigma 2 SPC CALCULATIONS CONTROL CHARTS A TABULAR Tabular calculations estimate 3 standard deviations Therefore anywhere throughout the ProStat package if TABLE is selected the Sigma Multiplier will be ignored UCL X A R UCL D R Copyright 2002 MATTEC 5 53 710 0092 LCL X A R NOTE A gt D D4 are tabular constants for the above formulas B SIGMA OF INDIVIDUALS ofo UCL X o Jn i UCL d a D R R R LCL X d tore O Vn LCR 22 D R R R NOTE of o Sig
334. ntrol is active a job s desired start and or end date will only be used to determine whether the job is on time or not The other control will be labeled Desired Date Scheduling When this control is active the job s desired start date and or end date will be used to determine when a job is started on a machine The final toggle is labeled Use Sched Method setting in Misc Options When this toggle is active the schedule method setting in the dynamic misc config file will be used This final toggle will be active by default RESOLUTION This group in the control area consists of three 3 mutually exclusive toggle controls This group is labeled Resolution Copyright 2002 MATTEC 12 16 710 0092 ProSched Preferences X Low resolution 600 pixels wide Medium resolution 1000 pixels wide High resolution 1600 pixels wide Apply Save CANCEL Figure 12 20 Preferences Resolution The toggle controls are labeled Low resolution 600 pixels wide Medium resolution 1000 pixels wide High resolution 1600 pixels wide The button will specify the number of pixels to be used for the width of the Gantt Area Low toggle will indicate that ProSched should draw the Gantt in 600 pixels Medium toggle will indicate that ProSched should use 1000 pixels and the Large button will result in 1600 pixels being used MISC The final group within the ProSched Preferences provides several non exclusive toggle controls Thi
335. number parameter data type limits and auto store choices as defined above ProHelp Millennium O x Figure 5 15 Calculation Limits Screen To have the limits calculated for all automatic process parameters all manual process parameters all attribute data or all variable data go to the bottom of the parameter choices picklist and select All If Auto Store is N o the selection will cause the system to calculate the limits and display the calculated results with the message Enter Y to replace the average s and limits in the SPC file The user may choose to replace the limits or Press Esc to exit the function and keep the old limits Copyright 2002 MATTEC 5 44 710 0092 Reminder This function will calculate and replace limits in the requested date set of samples only If the job has run on multiple dates the limits from these other dates will not be replaced Limits can be updated in the job descriptor in only two ways 1 The job is currently running and the sample date is equal to the current ProHelp Millennium system date 2 The job has been completed and the sample date is equal to the current ProHelp Millennium system date NOTE These are the ONLY circumstances for which the limits in the job descriptor will be updated If the limits have been calculated for a sample whose sample date is prior to the current ProHelp Millennium system date the job descriptor record WILL NOT be updated 5 8 6 At
336. o configure Press spacebar Press Enter To move the cursor to the Legend column Press Enter The index numbers correspond to function key numbers Enter the real time screen name that will appear on this function key Press Enter Note Any name may be entered However if there is no real time screen configured with this name an error message will appear whenever requesting this screen This also applies to deleted custom displays Continue moving the cursor and entering legend names in this manner Note The cursor will not position at F9 Std or F10 Other F9 Std is the standard MATTEC real time screen and it may not be deleted F10 Other allows access to all other user defined real time screens To save your changes Press Esc 7 7 3 Set the Real Time Default Display The default display under F1 View F1 RealTm may be changed from the standard MATTEC screen to any of the screens defined in a custom menu To set the real time default display for a user follow these steps Copyright 2002 MATTEC 7 29 710 0092 Press F4 Aye Man Figure 3 1 Copyright Screen Press F5 RITmDf Press F10 Config Select the user to configure Press Enter Position the cursor to the number field next to Default The number entered here is the number of the function key whose screen is displayed as the default The typical default is F9 Std which is always the standard MATTEC screen Enter the index number
337. o exit the histogram Click File Select Close 5 8 4 SPC Summary Report The summary function allows the ProStat user to generate a summary report of all the actual data values recorded during each SPC sample These data values are the values used in all of the ProStat calculations In addition to the recorded values the report lists information from the job descriptor such as sample size sample period high and low specification limits control limits and Xbar and Rbar values To generate the SPC Summary Report follow these steps Press F1 View or F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F4 Summry Enter the start and end dates Press Enter Copyright 2002 MATTEC 5 41 710 0092 Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To select the parameter data type Press spacebar The available choices include none automatic process parameters manual process parameters variable data and attribute data Use the cursor key to position to the desired choice Press Enter Press F1 Done Fill in the new report interactive screen that is displayed Press F1 Done The SPC Summa
338. o represent the date separator i e The system will translate the entered separator to a Time Time fields consist of two numbers separated by a colon The first number is hours and the second minutes hh mm A twenty four hour format is used so that 11 45 PM won appears as 23 45 When entering a time field a or space may be used to won represent the time separator i e The system will translate the entered separator to a on e Yes No These fields have only two possible values They are modified by simply typing the letter Y or N Either upper or lower case may be used Copyright 2002 MATTEC 2 11 710 0092 3 View Mode The preceding sections gave you an overview of the system and showed how to turn the power on Now you re sitting there looking at a red and blue MATTEC copyright screen with a blue menu line at the bottom If you pressed some function keys you may be looking at something different Press Esc a few times until the copyright screen is displayed If you Press Esc too many times the system asks Do you want to end this session N Answer N o 3 1 Copyright Screen The copyright screen is the main menu mode This screen must be displayed before you can switch to another mode Pressing the Esc key several times will always return to this screen One important point to note about the copyright screen is the Release level indicated on the screen When talkin
339. ob number producing part 6774 on December 1 Part Number The part number is a 22 character alphanumeric field identifying the items being produced for this job This is an optional data field However part standards can be stored and selected by this number Part Name This optional field can be any string of up to 10 alphanumeric characters that helps you recognize the part being produced The field is for display only and plays no part in any calculation or report sorting Tool Number Each job has an 11 character alphanumeric tool number This is an optional field However ProHelp Millennium provides a year to date tool usage report sorted by this number In ProHelp Millennium the tool number assigned in the job controls the collection of mold tool history and is used to retrieve the collected information Each job has an optional 11 character tool base number Customer Name The customer name is an optional field intended to display the name of the customer for which the job is being run This field plays no part in any calculation or search The customer identification number is an optional field This is a 10 digit field This field plays no part in any calculation or search Machine Number The machine number is a 6 character field used to record where a job is actually running or scheduled to run When a job is ended the number of the last machine to run that job will be recorded here Machine numbers are defined by the Sy
340. oduction Entry Screen feature Press F2 Job Man Figure 3 1 Copyright Screen OR Press F3 QC Man Figure 3 1 Copyright Screen Press F10 ManEnt An interactive screen is presented which permits selection of a department and field configuration Copyright 2002 MATTEC 11 2 710 0092 ProHelp Millennium Tenplate DIEE Dept BLOW Figure 11 2 Manual Production Entry Setup Screen Pressing the F1 Done key causes the user to be prompted for a e Date e Shift Tag picklist appears e Job Number hit spacebar for picklist Enter the appropriate information and the following screen will appear ProHelp Millennium Manual Production Entry DATE SH RUN HR _GOOD PRO SPLAY BURNS BUBBLES 05 27 97 3 0 0 0 0 BAddRow E Figure 11 3 Manual Entry Production Screen Copyright 2002 MATTEC 11 3 710 0092 The entered values are used to define the first row Additional rows up to a total of 200 may be created by pressing the F2 AddRow key which also prompts for e Date e Shift Tag picklist appears e Job Number hit spacebar for picklist To delete any line of information Press F3 DelRow At least one line of information must remain on the screen To exit this line Press Escape Used for moving through the active field Home End Page Up Used for moving through the active field and Page Down keys Home key Pressing once will move the active field to the beginning of a line Pressing twice wil
341. of Chart of Individuals which are 1 to 9 The number entered here applies to automatic manual and variable SPC data Random Observations A Y es or N o in this field represents a yes or no for random observations being turned on If Y es the number of cycles per sample are recorded at random times within the sample period They are not consecutive machine cycles If N o the cycles per sample are consecutively collected from the machine Modification of this field becomes active at the end of the current sample period Auto SPC Lim Calculate This field describes the status of the automatic limits calculation function Reference Section 5 6 9 for additional information Part Qual Enable Set to Y es to enable part qualification Reference Section 5 9 for additional information Manual Sample Enable Enter Y es to enable manual data sampling that is initiated at the MIU by the machine operator Reference Section 5 6 2 for information on modifying automatic and manual process parameter control and specification limits Reference Section 5 6 3 for information on modifying which process parameters automatic and manual are collected alarm conditions and part qualification conditions This field specifies the number of consecutive sample points which define a run trend or shift This field applies to all data types automatic manual variable and attribute A value of zero turns off run detection Copyright 2002 MATTEC 5
342. of the new default Press Enter To save your changes Press Esc 7 8 Preventative Maintenance Names The names for the machine and tool preventive maintenance codes are defined by the System Manager Names that are defined for System can be copied into individual departments 100 codes are defined for machine maintenance per department and 100 codes are defined for tool maintenance per department To configure machine or tool preventive maintenance codes follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F6 PMCode To select individual departments Press spacebar To copy names from other departments Press F3 Copy The Preventive Maintenance Code definition screen will be displayed See Section 9 1 for additional information 7 9 Master Setup Sheets Specific machine tool or QC related information can be logged into the ProHelp Millennium system and added to jobs with the setup sheets software option A setup sheet is a free form user defined text up to 99 pages screens in length containing information about a tool or machine setup procedure A gif image file can Copyright 2002 MATTEC 7 30 710 0092 be inserted into a setup sheet and displayed by using the mouse and clicking on the inserted image name These gif files must be copied into the following directory before they can be displayed usr prohelp images filename gif Master setup sheets can be created and
343. of the screen for any of the above functions The second line of the screen allows for generating the selected function for a part number multiple job runs with the same part number To generate the function for multiple job runs set the Select For field to ONE PART You must still select a job number to generate the function However the selected job s part number will be used to select other jobs which ran during the same time frame for that part number You may also select jobs that ran on the Same Mach or used the Same Tool as the selected job s part number The selected job s control limits part number machine number tool name etc will be used when appropriate To generate the selected function for one job only set the Select For field to ONE JOB Select the job to generate the function for and fill in the rest of interactive screen as appropriate 5 8 1 SPC Charts When SPC Chart is selected the user is offered the choice of Single or Multiple Selecting Single accesses the familiar interactive screen for the Averages and Range Chart X Bar and R or the Individuals and Moving Range Chart X and MR which plots a single SPC variable or signal Copyright 2002 MATTEC 5 35 710 0092 Multiple Selecting Multiple accesses the interactive screen with four sets of value selection fields E xterm me x Figure 5 10 Chart Screen The first selection field provides an AL choice so that all of
344. oking at the Sched Disp index field Figure 12 18 Preferences Sched Disp in the ProSched Preferences section Copyright 2002 MATTEC 12 19 710 0092 X Prohelp Millennium ProSched Ee eee Jest Za x LL 08703796 08 15 96 08 28 96 09 09 96 09 22 96 10 04 96 10 17 96 11 00 23 00 11 00 23 00 11 00 23 00 11 00 JOBO8 SEHR 166 6 Be RETEST ERE 08 30 7 PEND JOBOS peneiceed 166 6 TEZA 09 306 5 PEND 10 bk _388 4 SUSP 03200_08707796 18 13 0 a Figure 12 23 Machine Schedule UNSCHEDULED JOBS The cascading pop up Unscheduled Jobs will provide several push buttons Off Prod To Go Hours To Go X Prohelp Millennium ProSched Iof x 08 28 96 0 7 16 00 Figure 12 24 Unscheduled Jobs Cascade When Off is activated the Unscheduled Jobs area Section 12 2 2 5 is not visible to the user Copyright 2002 MATTEC 12 20 710 0092 The third column of this screen will change headings and criteria dependent upon the choices of Prod To Go or Hours to Go Example Prod To Go when selected will cause the Prod To Go to be displayed in the third column instead of Hours to Go By selection of one of the following choices Prod to Go or Hours to Go the Unscheduled Jobs Area Figure 12 24 Unscheduled Jobs Cascade will display the following fields at the bottom of the screen Job Number Part Number Prod To Go subject to change per choice Desir
345. on and is intended to motivate all personnel towards improvements in productivity All personnel using the View mode must recognize the importance of any value displayed with a MAGENTA PURPLE RED YELLOW WHITE or GREEN background Copyright 2002 MATTEC 3 8 710 0092 COLOR DESCRIPTION GREEN The machine is running within acceptable limits for all processes being monitored Green is good RED The machine is not running within the set standards For machine processes such as cycle time or pressures red means actual values are above the standard set in the system Timings shown in red are too slow Pressures or temperatures in red are too high White means actual values are below the standard set in the system Timings shown in white are too fast Pressures or temperatures in white are too low A machine and job number shown in yellow indicates the machine is not cycling The reason for the machine being down is shown on the standard real time screen in the Machine Parameters column A machine number shown is cyan indicates that no job is currently running on the machine A job number will not be displayed A machine number shown in magenta indicates that the MIU is not communicating with the Host computer If you can not resolve this situation please contact the MATTEC Customer Service Department immediately Operators and production foremen should concentrate on keeping all machines in the green Copyright 2002 MATTEC
346. on the screen the upper left hand side of the screen shaded in light blue contains general information Refer to Figure 4 1 Job Descriptor General Information Fields ProHelp Millennium Ioj x Figure 4 1 Job Descriptor General Information Fields Copyright 2002 MATTEC 4 4 710 0092 FIELD DESCRIPTION Job Number The job number is a 12 character alphanumeric field containing the unique identification number for this job descriptor ProHelp Millennium records all the data pertaining to a manufacturing activity in the job descriptor Each job descriptor records the activities of a specific machine making a specific part at a specific time To maintain accurate job records it is necessary to use job numbers such that each can be identified separately from all others A job producing 100 000 parts on Machine 10 in July is a different job than the one that ran in December even though the same part lot size and machine are used Each job run has a unique history that can contribute to improvements in manufacturing procedures and product costs By reviewing job histories trends can be identified that lead to preventive maintenance of tools Efficient operators can be identified for that job Total job profit and loss can be identified The uniqueness of job numbers is a key to success in this area Job number schemes can incorporate the use of a part number or tool number appended with a date code For example 6774_1201 could be the j
347. onitoring Nodes appear to have four channels of sixteen addresses each and machines can be defined for these nodes just as for any other With the exception of data collection methods there is little to distinguish manual machines from those with automatic monitoring They are assigned to departments and therefore have scrap names down reason names and work schedules Copyright 2002 MATTEC 7 70 710 0092 A natural result is that they can participate in the various ProHelp predictors and information such as end dates material needs and maintenance due dates is available The accuracy of predictions is of course dependent on the accuracy and timeliness of production data input One exception is that although PM may be scheduled and performed on Manually Monitored Machines and they appear properly on PM Due reports they do not provide the Next PM fields which this release adds to the Real Time Display Press F4 Sysman Figure 3 1 Copyright Screen Press F8 Install Press F9 NetWrk The Server Node Configuration screen will appear Double Click on Type field located under the Server and Machine Name The following picklist will display ProHelp Millennium Items None Monitoring Node 64 PC MIU Cell Controller Manually Collected Data ProHelp Millennium Copyright 2002 MATTEC 7 71 710 0092 Figure 7 33 Manual Monitoring Nodes Screen Double Click on any field located under Date Collect
348. onsibility to prepare the backup device in advance For example the user is NOT prompted prior to the archive or backup to insert the tape While an archive purge or backup may be requested at any time it is a good idea to schedule these functions to occur with sufficient time to complete before the occurrence of the next shift change COMMAND DESCRIPTION mbackup A Executes the ProHelp Millennium archive command Executes the ProHelp Millennium purge command mbackup B Executes the ProHelp Millennium backup command Figure 6 5 Automatic Archive Purge and Backup Commands Copyright 2002 MATTEC 6 13 710 0092 ITEM DESCRIPTION DEFAULT ALLOWABLE VALUES VALUE Directory to copy the archive or backup to Archive and Backup Only Earliest Date to Archive Archive Only Latest Date to Archive Archive Only Retain Purge Only Earliest Active Data to Retain Purge Only Full Backup Backup Only Incremental Backup Backup Only Earliest Standby Data to W None ddirectoryname where directoryname is the name of the directory on the hard disk where the archive or backup will be copied Required if archive or backup is the selected command None Exxx where xxx is a positive number relative to today e g E60 tells the archive command to archive any data that is less than 60 days old Required if archive is the selected command None Lxxx where xxx is a positive number
349. or may be copied from one job to another As described above to view any of the saved standard profile graphs Press F4 InjStd Press F5 VelStd OR Press F6 PosStd If any of the standard profile graphs have not been created yet the message Data Not Found will be displayed Current Last Cycle s Profile Graph The last cycle s profile graph may be viewed at a computer terminal or MIU To tell the MIU to collect the last cycle s profile graph data Press F7 InjCur Press F8 VelCur OR Press F9 PosCur The message Collecting Data will be displayed while the MIU collects graph data for all three graph types not just the graph type selected Once data is collected the selected graph will be displayed To exit the graph Click File Select Close Once you exit the graph you may select any of the other graph types by pressing the appropriate function key Data is not collected again thus allowing the user to move from one graph type to another for the same machine cycle Copyright 2002 MATTEC 4 29 710 0092 ProHelp Millennium File Graph Figure 4 6 Position Profile Graph When the last cycle s profile graph is displayed the saved standard profile graph will automatically be displayed if it exists To view profile graph data for another cycle Press Esc a sufficient number of times to return to the job descriptor Press F3 Disply A picklist will appear Highlight Profiles Click O
350. ord or retry the operation at a later time Record in use cannot edit at this time cause Someone at another terminal is editing this data remedy Have the user release the record or retry the operation at a later time Record in use ENTER to retry ESCAPE to abort cause An attempt was made to access a record while another user was accessing it remedy Have the user release the record or retry the operation at a later time Remote calibration is already active cause An attempt was made to enter into remote calibration mode while another user was already in this mode remedy Wait until other user has escaped from the mode or perform calibration setting while other user is in the mode Remove the item from the active script before changing its length cause An attempt was made to change the length of a real time display item that was already in the active script remedy Remove the item from the active script before changing its length Requested Profile Graph data busy cause An attempt was made to access profile graph data while another user was accessing this data This can be due to a user accessing the data at an MIU or a terminal remedy Wait until other user is finished and retry procedure Requested sample not found cause The sample you requested to examine could not be found Copyright 2002 MATTEC 15 36 710 0092 remedy Make sure you entered the correct sample date and time and that you are editing viewin
351. orecasted total material needed for a non running job The actual setup material weight used adds to the total material used for a job For family jobs the setup material used values are entered in the son component jobs and do not appear in the father job descriptor Incremental amounts of setup material may also be entered at an MIU Reference the MIU Operator s Manual for additional information 4 1 9 Enable SPC and Part Qualification To enable SPC or part qualification for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Reference Section 5 6 for additional information 4 2 Job Descriptors A job descriptor is a shop order production record that is stored at the main computer Each job descriptor active in the system has a unique number and provides current and historical information related to the production of a part The ProHelp Millennium job descriptors report on parts made machine cycles hours run hours down tool usage and Copyright 2002 MATTEC 4 20 710 0092 material usage ProHelp Millennium jobs also report on when where and how well they were run 4 2 1 Create a New Job To create a new single son or bachelor job follow these steps Press F2 JobMan Figure
352. ortion of the setup sheet s first page that may be displayed at the MIU Press F4 OvlOn Information values that are in an unprotected white character mode may be edited and additional information screens may be created and added There is a limit of 99 pages per setup sheet Copyright 2002 MATTEC 4 26 710 0092 Remember any information entered in the Job Manager mode will be in an unprotected mode white characters They exist in the system only as long as the job descriptor is on line Only setup sheets created in the System Manager mode are master setup sheets Refer to Section 7 8 To save your changes Press Esc To create or modify a job s QC document follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number Press F3 Disply A picklist will appear Highlight QC Document Click OK If you have copied a QC sheet with the job or part when creating the job it will be displayed If not the message Press Y to create a QC sheet any other key to continue is shown To create the QC sheet Press Y es At this point you may type in any setup information in a free form unprotected text To copy another existing QC sheet to the job Press F1 Copy If you choose to copy a QC sheet the following selections are then available FUNCTION KEY DESCRIPTION F1 CpyJob Copy a job s QC sheet to
353. ove the cursor to the proper field to be changed ProHelp Millennium Of x MACHINE 03 CODE DESCRIPTION DAYS RUN HOURS Figure 9 3 Machine Maintenance Schedule The fields for days and run hours are five digits Enter the new schedule for days or run hours Press Enter Copyright 2002 MATTEC 9 5 710 0092 Continue to move the cursor to the fields to be changed To modify the schedule for another machine Press F1 Mach Enter in the new number Press Enter To save your changes when you are complete Press Esc 9 2 1 Machine Maintenance Schedule The Delete key deletes the schedule for the currently displayed machine The Time To PM column on the schedule report may now show negative numbers for overdue items There is no attempt to determine exactly when the item became overdue but the negative days or hours do give an indication of how late the maintenance is To access the PM screen Press F7 MntMan Figure 3 1 Copyright Screen Press F1 Mach Press F2 Sched Enter the machine number Press Enter ProHelp Millennium OF x MACHINE 01 CODE DESCRIPTION STD ELAPSED TIME DAYS RUN HOURS Figure 9 4 Preventive Maintenance Screen 9 2 2 Tool Maintenance Copyright 2002 MATTEC 9 6 710 0092 To schedule tool maintenance follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F2 Tool Press F2 Sched Enter the tool number Press Enter The computer
354. ove the highlight to the next definition to be changed Follow the same procedures until completed To save your changes Press Esc To define tool maintenance codes follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F6 PMcode Press F2 Tool Copyright 2002 MATTEC 9 3 710 0092 De m Maintenance Code Number Definitions Figure 9 2 Tool Maintenance Codes The first field is highlighted Use the cursor keys to move the highlighted area to the field that you desire to change The first 20 definitions are set Figure 9 2 Tool Maintenance Codes Using PgUp and PgDn keys will display the next 80 codes that can be utilized Place the cursor on the Code to be utilized Type in a description for that code number Use the cursor keys to move the highlight to the next definition to be changed Follow the same procedures until completed Type in the new maintenance description Press Enter Use the cursor keys to move the highlight to the next definition to be changed Follow the same procedures until you are completed To save your changes Press Esc 9 2 Schedule Preventative Maintenance Two independent preventive maintenance scheduling functions are provided one for machine maintenance scheduling and another for tool maintenance scheduling A preventive maintenance schedule is a list of maintenance code numbers There is one list for each machine or tool These lists indicate what future prevent
355. p Millennium allows for each job to have ten different materials of which one is the primary input material and the others may be either additive input materials or auxiliary materials Auxiliary materials are materials required by the manufacturing process e g boxes electricity but are not directly a part of the production unit A regrind percentage may be specified for the primary material to divide that material between virgin and regrind material As a result the material used is accumulated for eleven different sources instead of ten To modify the materials list setup for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight Materials List Click OK Modify the materials list setup as required To save your changes Press Esc The materials list setup can be modified for a part descriptor in a similar manner The following is a definition of each of the fields that appear in the materials list setup screen Copyright 2002 MATTEC 4 18 710 0092 DESCRIPTION Type A material can be one of the following three types Primary one per job Additive multiple or Auxiliary multiple Primary and Additive materials are considered input materials and are processed by the machine to become direct components of
356. pable of running the same software that runs on the Host computer This can effectively turn your entire shop floor into a large office for the QC and production departments 1 3 7 Auxiliary Interface Unit AIU AIU AIUs Auxiliary Interface Units interface to the MIU 10X through RS 485 and contain physical connections for 4 digital and 6 analog signals The first digital is always a repeat of the cycle signal for synchronization purposes The number of AIUs if any depends on the customer s process parameter requirements for the associated machine Up to 15 AIUs may be added unless the MIU 10X board is populated to provide an additional 6 analog and 4 digital signals These signals effectively replace the signals otherwise provided by the first AIU and only 14 AIUs may then be added Copyright 2002 MATTEC 1 17 710 0092 2 General Information The ProHelp Millennium system includes at least one approved IBM compatible personal computer a keyboard a VGA color monitor a mouse and an Epson compatible printer In most cases you will have an assortment of computers creating a network throughout your plant The keyboard monitor and MIUs are the primary user interfaces for running ProHelp Millennium Once powered up the system should run 24 hours per day every day Operational Characteristics When you are looking at the copyright screen there are many things actually happening All of the Machine Interface Units MIUs are b
357. permanently stored on the hard disk for each tool you may ever run Once a master setup sheet has been created it may be copied and information added or deleted to create a new master When a particular tool is scheduled for a job or a job or part descriptor is created the master setup sheet for that tool may be called up and permanently placed in the job or part descriptor At the proper time the setup sheet associated with the job may be printed and distributed to plant personnel Because the setup sheet is a unique part of a job s history all of the information temperature pressure settings etc is available for review at any time Setup sheets may be created in the Job Manager mode for job or part descriptors but these are created in an unprotected mode and live on this system only as long as the job or part remains active Master setup sheets differ in that they may be created with fields protected from change and they remain on the system until they are deleted by the System Manager A setup sheet can also be viewed at the MIU for either the current job or the next scheduled job Only a single page setup sheet 15 Rows by 40 Columns is displayed at the MIU 7 9 1 Create Master Setup Sheets To create a master setup sheet follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F7 Documt Press F1 Define To create a master machine setup Press F1 Mach To create a master tool setup Press F2
358. pful when performing these functions Copyright 2002 MATTEC 6 3 710 0092 cpio ocBv O dev rdsk f0q18dt Die file2 This command will copy the specified files file1 file2 to the specified device dev rdsk f0q18dt This cpio command will DESTROY any information that already exists on this device cpio icBdumlv I dev rdsk f0q18dt filename This command will read the specified file filename from the specified device dev rdsk f0q18dt into the current directory OR into the directory tree that was specified when the file was written to the device cpio icBtv I dev rdsk f0q18dt This command will list the contents of the device that is specified dev rdsk f0q18dt This command is very helpful to verify that you have successfully copied files to the device WARNING THE cpio WRITE COMMAND WILL DESTROY ANY INFORMATION THAT ALREADY EXISTS ON THE TARGET DEVICE To copy a ProHelp Millennium archive or backup from the hard disk to a tape drive follow these steps Open an X Terminal window by Click Terminal icon on the desktop Enter the following to copy the archive or backup to the tape drive cpio ocBv O dev rmt cOsOr usr prohelp mat_backup where dev rmt cOsOr is the actual device name See System Device Names of the tape drive that you are using and usr prohelp mat_backup is the location of the archive or backup files To verify that the archive or backup was successfully copied to the tap
359. ports exist 3 6 1 2 Report Generation Following selection of the desired report an interactive report options screen as shown in Figure 3 18 is displayed and the appropriate options can be set ProHelp Millennium Figure 3 18 Sample Report Options Screen Most fields other than dates are set from picklists that are accessed by positioning to the field and hitting the spacebar Use arrow keys to move from field to field Report specific Copyright 2002 MATTEC 3 27 710 0092 fields appear in the upper portion of the screen and may include fields to specify dates filters or other items The lower portion of the screen is common for most reports For many reports the Format fields allows you to choose between a form suitable for printing a flat ASCII file suitable for transfer to other applications or a chart for quick visual analysis The File field identifies the target of a Copy operation and is present only when the Action is Copy The fields below this specify formatting options for ASCII files and are present only when the Format is ASCI ASCII formatting choices are Variable or Fixed Decimal Points Date Separators None Slash Dash Time Separators Copyright 2002 MATTEC 3 28 710 0092 Figure 3 19 through Figure 3 25 illustrate the common report picklists gt lt ProHelp Millennium Bisi ES gt lt ProHelp Millennium Iof x Figure 3 21
360. ppear Highlight SCP Settings Click OK Press F5 Basic To enable part qualification for the job set the PART QUAL ENAB field to Y es To modify the signals and conditions for which parts are qualified follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F7 ProEna Under the Parts Qualification Machine Parameters column move to the appropriate signal name and enable specification SPEC or SPC control limit CNTRL qualification as required The MIU OUTPUT LOW HI column is for display purposes only and displays the values that are enabled as described in Section 5 8 1 5 9 3 Operation of Part Qualification When the MIU has been configured and part qualification is enabled or disabled in the job descriptor the system will operate in the following manner During each cycle the selected processes are compared to the control or specification limits that are set in the job descriptor If Part Qualification is set to Y es in the job descriptor the MIU output contact will close during the next cycle if in the current cycle any of the following conditions occur for any signal SPEC set to Y es and Hi set to Y es goes above the specification limit SPEC set to Y es and Lo
361. process parameters with no means of changing that association Copyright 2002 MATTEC 7 54 710 0092 In other words an MIU or AIU has 12 Process Parameters and each of them has a natural source In some MIUs a parameter may only be supplied by its natural source or disabled In others it may be supplied by a PLC in place of its natural source In this case a separate configuration screen determines how the PLC supplies the value In the newest models any analog signal on the same MIU or AIU may be selected as a source This means that multiple values may be obtained for the same signal An example may make this less confusing Figure 7 26 Sample MIU Configuration Old Style shows how a machine might be configured to monitor e cycle time hold time gate time melt temperature inject hold back pressure ProHelp Millennium 1 mrktog i i INJECT 1 000 Figure 7 26 Sample MIU Configuration Old Style For this example it is desired that other aspects of these signals be monitored Figure 7 27 Sample MIU Configuration New Style shows a configuration that provides average value for all three pressures the area under the curve for injection pressure plus the time in the cycle that peak injection pressure was reached Note that although it somehow seems natural to place the time of injection pressure peak InjPk Tm in the area where timers have traditionally appeared this is not necessary For example Inj PrAr and
362. profile graph s associated with it the message COPY PROFILE GRAPHS S FROM oldjob TO newjob will appear To copy Press Y es If you do not wish the saved standard profile graph s to be transferred to the new job from the job being copied Press N o The system will now display the first screen of the new job descriptor with the general information fields on the left and the standards fields on the right If the job is all new the only data field filled in will be the job number If you are creating a job that is to run on a rate machine versus a cyclic machine or vice versa then enter a value in the machine number field that represents that particular machine number The cycle time field and other fields will toggle to the proper name ProHelp Millennium Bisi x 0 0 PEND Figure 4 5 New Job Descriptor If you have copied an existing job or part descriptor standards will already be entered You may begin to edit and fill in standards by moving the cursor to the appropriate fields Use the arrow keys to move the cursor to the data field to be entered Data values are stored when the Enter key is pressed You must enter a value for cycle time cavities and the non production limit before the system will allow you to exit from this job Ensure that the non production limit is greater than the cycle time high limit Copyright 2002 MATTEC 4 22 710 0092 The scheduling information is on the top right hand side It
363. program to execute automatically To purge data follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F2 Purge E xterm II x Figure 6 2 File Purge Earliest Condensed Data to All data collected before this date will be permanently Retain deleted from the system Earliest Standby Data to With the exception of Condensed Production History Retain data collected before this date will be permanently deleted from the system Copyright 2002 MATTEC 6 7 710 0092 Earliest Active Data to Data collected on and after this date will remain in the Retain active data directory Together these two dates form a window and any data between these two dates will be copied to the standby data directory Fill in the interactive screen as appropriate Press F1 Done The system will proceed with deleting the specified data from the system IMPORTANT Once active data has been changed to standby data it may no longer be edited Any data that is purged from the system but has not been archived may not be retrieved back onto the system for future use 6 4 Condensed Production History Condensed Production Data is maintained per department per day with run hours down hours earned hours direct labor hours earned labor hours material used material scrapped values By eliminating some of the detail contained in the Daily Production History several years of this condensed data can be maintained in a reasonable
364. pyright 2002 MATTEC 15 48 710 0092 remedy Check the integrity or existence of the specified file Upper Control Limit and Lower Control Limit are equal cause While setting up upper and lower control limits an error occurred where the upper and lower limits are equal remedy Adjust the control limits so that the upper limit is greater than the lower limit Upper Control Limit less than Lower Control Limit cause While setting up upper and lower control limits an error occurred where the upper limit is less than lower limit remedy Adjust the control limits so that the upper limit is greater than the lower limit Value entered has no associated characteristic cause The characteristic number entered is not in use remedy Make sure the number entered is the one in front of the characteristic name you have selected Voice Board open error cause An attempt to use the voice board resulted in an error remedy Contact MATTEC for assistance X Upper Control Limit and X Lower Control Limit are equal cause The current upper and lower control limits are equal remedy Use the SPC editor to enter valid control limits for this set of data X Upper Control Limit less than X Lower Control Limit cause The current upper control limit is less than the lower control limit remedy Use the SPC editor to enter valid control limits for this set of data Xbarbar is not between X Upper Control Limit and X Lower Control Limit Copyrigh
365. queeze in a one character wide field into a blank space between two existing fields and not affect the columns remaining indicator When the display is completed you must SAVE the display onto the hard disk Attempting to escape without saving the display will cause the system to display the message You have made unsaved changes Enter Y to escape without saving To save the real time display that you have created follow these steps Press F3 Files Press F1 Save Copyright 2002 MATTEC 7 20 710 0092 A new screen showing existing display names will appear with the message Enter display name Enter the name Press Enter The new name should be unique Using one of the existing real time names for the new screen will cause the system to overwrite the existing screen with the new screen 7 6 2 Add or Delete Items from a Display To add or delete items from an existing real time screen follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5 RITmDf Press F3 Files Press F2 Load The first choices of screens to load are any custom screens defined as menu selections F1 through F8 F9 always displays the Standard MATTEC real time screen To display a list of all real time screens defined in the system Press F10 Other Enter display name by Press spacebar Select any of these screens to load When the display is selected the existing format of that display is shown on the
366. r abrupt Copyright 2002 MATTEC 1 13 710 0092 movement of the computer It is necessary to use the power off procedure described in Section 2 1 before turning off power to the computer A final word on the disk drive units Keeping the environment as free as possible from extreme temperatures dirt and smoke will help to improve the performance of these drives Periodic cleaning of the floppy drive and avoiding abrupt movement of the computer will further help to eliminate problems 1 3 6 Machine Interface Unit MIU The link between your machines on the plant floor and the Host computer where data is collected is the microprocessor box mounted on each of your machines called the Machine Interface Unit MIU The MIU is designed and manufactured by MATTEC for proprietary use with the ProHelp Millennium system The basic function of the MIU is to collect and process information from your machine and store it until it is collected by the monitoring node Communication Communication between the MATTEC Host computer and the MIU is performed over the 4 or 6 conductor shielded cable going to each MIU The MIU collects information from your production machine such as number of cycles cycle times and process parameters It collects input from a machine operator such as scrap input calls for help and a change in cavities This data is held in the MIU until it is polled by ProHelp Millennium The MIU also receives data from the central compu
367. r time or cycle decrement the run hours or cycles since last performed value is displayed as part of the new line prompts and decrements can be no larger than this number For normal operations where preventive maintenance logging at PCs is used as s substitute for MIU logging the appropriate decrement might be the amount of time or cycles separating the operation being logged from the one preceding it For example if a certain tool operation was performed once on Monday and 25000 cycles later on Wednesday the proper decrement is 25000 Copyright 2002 MATTEC 9 17 710 0092 10 Cost Manager The optional Cost Manager program is used to obtain profit and loss reports on all jobs on a daily basis The Cost Manager sets the standards in the job descriptor for the machine hourly cost material cost direct labor hour cost etc This mode is used to enter actual daily indirect labor hours direct labor hours and actual material used Direct labor hours and material used need only be entered if they are different from the data collected by the system Linear Rate Note The Cost Manager functions do not work with Linear Rate machines 10 1 Modify Standard Cost Data Job Descriptor To create or edit standard cost data for a job follow these steps Press F8 CstMan Figure 3 1 Copyright Screen Press F1 CstEdt Press F1 JbDesc Press F1 Job Enter the job number for a non running job OR Press F2 Mach Enter the m
368. r was entered for which no data is currently on the hard disk for the date being referenced remedy Verify the entered job number and date No data available for requested shift cause A shift number was entered for which no data is currently on the hard disk for the date being referenced remedy Verify the entered shift number and date No data points found for analysis cause An analysis was attempted that contained no data remedy Check dates to make sure that data occurred during the time frame No data records in report cause An attempt was made to construct a report that contained no data Copyright 2002 MATTEC 15 28 710 0092 remedy Check dates to make sure that data occurred during the time frame No definition found for this terminal cause An attempt was made to view the real time screen from a terminal that had not yet been configured for a real time display remedy Have the System Manager configure all of the terminals No definition found for this terminal Press enter to set defaults cause The real time definition has not been set at the current console remedy Press Enter to establish the default definition No definition found for this terminal Use Setup to create cause An attempt was made to view the real time screen from a terminal that had not yet been configured for a real time display remedy Have the System Manager configure all of the terminals No departments defined cause An opera
369. ration Job member of family Cannot delete cause An attempt was made to delete a job descriptor which is a component in a family job remedy Either the entire family must be deleted by deleting the family descriptor or the job may be removed from the family and deleted separately Job not found cause No job descriptor exists for a job number entered remedy Verify the entered job number Job not running cause An attempt was made to modify active data for a job which is not presently running remedy Verify the entered job number If it is correct the desired data may be available as previous data Job number not specified cause An attempt was made to specify the data type or activate a ProStat function and no job number was specified remedy Specify the job number Copyright 2002 MATTEC 15 24 710 0092 Job running Cannot Edit cause An attempt was made to access a running job with the job descriptor edit function Only non running jobs may be edited remedy Verify that the correct job number was entered If editing is required on a running job that job may be suspended edited and restarted Job running on another machine cause An attempt was made to start a job that was already running on another machine remedy Suspend the job from its current machine and start it on the desired machine Job running or scheduled to run Cannot delete cause An attempt was made to delete a job which is cur
370. ration screen function allows the System Manager to customize real time menu selections and functions for each user of the system 7 7 1 Display the Configuration Screen To configure real time screens for a user follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5 RITmDf Press F10 Config ProHelp Millennium 0f x Figure 7 16 Real Time Configuration Screen Simply select the appropriate user to configure by moving to the user field Press spacebar Select the user Press Enter Set defaults for the user as appropriate Select a Mode Filter Paging AutoPage or SinglePage and Department one department All or Off as appropriate Use the spacebar to make your selections Copyright 2002 MATTEC 7 28 710 0092 To save your changes Press Esc 7 7 2 Allocate Custom Screen Names to Function Keys When a custom real time screen is created it can be allocated to have its name show up on a function key Then when you desire to view the screen you need only press the particular function key It is possible to configure the real time screen to appear on a function key for one or more terminals However it is not necessary to put custom made real time screens on function keys to access them To put a custom real time screen on a function key follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5 RITmDf Press F10 Config Select the appropriate user t
371. rd you may also Click on the white J Wu EW box at the lower left hand part of the screen Escape Copyright 2002 MATTEC 2 3 710 0092 Clicking in the upper left hand corner of a ProHelp Millennium screen is equivalent to Pressing the Esc key Some functions also have an X in this position of the screen Clicking on the X is equivalent to Pressing the Esc key ProHelp Millennium D Restore Move Size Minimize Maximize Close Alt F4 Selecting Fields When in edit mode e g when editing a job descriptor in Job Manager mode you may use the mouse to move from one field to another Click the mouse on any editable field and the cursor will move there Picklists You may use the mouse to bring up picklists page down through the list and select a field For example instead of pressing the spacebar to bring up a picklist Click on the field twice with the mouse When the picklist appears Click on the arrows on the side of the box to move up or down through the list To select a field Click on the field with the mouse and Click OK To close the picklist without making a selection Click the Cancel button or Press Esc 2 3 1 Real Time Screen Additional mouse support has been added to the real time screen This support is for the standard MATTEC real time screen and user generated real time screens It allows you to click on certain fields with the mouse and have related information appear To return to the
372. re 3 20 lt A Cu Gi PIC E 3 29 Figure 3 21 Field Size E mca Gioia ance ae ean aaa 3 29 Figure 3 22 Field Separator Picklist sas scccsccs ests eanaeindniee ened dicate 3 29 Figure 3 23 Record Separators Picklist sc eejotien acini enlace Geddes 3 30 Figure 3 24 Date Separators Picklist joo assin ges sainceateeaawacdesscuesnarsn eoue tae teieedaneaseugeeadvoteeeonaaeeag ides 3 30 Figure 3 23 TT NEE 3 30 Figure 3 26 Sample Bar CU art iste s ccssdegecctatiesecticeseteesstianscetel seaside absaeteseceuatuadeeeeacurasedeseeedlibcs 3 32 Figur 3 27 Graph Control inisin eee a ie dae ie ie i ae ee es ee 3 32 Bis re 3228 ECH deene Eege 3 33 Figure 3 29 Graph S17 sie eee oS GSN NG aie Aa eee a al he REAA 3 33 Figure 3 30 E EE 3 33 Figure 3 31 Annual Comparison Report Calculated Fields A 3 34 Figure 3 32 Annual Comparison Report cereen 3 35 PISUte RT EE 3 36 Figure 3 34 Item Picklist lt tecint atte dtee Noes eae i ee ey ees 3 36 Figure 3 35 Annual Comparison Report Option 3 37 Figure 3 36 Sample Quarterly EE eeh eener ed rer Eege AE 3 38 Figure 3 37 Sample Monthly Report Zeg Eeer i al eee ees 3 38 Figure 3 38 Quarterly Cliart 322i vetsaaciueed atid eietiee leed ne edie le 3 39 Figure 3 39 Future Requirements E MOIEN 3 40 Figure 3 40 Future Requirements Field Choice 3 41 Figure 3 41 Detail and Value Relationships seseseseesssesssessessseeesseessesseesseeesseesseesseesseesseee 3 41 Figure 3 42 Second Requirem
373. re you agree that they are to run in the red Otherwise go and see what is really happening at the machines 1 2 6 Setup Person The Setup Person is responsible for tool changes and getting machines ready for production Setup people must become familiar with the MIU and how to perform the various functions when needed The setup person should have a general understanding of job scheduling and real time displays The responsibilities of the setup people are l Review the schedule every day Determine the tools that will change and prepare the new tools ahead of time Prioritize setup people to particular machines before the old jobs are complete Minimize machine downtime for job changeover Copyright 2002 MATTEC 127 710 0092 3 Resolve conflicts of scheduled job changeovers versus manpower available Determine with the Production Control Manager which jobs to change first Determine if some machines should be left idle and if some machines should make overruns 4 Before changing jobs make sure the order lot size has not changed Ensure the Q C department has entered all scrap into the part counts 5 Throughout the day review the real time screens to assure that cycle times and process parameters are running according to standards Make sure someone else has not changed your setup without permission 1 2 7 Material Controller The Material Controller is the person who is responsible to see that a sufficient amount of t
374. real time that has been defined for a function key Press F1 through F8 To select the standard MATTEC real time screen Press F9 Std To access all existing displays by entering the desired display s name Press F10 Other To see a summary of every display name defined on the system Press spacebar Select the display you wish to view Press OK 3 3 4 Elapsed Downtime Reset Traditionally the Elapsed Downtime field available to the Real Time Display has registered the time elapsed since a machine was last in production There is a system wide configuration item which allows this to be altered If Reset Elapsed DFT by Reas is set the Elapsed Downtime field is reset each time the selected Downtime Reason changes even though the machine remains down No other aspect of downtime report or recording is affected 3 3 5 Real Time PM Notification Specific pending preventive maintenance operations may be viewed by clicking on the PM Notification Flag This presents a list of up to five machine preventive maintenance operations and up to five tool preventive maintenance operations The list is limited to Copyright 2002 MATTEC 3 13 710 0092 the current job and tool Each operation shows its numeric identifier text description and hours or cycles to go To Go numbers may be negative for overdue operations 3 4 Job Descriptors A job descriptor is a shop order production record that is stored at the main computer Each
375. reated and scheduled ahead of time To use your time most efficiently you should 1 Create part descriptors for all parts to be run within the next 30 days 2 Use the new part descriptors to create jobs for the orders to be run within the next 30 days Copy the part descriptors and add the new lot size and desired delivery date 3 Schedule the new jobs to the machines they are to be run on 4 Start the job on the machine at the time the tool is changed Use the MIU End of Job function or use the Job Manager control functions 4 1 Job Descriptor Field Definitions A job descriptor is the area in the system where the statistics of a particular job are recorded accumulated and retained for history Each job runs a part whose standards were previously created in a part descriptor To edit a job descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job The following sections describe the fields associated with a job descriptor 4 1 1 General Information Fields To edit a job descriptor s general information fields follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Copyright 2002 MATTEC 4 3 710 0092 When a job is displayed
376. rently running or which appears in the list of scheduled jobs remedy If the job is running it must be ended or suspended before it can be deleted If it is scheduled it must be deleted from the schedule in which it appears Job running scheduled or family member Cannot add cause An attempt was made to add a component to a family which is currently running scheduled to run or already a member of another family remedy Determine which of the above conditions exists and correct it Length error while reading file cause While reading file the maximum length error for that file was exceeded remedy Retry operation If error reappears contact MATTEC for assistance Machine history not found cause An attempt to obtain machine history data was performed but failed because there was no history file for the desired date remedy Check the validity of the dates and existence of the history file in the data directory usr prohelp dtadir Copyright 2002 MATTEC 15 25 710 0092 Machine is busy Try again later cause An attempt was made to pull collect from an MIU that was busy collecting other data remedy Try performing the same operation at a later time Machine not found cause A string has been entered which does not match a known machine number remedy Verify and enter the correct machine number Machine number may not contain embedded spaces cause An attempt to create a machine that had spaces in the actu
377. ress Esc To add or delete data from the tool maintenance history log follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F2 Tool Press F1 Histry Enter the tool number Press Enter The computer will display the history record To add lines to the maintenance history Press F1 Add Ln To delete lines from the maintenance history Press F2 Del Ln Use the cursor keys to position to the fields to make data entries for the person performing the maintenance labor hours etc Copyright 2002 MATTEC 9 12 710 0092 To save your changes Press Esc 9 6 Define Maintenance for a Machine Not Monitored Any number of machines can have maintenance activities logged and forecasted by the system For machines not being monitored in real time by ProHelp Millennium manual maintenance activities must be entered These non monitored machines can only be tracked by days To define maintenance for a machine not monitored by ProHelp Millennium follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F1 Mach Press F1 Histry Enter the machine number Press Enter A message will be displayed stating that this machine is not being monitored Press Y es to continue If a maintenance history already exists for this machine it will be displayed If this is a new machine a new history record will be displayed To add lines to the maintenance history Press F1 Add
378. rmation about the performance of the machines The time frame for the Machine History Report can be weekly month to date or year to date The time frame is from the last reset to the present time You may reset all machines at once or particular machines at one time To reset the machine history log follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F8 MchRst Enter the desired machine number to reset or Press Enter to reset all machine histories The system will ask you if you want to reset the machine history log Press Y es to reset the log or N o to abort this request Note It is wise to print a Machine History Report before resetting the log and file the printed copy for future references 6 12 Tool History Reset The Tool History Report is used to provide various information about the performance of the tools in your plant The time frame for the Tool History Report can be weekly month to date or year to date The time frame is from the last reset to the present time You may reset all tools at once or particular tools at one time To reset the tool history log follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F9 TolRst Enter the desired tool number to reset or Press Enter to reset all tool histories The system will ask you if you want to reset the tool history log Press Y es to reset the log or N o to abort this request Note It is wise to print a Tool Histor
379. ror Cannot delete total record used by either a report graph or export Copyright 2002 MATTEC 15 10 710 0092 cause An attempt was made to delete a total record that was used by a report graph or export remedy Delete the desired total record from the report graph or export before completely deleting it Error Cycle time above non production limit cause While establishing job standards the cycle time field was set to a value greater than the non production limit remedy Either lower the standard cycle time or increase the non production limit time Error Cycle time below minimum cause The cycle time value is below the minimum value of 0 2 for Low Res Mode or 0 02 for High Res Mode remedy Adjust the desired cycle time to conform to the ProHelp Millennium standards Error Cycle time low spec limit above high spec limit cause While setting up upper and lower specification limits an error occurred where the lower limit is greater than the upper limit remedy Adjust the specification limits so that the lower limit is less than the upper limit Error Field is not selected as a sort field cause An attempt was made to enter this field into a total record remedy In order for a field to be entered into the total record it must be used as a sort field Error Grid definition is incompatible with currently selected machine data cause An attempt was made to place a grid that did not fit over the
380. rs end dates material needs etc more accurate This number is multiplied by and added to the STANDARD SCRAP that the user enters in a job descriptor and is used as the maximum value that the system will use in its calculations For example STD SCR 10 Scrap Pred Lim 20 10 X 20 2 12 would be the limit for scrap used in any system calculation This feature eliminates using an inflated ACTUAL SCRAP that is present after a large scrap entry is made especially at the beginning of a job run Entering a value of 999 disables this function and uses the actual scrap CycTm Pred Lim This functions in the same manner as the Scrap Pred Lim It acts as an internal high and low limit on cycle times The value entered here is the acceptable limit above or below the actual cycle time value Entering a value of 999 disables this function and uses actual cycle time For example STD CYC 20 seconds Cycle Tm Pred Lim 10 20 X 10 2 sec The system limit on cycle time will be 22 sec high and 18 sec low EOJ Lot Size Ck When set at Y es it means that the MIU End of Job function will operate only when the specified lot size in the job descriptor is at 0 or below overrun calculation The most common are 8 or 12 hour yields Downtime Unknown Y es forces downtime to be accumulated in the unknown category when the non production limit is reached N o places downtime in the most recently selected downtime reason SPC Samp
381. ry usr prohelp mat_archive follow these steps Copyright 2002 MATTEC 6 15 710 0092 Open an X Terminal by Click Terminal icon on the desktop Enter the following to copy the archive data on the tape to the hard disk cd usr prohelp mat_archive cpio icBdumlv I dev rmt cOsOr Where dev rmt cOsOr is the actual device name of the tape drive as described in System Device Names To retrieve archived data on the hard disk into the standby directory follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F4 Retrve Directory Name You must specify the proper directory name that the archive was copied to on the hard disk For simplicity the directory usr prohelp mat_archive has been created for you to copy the archive to the hard disk To begin the retrieval Press F1 Done After the retrieval data from that time period will be available when reports are requested The data has now been placed in the standby directory To view a job descriptor in the standby directory follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F4 ViewSB Enter the job number you wish to view Press Enter To produce a summary report of jobs in the standby directory follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F5 SummSB Fill in the interactive report screen as appropriate Press F1 Done The Job Descriptor Sum
382. ry Report will be generated Mach Num 03 gi 0 00200 DATE TIME vpap RANGE CAUSE Figure 5 14 SPC Summary Report 5 8 5 Calculating Limits The ability to calculate control limits exists in several places throughout ProStat and gives the user the ability to generate limits based upon actual collected values of machine process and part related data Once calculations are complete the results are displayed Copyright 2002 MATTEC 5 42 710 0092 and the user has the option of discarding the calculated limits or replacing the existing limits with these new values Reference Section 5 6 9 for information on the automatic limits calculation function in ProHelp Millennium The calculate limits function uses only the data specified by the user during the specified date range Limits are calculated with this data and if specified used to replace the old values for the requested dates only Theoretically a job which runs for multiple days could display different control limits for different dates if the calculate limits function is used for only part of the job s run To calculate control limits for multiple days of a job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F5 CalcLm The calculate limits function requires the user to specify a start date and end date This function should be used for SPC jobs that span multiple dates Enter the start and end dates Press Enter Enter
383. ry node When booting ensure that the primary node is running before starting the secondary nodes 2 2 X Server and X Terminal Clients The multi user characteristic of the system provides ProHelp Millennium the ability to connect additional users to each node depending on the type of licensing that you have purchased X Servers will allow you to connect to ProHelp Millennium from a DOS MS Windows OS 2 or Macintosh computer and become a full user of the system with the following exceptions e You may not use a GagePort at the X Server e You may not copy files to or from your local hard drive via ProHelp Millennium You will however be able to access drives that are defined to the ProHelp Millennium node that you are connecting to including remote Novell NetWare drives Additionally a good X Server will offer file transfer programs like FTP e You may not print to a local printer but instead must use a printer defined to the ProHelp Millennium node that you are connecting to including remote Novell NetWare print queues 2 3 Mouse Support ProHelp Millennium offers mouse support for monitoring nodes non monitoring nodes and other client PCs that are connecting with an X Server The following rules regarding the use of a mouse are true throughout most of ProHelp Millennium Function Keys You may use the mouse to Click on any function key For example instead of Pressing the F1 function key on your keyboa
384. s Immediately following a large scrap input by the Q C inspector the current scrap percent could be very high When this happens the total parts to go value may be very large As good production continues and the actual scrap percentage decreases the parts to go value will regain accuracy This can be controlled in the System Manager mode by setting the Scrap Prediction Limit Refer to Section 7 11 Good Parts The good parts fields contains accurate values based on the following calculations GOOD PARTS SHIFT TOTAL PARTS SHIFT SCRAP SHIFT GOOD PARTS JOB TOTAL PARTS JOB SCRAP JOB GOOD PARTS TO GO LOT SIZE GOOD PARTS JOB Copyright 2002 MATTEC 4 8 710 0092 FIELD DESCRIPTION The bad part fields are not calculated they are accumulated from entries at the Machine Interface Units and from the computer keyboard For every part entered as scrap one part is subtracted from good parts and approximately one see calculations above is added to parts to go This field will be displayed if Cases is selected as the production quantity unit The value is in total cases of parts made not counting any hold parts Machine Cycles The machine cycles field is a simple cycle counter All machine cycles except for setup cycles are counted This value is accurate for the time the Machine Interface Unit is powered on This value can be modified in the File Manager mode Refer to Section 6 8 for additional information when the MIU
385. s and movements and labor assignments They may also reveal overloading of tools or labor or excess material needs Overloaded machines simply do not exist in the Forecasted schedule Machine time is treated as a finite resource and excess demand for a particular machine is dealt with by modifying forecasted dates Using the Desired schedule selection essentially views all resources as infinite and simply reports what would be needed including machine hours to run every job at the desired time This type of report should not be used for things like material purchases Copyright 2002 MATTEC 3 41 710 0092 since the situation represented may not be realistic It does however serve to identify what desires may not be attainable and to highlight bottlenecks The resolution of all estimated requirements is the selected Interval To illustrate how this can be significant consider two 20 hour jobs with desired end points of 16 00 Friday Since the assigned machine runs 24 hours a day a weekly report based on Desired schedule would show no conflict There are 144 machine hours available and only 40 required If the same data is used to produce a daily report the assigned machine would show 32 hours required during the 24 available on Friday In many cases overlaps of a few hours are not important This is increasingly true as predictions stretch further into the future Therefore reports with one week intervals might be adequate for periods exten
386. s are erased when the help called is canceled at the MIU This function displays only machines that are not cycling down and have running jobs scheduled on them ProHelp Millennium assumes that all manufacturing plants strive for 100 machine and manpower usage to maximize productivity and profits When a machine is down there is no productivity associated with it It actually becomes lost dollars The machine maintenance and scheduling group can make use of the down display to direct their actions toward keeping the machines running more productively The amount of current downtime is displayed along with the downtime reason on the right side of the screen under the machine parameters column Short for Exception display This function displays on the screen only those machines operating outside of standards red OR white or that are scheduled to run but are not cycling at all yellow This function can be used to prioritize the activities of maintenance setup and other floor personnel by showing them just the machines in trouble This function displays those machines cycling but not within the limits of the standards set for the job Management personnel can refer to this display for a feel for general job status in the plant Copyright 2002 MATTEC 3 7 710 0092 F1 FILTER DESCRIPTION NonRun This function displays machines that are not cycling non running Non running machines are identified and divided into two classes
387. s group is labeled Misc The toggle control s labels and functions are displayed in the table below LABELS ON FUNCTIONS OFF FUNCTIONS Show Available Hours In the space between bars Nothing will be displayed default on in the Gantt chart the in spaces between bars on available hours will be the Gantt chart displayed Copyright 2002 MATTEC 12 17 710 0092 Show Partial Labels default off Monochrome Each Gantt bar s label will be displayed If the bar is too small to display its entire label the label will be truncated Gantt bars do not use color In this mode outlined bars with no hatch fill will indicate jobs on time Bars filled will indicate jobs not forecasted to complete on time All other bars will be drawn with a cross hatch fill pattern If a given Gantt bar s label is too large to be displayed in its entirety in the Gantt bar it will not be displayed Gantt bars will show color A green bar will indicate a job forecasted to complete on time A red bar will indicate a job forecasted to not complete on time All other bars will be yellow Disable Dyna Scroll default Dyna Scroll will be Dyna Scroll will be off disabled enabled Refer to Section 12 2 4 2 for information on Dyna Scroll ProSched Preferences x Show available run hours in gantt w Show partial labels inside gantt bars Draw monochrome gantt bars Disable dynamic scrolling during drag oK SCHEDU
388. s in length then the heading for a part number would include two lines each of 22 characters The data fields that are used for the real time screen have a preceding blank character as a separator It is not possible to put multiple spaces between fields You can create a real time screen as an unique format or you may modify an existing screen and change it accordingly You may select the standard MATTEC real time screen as the basis for your screens and then make changes as you wish Numeric data formats may be modified only on the left side of the decimal point You may not change the accuracy of the data fields to the right side of the decimal point The width displayed on the screen includes the decimal point It is very easy to create a display full of meaningless numbers by eliminating significant digits so be careful Figure 7 12 Real Time Screen Template for Std MATTEC Screen shows the standard screen that is used to create new displays You can create a real time next son data field into a custom real time screen For family jobs the following points are important to remember e When a family job is running the first inactive son job of the family has its job number and part number displayed on the custom real time screen e Ifa running family job has all active son jobs the next son job and part number fields are displayed as blanks on the custom real time screen e Ifa family job is scheduled on the machine as the next sched
389. s may be changed in this mode F7 MntMan This is a password protected mode The Maintenance Manager mode allows entries to be made to the tool and machine maintenance records Descriptive values of what maintenance F6 PrdMan This is a password protected mode The Production Manager mode allows second and third shift foremen to change machine schedules actual cavities for a job regrind for a job and the amount of occurred may be entered This is an optional program F8 CstMan_ This is a password protected mode Actual cost values for labor hours machine hours material costs etc may be entered This is the only mode in which the daily Cost and Contribution Report and Job Cost Report can be seen This is an optional program F9 The F9 key on the copyright screen is reserved for customers who have special software created by MATTEC that requires a special user F10 Lang The language key is used to select a different language for display at the computer This is an Optional Program 3 2 View Mode Menu Selections To display the View mode menu screen follow these steps Press F1 View Figure 3 1 Copyright Screen The system will display the main View menu ProHelp Millennium pam AbDesc BSched HReport HProsat B BPgraph Bexport Botadcc PMP1tSts Copyright 2002 MATTEC 3 3 710 0092 Figure 3 2 View Mode Menu Selections The functions available in the View mode Figure 3 2 View Mode Menu Selections are
390. s two remedy Adjust other terminals so that a total of 2 languages exist Too many columna delete first Copyright 2002 MATTEC 15 46 710 0092 cause An attempt was made to insert too many columns of data into a real time display remedy Delete an existing column of data before inserting any more Tool maintenance history not found cause An attempt to obtain tool maintenance data was performed but failed because there was no history file for the desired date remedy Check validity of dates and existence of the history file in the data directory usr prohelp dtadir Total part weight exceeds shot weight cause The job standards value for part weight exceeds the shot weight remedy Reset the part weight so that the part weight times the number of active cavities does not exceed the shot weight Unable to access SQC data for filename cause ProHelp Millennium tried to access an SPC file that did not conform to standards remedy Check the integrity or existence of the specified file Unable to allocate sufficient memory cause ProHelp Millennium attempted to allocate more memory than exists remedy Contact MATTEC for assistance Unable to copy xxxxxxxxxxxx cause During a backup operation something prevented the file identified by XXXXXXXXXXXxX from being copied to the floppy diskette remedy The backup diskette s are usable although the named file is absent Unless you are sufficiently familiar
391. sae es NEEN NENNEN asdeeatedesdaceasaeanvene 3 17 3 4 3 Pareto Charts of Downtime and Eeer ed ee 3 18 3 4 4 Job Descriptor Summary Report 3 19 39 E ENN E 3 19 3 5 1 Display a Machine Schedule sogisicdsvacesaciaversccaseecaees spavedeaigesaesessaceauensusnaceusdeceueatpevadees 3 20 3 2 Gantt Chart E TE 3 21 3 5 9 schedule Summary Ee EE 3 22 E SE A KoI M Et e i APTA A E EATE see 3 22 3 6 _ Reports and Charts a enunni nasses nnna i ea E R 3 26 Srel General Operation sarne cata E erh eer 3 26 JOLA REDO EE 3 26 3 0 1 2 Report Genel atl EE 3 27 3 6 1 3 Chart Manipulation sisirin ianei a i ia o E a N h 3 31 EEN SPECI REPOS kerien een 3 34 3 6 2 1 Annual Comparison Report EE 3 34 3 6 2 2 Future Requirements Report sssssssssssssesesseesssttssressersseresseesssressresseesseessseesssees 3 39 3 6 2 3 Tool Conflict Reports EE 3 46 36 2 4 Process Parameter Graphs rnense a A E E ones 3 48 NEE 3 53 Dror Dat EDOM EE 3 53 3 9 IQ Report WE siccacsastaversccasnevervassovcatataisnetassaveisisagoa E E E E Aia E TE AN ER ES 3 54 SSC General Pick Lists ach e E tll ee 3 55 As JOM ANAS EE 4 4 1 Job Descriptor Field Definitions ifsc 5cc vaca dee Vie dee 4 3 4 1 1 General Information Fields scccssssjsceisss pcsaateessiatvisesdcarasastaacssededavs a galeetestaatesnstaatees 4 3 4 1 2 Prod ction Data Fieldsi deet 4 6 413 ENEE 4 10 4 1 4 Machine Process EE 4 14 ATS Least 50O Cycl KEE 4 16 AL TD wntimeand Scraps cenene
392. save your changes Press Esc The system must be rebooted for your changes to take effect 7 4 2 Schedule Exceptions To set plant exception periods follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F3 WrkSch Press F2 PItExc The system will display the Plant Wide Shift Exception Schedule screen Figure 7 7 Plant Wide Exception Schedule PLANT SHIFT EXCEPTION SCHEDULE START END ACT COMMENT Figure 7 7 Plant Wide Exception Schedule Press F1 Add Enter the start date Press Enter Enter the start time Press Enter This is the date and time that is the beginning of the exception period Copyright 2002 MATTEC 7 9 710 0092 The system will enter the date and time on the first line of the screen if this is the first entry or it will place it in the correct position if there are other dates already entered If the start date and time are correct use the Enter or arrow keys to position the cursor to the end date and time fields Enter the date and time that mark the end of the exception period The start and end date brackets a time period in which everything within that period is included in the exception Active Specifies this period as active Y es or inactive N o regardless of the weekly shift array Comment This optional field is provided for entering a reason comment for the exception period FUNCTION KEY DESCRIPTION F1 Add Press F1 Add to enter any additional
393. screen To insert a field into the display Press F1 Insert Select the appropriate item to be added Press OK Enter the sequence number location of the new item Press Enter This number is the position of the field in the display Enter the top and bottom header information Press Enter To delete items from the display Press F2 Delete Enter the item number to delete Press Enter Continue deleting or inserting items as you choose Copyright 2002 MATTEC 7 21 710 0092 When completed always RESAVE your file to hard disk To resave the real time display follow these steps Press F3 Files Press F1 Save Enter a unique display name Press Enter 7 6 3 Delete an Entire Display To delete an existing real time screen follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5 RITmDf Press F3 Files Press F3 Delete To display a screen of all custom real time screen names defined on the system Press spacebar Enter the display name to delete Press Enter To delete the display Enter Y es If the deleted display was configured as a custom real time menu then the deleted display name must be removed from the custom menu configuration See Section7 6 2 7 6 4 Create a New Display from an Existing Display To create a new real time screen from an existing real time screen follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5
394. sed to change the status of a job from suspended to ended To end a job which is currently running follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F2 End Enter the machine number on which the job is running Press Enter The job is ended and removed from the schedule A job which was stopped before the lot size was completed was marked as suspended by the system If the job is never to be rerun it should be changed to ended status so that it can be removed from the hard disk via the archive and purge functions To end a job which is marked as suspended change the job s status from suspend to end follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F4 Contrl Press F2 End At the machine number prompt Press Enter When prompted for a job number enter the job number to end Press Enter 4 5 3 Suspend a Job The Suspend function is used to temporarily stop monitoring a job This function is used when the job descriptor is to be used in the future to continue monitoring the job Reasons for suspending a job include pulling the tool for repairs or prioritizing a hot job which must run immediately Copyright 2002 MATTEC 4 49 710 0092 Suspended jobs are not archived by the File Manager archive function The suspend function is also used to change the status of a completed job to the state of suspended This may be necessary when it is desir
395. separated into five categories DATA TYPE DESCRIPTION Descriptors These are definition files that describe what will be monitored and how This category contains active job descriptors part descriptors real time schedule information machine maintenance schedule information and tool maintenance schedule information Production This data consists of production history that has been collected on History running jobs At the end of every shift production history is saved under the date and shift number When a job is completed a permanent record is made with the completion date and shift number This category contains shift history machine and tool history and machine and tool maintenance history SPC History All active SPC data and samples collected under ProStat are stored under this category Operator History All history of operators logging onto a machine at the MIU is stored here This includes operator efficiency and operator tracking history Log History This category consists of data collected from the down log help log and parameter exception log functions These five categories of files are further broken down into the active drive and standby drive DRIVE DESCRIPTION Active Drive This designates where the active data is stored Active data are files that are used in current ongoing operations which may be edited or modified by the user These files are heavily accessed by many users on the system and therefore caref
396. ss the appropriate function key to display your choice These choices are described in Section 4 2 1 3 4 1 Last 50 Cycle Times The last 50 cycle times can be viewed on any particular machine or for any particular job that is presently running To view the last 50 cycle times for a job follow these steps Press F1 View Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear from which to select the type of information needed Make your selection Press OK The Last 50 Cycle Times for the selected job number will be displayed on the right hand side of the job descriptor Copyright 2002 MATTEC 3 15 710 0092 Cycle times in green are within the high and low limits Cycle times in red are slower than allowable Cycle times in white are faster than allowable Cycle times are constantly updated with the newest value displayed in the 1 position and the last value removed from the screen 3 4 1 1 Machine Signal Display The Last 50 Values may be displayed for all Primary Machine Signals while a job is running When the Last 50 Cycle page is initially selected it displays cycle time values A menu key allows selection of any Primary Machine Signal The signal selection is retained even though the specific job displayed is changed through paging or other operations Whenever the displayed
397. standard cycle time Yield efficiency during the time period Yield efficiency is the ratio of oe R R actual yield to standard yield To view the Operator Tracking Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4 Report Press F10 more Press F1 Opratr Press F2 Track Fill in the interactive screen as appropriate Use the spacebar for picklist of options Use arrow keys to move from field to field Press F1 Done The Operator Tracking Report will be displayed The Operator Tracking Report contains the following information FIELD DESCRIPTION The operator s identifying number The machine number non blank non blank 4 8 Manual Data Input The Job Manager or QC Manager can manually introduce production data not collected through an MIU This function actually produces a set of Production Data Import records as described in the ProHelp Millennium Data Exchange Manual 710 0085 Copyright 2002 MATTEC 4 60 710 0092 Data is entered via a spreadsheet style interface The first three columns of each row contain e Job Number e Date e Shift Tag The remaining columns contain various production values The default spreadsheet includes all possible scrap and downtime columns A new System Manager function allows up to ten named configurations of different column sets to be maintained Any of these configurations may be selected for use The full set of av
398. status switch is in the setup position Pulse 2 3 4 These fields represent optional counters The name of these fields Signal 3 4 5 may be preset by the System Manager to something different than Pulse 2 4 These counters have shift and job totals but do not have a to go value They may be used to track hot stamp cycles or some other secondary operation Run Hours Run hours contains the actual time the machine cycled Cycle time exceeding the non production limit is not included in run time It is counted as downtime Run Hours To go A maximum of six numbers digits can be displayed for run hours to go Run hours to go is calculated as Parts to go x Run Hrs Job Actual Cavities Machine Cycles Job Downtime hours contain the actual time the machine did not cycle Long cycle times exceeding the non production limit are counted as downtime Power off time of the machine or MIU is counted as downtime Material lbs The material used for the job is shown here Material The sum of each machine cycle x actual shot weight Material to go actual shot weight x cycles to go The amount of primary material used and to go takes into account the regrind Material values are estimates based on standards and assumptions Actual material used from inventory may be different due to over packing loss unreported scrap or spillage Material lbs hr This is the present rate of material used per hour Copyright 2002 MAT
399. stem Manager A job may be placed directly into the schedule by entering the machine number in this field and pressing F9 Sched When the machine number is entered into the field the corresponding signal downtime and scrap names are automatically copied to the job descriptor Machine Class The machine class is an information field that is used to relate the class of machine that the job is to run on This is a 6 character alphanumeric field The machine class fields are defined by the System Manager Copyright 2002 MATTEC 4 5 710 0092 This field is 9 digits long and is used to tell ProHelp Millennium how many good parts should be run for this job This field must be set properly for ProHelp Millennium to operate The units for the lot size will vary depending on the type of machine that the job will run on and on the specified production quantity units This field defines the quantity units to use for production For machines specified as seconds cycle cycles hour or cycles minute valid choices are Parts or Cases For rate machines specified as meters minute valid choices are Parts Meters Cases Rolls and Parts Meters 4 1 2 Production Data Fields To view a job descriptor s production data fields follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Wh
400. story These files continue to grow in size and number New files are created each day to contain operator history data tracking and efficiency Log Files These files continue to grow in size and include the process exception log down log and help log Production history and descriptor files are further broken down into active and standby files Refer to Section 7 16 for additional information Active files are those which are being used in ongoing monitoring operations and which may be edited or modified by the user Standby files are those for which the need for modification has passed but which may be required in reports or charts With standby files there is no need to access archived data stored on an external device Keep in mind once a file is changed to standby status it may no longer be edited The size and number of certain descriptor files and history files can directly affect the performance of the system and must be controlled by the File Manager to provide maximum system performance The File Manager mode provides the functions to assist in this effort The File Manager s job is critical and there should be one person responsible for this function with another person trained as a backup It is important that the company set up Copyright 2002 MATTEC 6 1 710 0092 a procedure of archiving purging and backing up data This procedure should be strictly followed and will vary depending on the amount of data you collec
401. t EXCL or INCL and press spacebar To copy the department cause reasons to the job or to modify the job s cause reasons follow these steps once the sample is displayed Press F8 Cause If the department cause reasons haven t already been copied to the job Press Y es to copy the reasons You may now modify each of the cause reasons as required for this job To save your changes Press Esc 5 7 5 Variable Data Entry To enter variable data from a computer terminal for a job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F 1 Edit Enter the sample entry date Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist Select the parameter Select Variable Copyright 2002 MATTEC 5 32 710 0092 Press F1 Done The message Reading sample data will be displayed momentarily before the variable sample entry edit screen is displayed If this is the first data sample to be entered an error message No samples found will be displayed Press Enter The Edit menu will appear To insert a new sample or you may select an existing sample to edit
402. t 2002 MATTEC 15 49 710 0092 cause While calculating upper and lower control limits an error occurred where the lower limit is greater than the upper limit remedy Examine the machine for problems Copyright 2002 MATTEC 15 50 710 0092
403. t Chart of Individuals The chart function allows the user to display the chart of a specified sample data subset at a computer terminal XbarR charts Moving Range MRx charts and Charts of Individuals X chart may be generated The Moving Range MRx chart displays the range of observations within a moving range A moving range size of two to nine is allowed The Chart of Individuals X chart displays the individual observations in each sample If SPC data is collected with more than one observation per sample then each observation is plotted in the order in which it was collected If the field Moving Range is set to Y es both the MRx and X chart will be generated To generate an XbarR chart Moving Range chart or a Chart of Individuals for automatic manual or variable data follow these steps Press F1 View or F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F2 Chart Copyright 2002 MATTEC 5 37 710 0092 Enter the start and end dates Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To generate the chart for a part number multiple job runs with the same part number reference
404. t such as holidays may be entered for the entire year Departments and machines that are active or inactive on an independent basis from the rest of the plant may now be recognized as such by the system Downtime can only be recorded against a period marked as active and only active periods are considered when predicting dates for forecasted start and end dates in the real time scheduler 7 4 1 Weekly Schedule Configuration To define the department schedule follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F3 WrkSch Press F1 Shifts ProHelp Millennium Iof x Figure 7 4 Shift Configuration Copyright 2002 MATTEC 7 6 710 0092 FIELD DESCRIPTION Department To select the department press the spacebar make a selection and press Enter Note The department names must already be defined See Section 7 15 for additional information Start Point This field specifies the date and time from which the definition of shifts is assumed to begin The period defined by shift index number 1 will begin at this point The remaining shifts will follow in order and repeat indefinitely Shift Date This applies to the shift that crosses on the date boundary of 00 00 hours You must specify which day you wish to record the data for history and reporting purposes If you wish the data be recorded on the day the shift begins select start of shift If you wish the data be recorded on the day the shift ends selec
405. t Qualification Specification and control limit violations for part qualification violations are logged All types of process exceptions are logged The process exception log has the potential to grow very rapidly and as a result should only be turned on if the data collected will be used The process exception log is backed up archived and purged when the equivalent functions for shift history are performed Copyright 2002 MATTEC 5 23 710 0092 To enable process exception logging for an individual job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F5 Basic Set the Process Exception Log field to the desired type of process exception logging for this job For this job to log process exceptions the department process exception logging must also be turned on To enable process exception logging for a department for all jobs in the department that have process exception logging enabled follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F4 Misc Press F1 Dept Select the department to turn process exception logging on or off Set the Exception Log On field to Y es or N o as appropriate When the department process exception logging is turned on only
406. t and process The MATTEC Customer Service Department can assist you with defining these procedures The file maintenance functions may be operated from any node or terminal and will be run for data on all nodes If you are performing a file maintenance function such as archive or backup to an external storage device floppy or tape drive that device must be defined to the local ProHelp Millennium node If you are writing to an internal AT hard drive any drive on the ProHelp Millennium network may be accessed from any node or terminal 6 1 Open Unix File Manager ProHelp Millennium is designed to limit the amount of time that you must spend interacting with the base operating system on which ProHelp Millennium is built Open Unix Open Unix is a UNIX System V Release 5 operating system from Caldera Many of the activities that require you to interact with Open Unix e g defining a new printer are handled through the Open Unix graphical desktop and are described in the ProHelp Millennium Software Installation Manual 710 0069 and the Open Unix documentation that was included with your ProHelp Millennium system This section will describe in limited detail the Open Unix commands that allow you to transfer archive backup data from the hard disk to a floppy diskette or tape For additional information or assistance reference the Open Unix documentation that came with your ProHelp Millennium system or contact the MATTEC Customer S
407. t end of shift Use the spacebar to make a selection Tag Tag refers to a shift number that repeats in the schedule The system supports anywhere from to 4 unique shifts per day with a maximum repeat factor of 112 unique shifts per department This feature allows swing shifts crews that alternate back and forth from week to week Length Len The length field specifies in hours and minutes how long each shift is Active Act The active field specifies whether work is normally planned for that shift For every day of the week you must specify for each shift whether work is normally scheduled or not For every shift in a given week you must specify a tag number length of time for that shift and whether it is active or not Saturday and Sunday must be accounted for in the weekly configuration even if work is not normally scheduled then To create a schedule insert the shift numbers as they occur in chronological order under index numbers through 112 Fill these in until you reach a point where the weekly array begins to repeat itself For example to define three shifts per day for a 7 day work week use shift tags 1 through 21 The lower half of the shift definition page displays what the actual weekly schedule looks like given the start point you specified Use the PgUp and PgDn keys to go through the schedule and verify it is set up as desired With these shift definitions many arrangements are possible Ho
408. t this field is a title and the translation should be centered in the description with spaces between words Some strings have no description given This is the case where the phrase is self explanatory Translation The bottom light blue area allows entry of the desired replacement phrase Pressing PgDn moves to the next string Pressing PgUp moves to the previous string Home moves to the first string and End moves to the last string To move to a specific string use the F1 StrNum key and enter the desired string number When finished entering and modifying phrases Press Esc A message Please wait updating configuration will be displayed while the translation is being copied to the system To print a copy of all of the language strings Press F4 Print 7 13 2 Copy a Language to User Defined The language option gives the ProHelp Millennium user the ability to copy a language to a file called User Defined Once copied the user may modify or edit any of the words or phrases that appear in the translation This is useful when the user wishes to modify some existing words on the system or when completely defining a new translation not available from MATTEC To copy a language to User defined follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F4 LangEd Press F2 CpyLng A picklist with the available languages on your system will be displayed Use the arrow ke
409. ta To save your changes Press Esc ProHelp Millennium A Figure 7 34 Location of Data Files 7 16 Rate System Setup ProHelp and ProHelp 1000 initially were designed for cyclical machines All machines were defined to produce parts and job descriptors kept track of in seconds per cycle cycle time Today ProHelp 1000 and ProHelp Millennium can be configured for rate machines as well This allows a job to track meters per minute meters per second or cycles per second as well as seconds per cycle Each MIU must be configured as a cyclical or rate machine Until a machine number is specified in a job or part descriptor however the default system wide speed units are used Copyright 2002 MATTEC 7 74 710 0092 To set the system wide default speed units to rate specifications follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F1 Misc Move the cursor to the Deflt Speed Units field and select the proper rate Use the spacebar for selection To set the installation parameters Speed Units and Linear Mult to the appropriate setting for each MIU in the plant follow these steps Press F4 Ave Man Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU Set the fields for the first MIU and page through the other MIUs to do the same Plants with Mixed types of Machines For best results in plants with mixed types of machines you c
410. ta press F3 Insert to add a new sample F4 Delete When editing SPC data press F4 Delete to remove the displayed data sample from the job s SPC file F5 InsChr When editing SPC data press F5 InsChr to add a part characteristic to the data type F6 DelChr When editing SPC data press F6 DelChr to remove a part characteristic from the data type Copyright 2002 MATTEC 5 30 710 0092 F8 Cause When editing SPC data press F8 Cause to insert a cause into a sample Calculating Limits When F2 Specs is selected control limits for the date displayed may be calculated by pressing F1 CalcLm If process parameter or variable data is being edited additional prompting will occur to specify the characteristic Calculations are performed using the data which is active i e for the specified job and shift date When calculations are complete the results are displayed and the user has the option of discarding the calculated limits or storing them Note The F1 CalcLm function under the Edit mode calculates limits for a daily data set only Since many ProStat jobs span multiple days special care should be taken when replacing limits with this function as it only applies to the date displayed An alternative would be the F6 CalcLm function key in the main ProStat menu Section 5 8 This CalcLm function allows the user to enter start and end dates multiple days for calculating and replacing limits If the sample dat
411. ta for extended time periods the limiting factor is the information contained on the hard disk This is an optional program F10 PltSts Used to display a real time department summary for the current shift for the entire plant This display adds totals for the entire department on run hours down hours setup hours good parts or total material scrap and yield efficiency 3 3 Real Time Displays Copyright 2002 MATTEC 3 4 710 0092 To view any real time screen follow these steps Press F1 View Figure 3 1 Copyright Screen Press F1 RealTm A new window will be opened Figure 3 3 Standard Real Time Screen which displays a summary of the status of all the machines being monitored on the plant floor To view machines that don t fit on the current screen Press PgUp or PgDn on the keyboard ProHelp Millennium Dept BLOW Shift 1 41 Dept EXTRUD Shift 1 10 Dept INJECT Shift 1 41C Filter Bo BVvoice FO Class Beton Bieo Figure 3 3 Standard Real Time Screen Copyright 2002 MATTEC 3 5 710 0092 The functions available Geseems 3 3 Standard Real Time Screen are described below FUNCTION KEY DESCRIPTION KEY DESCRIPTION F1 Filter This function key gives you the ability to choose machines for display that fall into specific exception categories You can choose to see All the machines machines that have a pending Help call machines that are Down machines that are not running to st
412. tem Manager to treat all parts as hold parts then you must edit the parts to the good part category or to any one of the scrap parts category Parts should be edited from hold parts many times throughout the day This will allow the real time screens to show meaningful values for hours to go and yield To move hold parts to good parts for the present shift follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QC Ent Press F1 Active Enter the machine number of a running job Press F6 GdPtSh Enter the quantity of parts Press Enter Parts will now be removed from the hold category to the good parts category Negative numbers cause parts to be removed from good parts and added to hold parts To save your changes Press Esc To move hold parts to scrap parts for the present shift follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QC Ent Press F1 Active Enter the machine number of a running job Press F5 ScrapP Press F5 ScrapP A picklist will appear Highlight the scrap reason Click OK Enter the quantity of scrap parts for the selected reason Press Enter Repeat this process as many times as required The additional scrap parts are added to the specified category The hold parts total is decreased by the amount entered the yield value is changed and the job history is updated Copyright 2002 MATTEC 5 6 710 0092 Negative numbers
413. tep the archived data will be copied by ProHelp Millennium to the hard disk In the second step the user must manually copy the archived data to an appropriate storage device e g a tape using standard Open Unix copy utilities Reference Section 6 1 for additional information Reference Section 6 6 for information on scheduling the archive program to execute automatically To archive data to the hard disk follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F1 Arch Copyright 2002 MATTEC 6 5 710 0092 done list Figure 6 1 File Archive Directory Name You must specify a directory name that the archive will be copied to The system will automatically copy a file under this directory using the date that was entered as the Latest Date to Archive For simplicity the directory usr prohelp mat_archive has been created for you to copy the archive to the hard disk Earliest Date to This date specifies from when the archive will start Archive Latest Date to This date specifies the date the archive will end The earliest and Archive latest dates to archive form a window within which all data will be archived It is important to document these two dates onto the storage device so that the information from this time frame may be retrieved in the future Fill in the interactive screen as appropriate Press F1 Done The archive will be copied to the location on the hard disk that was specified
414. ter data automatic or manual samples variable data or attribute data for a job follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F 1 Edit Enter the date to view Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist Select the parameter type to view or edit To display the allowable choices for the parameter Press spacebar Copyright 2002 MATTEC 5 29 710 0092 The available choices include none automatic process data manual process data variable data or attribute data Move the cursor to the desired choice Press Enter Press F1 Done The system will display the first sample recorded on the requested date To display any additional samples recorded on this date Press PgDn The Edit and View functions differ only in the ability in the Edit mode to modify existing data The View user is not permitted to modify the data Only data for samples which exist in the specified data subset are displayed When in Edit mode samples may be inserted or deleted for variable or attribute data types Process parameter data samples are recorded by the MIU at the m
415. ter related phrases Separate phrases may exist for each of the twenty Primary Process Parameters plus one additional for the auxiliary parameters as a group Copyright 2002 MATTEC 7 35 710 0092 Though the user may define signal names on machine by machine basis only a single set of sounds can be defined for each department The phrase will be repeated at a predefined regular interval until the machine gets in limits or the condition is acknowledged from the real time screen Help Down and Out of limits voice messages can be acknowledged from the ProHelp real time screen Once acknowledged the voice system will stop repeating the last message Acknowledging voice will not change the ProHelp Millennium system status For example acknowledging help voice will stop the last help voice message but it will not cancel the help message from the real time screen Also any new help message will be announced Press F4 SysMan Figure 3 1 Copyright Screen Press F2 Voice Separate phrases may exist for each department for each of the twenty primary downtime reasons To define the phases to be used press the following and fill in appropriately Use the spacebar to display picklists Press F1 Help Press F2 Down OR Press F3 Parms To activate Press F1 Play Enter reason or parameter number To copy the definition to another department Press F2 CpyDpt A picklist of departments will appear Enter a department n
416. ter such as job standards and answers to questions prompted by MIU keypad activation This communication process of sending and receiving data is an on going process as long as the monitoring node and the MIU are turned on and operational In the event that this communication is not possible e g the monitoring node is turned off due to a power loss the MIU can typically continue to collect data without loss for approximately 18 hours Physical Characteristics The MIU assembly consists of an outer shell a terminal strip board and the unit itself with power supply microprocessor board front panel and cables The shell is designed to be mounted to the machine with all conduit permanently attached The wiring is routed into the shell and terminated at the terminal strip board This allows for a modular connection of the MIU to the shell for easy installation There are different types of front panels depending on which level of MIU that you order The following paragraphs will describe the physical characteristics and general operational capabilities of each MIU level Copyright 2002 MATTEC 1 14 710 0092 MIU 0 The Level 0 MIU is designed to provide basic production monitoring for up to four machines per MIU This unit is normally located in a central location so that cycle signal wiring from all four machines can be routed and terminated in this one shell This provides an economical method of production monitoring However outp
417. than the maximum remedy The non production limit field must be set to value less than 327 6 seconds high resolution or 3267 seconds low resolution Error Nonproduction limit is zero must be non zero cause While establishing job standards the non production limit field was set equal to 0 remedy The non production limit field must contain a non zero number Error Part weight exceeds shot weight cause While setting up standards of a job an error was made in defining part and shot weight remedy By definition the shot weight must always be greater than or equal to the part weight Error Pulse high spec limit out of range cause While setting up upper and lower spec limits an error occurred where the high limit is out of range remedy Adjust the specification limits to a valid value Error Pulse low spec limit above high spec limit cause While setting up upper and lower spec limits an error occurred where the lower limit is greater than the upper limit remedy Adjust the specification limits so that the lower limit is less than the upper limit Error Pulse low spec limit out of range cause An attempt was made to enter a pulse specification limit that was out of range remedy Either increase the specification limit or create a pulse limit within range Error Shot weight above maximum Copyright 2002 MATTEC 15 14 710 0092 cause The desired shot weight value is above ProHelp Millennium s
418. that may be used for timers and counters and 2 digital outputs In its extended version it includes 6 additional analog inputs 6 additional digital inputs and 6 additional digital outputs Two auxiliary communications ports are standard in the MIU 10X Com 2 that is a RS 232 port with built in Gage Port interface and Com 3 that is configurable as a PLC interface port and may be current loop RS 485 422 or RS 232 This is jumper selectable in the MIU described in Manual 710 0043 TS MIU The TS MIU is a high performance process monitoring Machine Interface Unit It includes a color touch screen LCD display for operator interface In its standard configuration it includes 6 true analog input channels for monitoring temperatures pressures and other transducer inputs 8 digital inputs that may be used for timers and counters and 2 digital outputs In its extended version it includes 6 additional analog inputs 6 additional digital inputs and 6 additional digital outputs Two auxiliary communications ports are standard in the TS MIU Com 4 that is a RS 232 port with built in Gage Port interface and Com 3 that is configurable as a PLC interface port and may be current loop RS 485 422 or RS 232 This is jumper selectable in the MIU described in Manual 710 0043 PC MIU The PC MIU is a cell controller that can monitor from 1 to 8 machines each with process parameter capabilities In addition to an easy to use MIU interface the PC MIU is ca
419. the Job Manager function in order to schedule jobs The scheduling person must understand the report functions to view the tool year to date report and the schedule summary report The scheduling person must be able to read the real time screens to determine the status of all jobs The scheduling person should be familiar with the capabilities the foremen have to change the schedule via the Production Manager mode of operation 1 2 4 Production Control Manager The Production Control Manager is the person who oversees the entire production process This person is concerned with everything from the acquisition of raw materials to making sure that a quality product makes its way out the shipping door to the customer The Production Control Manager should assume full responsibility for the following L The timely implementation of the ProHelp Millennium system within the plant 2 Delegation and assignment of responsibility for the various duties on the ProHelp Millennium system 3 Establishment of an on going communication link whereby all users of the system monitor the progress being made implement changes when needed and verify that all duties are being completed 4 Daily review with other managers to monitor production rates efficiencies machine downtime and production schedules In light of these responsibilities the Production Manager must have a general knowledge of the entire system The Production Control Manager should
420. the MIU Reference the MIU Operator s Manual for information on entering scrap parts for the running job at an MIU Copyright 2002 MATTEC 5 1 710 0092 Figure 5 1 QC Scrap Entry Press F5 ScrapP A picklist will appear Highlight the scrap reason Click OK Enter the quantity of scrap parts for the selected reason Press Enter Repeat this process as many times as required The additional scrap parts are added to the specified category The good parts total is decreased by the amount entered the yield value is changed and the job history is updated Negative numbers can be entered A negative number has the effect of reducing the scrap category and increasing good parts To add scrap parts to previous shifts of production the job history records for that job must be on line and in the active directory Standby and archived data files cannot be edited To edit scrap parts for a previous shift of production follow these steps Press F3 QC Man Figure 3 1 Copyright Screen Press F1 QC Ent Press F2 Prev Enter the appropriate shift number Press Enter Enter the date of the shift to be edited Press Enter Enter the job number Press Enter The record for the specified job and shift is displayed Note that the shift and date is displayed on the bottom left hand corner of the screen Press F5 ScrapP A picklist will appear Highlight the scrap reason Click OK Enter the quantity of scrap par
421. the current job F2 Cpy Pt Copy a part s QC sheet to the current job F3 CpyMst Copy a master QC sheet to the current job AS appropriate Press F1 CpyJob Press F2 CpyPt Press F3 CpyMst Enter the sheet number to be copied Press Enter QC sheets that were copied from master QC sheets defined by the System Manager may have protected cyan and unprotected white fields QC sheets created in part descriptors or job descriptors are in the unprotected white mode Copyright 2002 MATTEC 4 27 710 0092 Move the cursor keys to fill in the data field values for the new QC sheet for this particular job When the cursor goes white an alphanumeric character can be entered It is not necessary to press the Enter key after entering a value This is a free form format which means that the cursor keys are used to position to the field that is to be changed To highlight the portion of the QC sheet s first page that may be displayed at the MIU Press F4 OvlOn Information values that are in an unprotected white character mode may be edited and additional information screens may be created and added There is a limit of 1 page per QC sheet Remember any information entered in the Job Manager mode will be in an unprotected mode white characters They exist in the system only as long as the job descriptor is on line Only QC sheets created in the System Manager mode are master QC sheets Refer to Section 7 8
422. the generation of maintenance due forecasts In the event that the number of run hours or cycles derived from the job schedule is less than the maintenance period associated with a maintenance code number and the maintenance period has been specified in run hours or cycles ONLY then the due date forecast for that code number is not possible A date of 01 01 80 is provided in this case as an indication to the user that there are insufficient jobs presently in the job schedule to consume the run hours or cycles of the maintenance period However in all cases the forecast provides the number of run hours or cycles remaining in the maintenance period To generate the Machine Preventive Maintenance Due Report follow these steps Press F1 View Figure 3 1 Copyright Screen Press F4 Report Highlight Maintenance Highlight Maintenance PM Due The Machine PM Due Report can be selected to show one or all machines one or all departments and one or all maintenance code numbers Fill in the interactive screen as appropriate To generate the report Press F1 Done ProHelp Millennium 10 96 MACHINE MAINTENANCE DUE FO ST NEXT 30 DAYS CODE All DATE LAST RUN HOURS TIME DUE 0 MACH CODE PERFORMED SINCE PM TO PM DATE D DESCRIPTION Figure 9 8 Preventive Maintenance Due Report Copyright 2002 MATTEC 9 16 710 0092 To generate the Tool Preventive Maintenance Due Report follow these steps Press F1 View Figure 3 1 Copyright Scr
423. the number of cycles since preventive maintenance was last performed on a tool follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F2 Tool Press F1 Histry Enter the tool number Press Enter Press F4 Cycles A new display is shown which lists the 20 maintenance code numbers and the last time each one was performed Use the cursor keys to position to the proper field Enter the new date and time or the new hours run since maintenance was last performed Press Enter To save your changes Press Esc Note If you change the date and time fields or the cycles fields since the maintenance was last performed this data is not automatically changed on the maintenance activity Copyright 2002 MATTEC 9 11 710 0092 event screen You should modify the history event screen with the same entries that you made for this machine 9 5 Create Maintenance History To add or delete data from the machine maintenance history log follow these steps Press F7 MntMan Figure 3 1 Copyright Screen Press F1 Mach Press F1 Histry Enter the machine number Press Enter The computer will display the history record To add lines to the maintenance history Press F1 Add Ln To delete lines from the maintenance history Press F2 Del Ln Use the cursor keys to position to the fields to make data entries for the person performing the maintenance labor hours etc To save your changes P
424. the part to be run on Machine Class The machine class is an information field that is used to relate the class of machine required to do the job This is a 6 character alphanumeric field that is inserted once a machine number is specified Production This field defines the quantity units to use for production For Quantity Units machines specified as seconds cycle cycles hour or cycles minute valid choices are Parts or Cases For rate machines specified as meters minute valid choices are Parts Meters Cases Rolls and Parts Meters To display the standard part descriptor items once in the part descriptor Press F4 Disply A picklist will appear Highlight Standards Click OK This information includes the following fields Copyright 2002 MATTEC 4 33 710 0092 FIELD DESCRIPTION The display of a cycle time is normally 4 digits to the left of the decimal place and 1 digit to the right This supports monitoring of machines that cycle in 0 2 seconds or greater up to 3276 0 seconds or approximately 54 6 minutes Another mode of display known as Hi Res Mode is available for the system High resolution effectively shifts the decimal place to the left resulting in 3 digits to the left and 2 digits to the right of the decimal place In Hi Res mode the monitoring range is 0 02 seconds to 327 60 seconds or 11 minutes The mode of the system is configured by the System Manager and may vary for each MIU The
425. ting the job it will be displayed If not the message Press Y to create a setup sheet any other key to continue is shown To create the setup sheet Press Y es At this point you may type in any setup information in a free form unprotected text To copy another existing setup sheet to the job Press F1 Copy If you choose to copy a setup sheet the following selections are then available FUNCTION KEY DESCRIPTION F1 CpyJob Copy a job s setup sheet to the current job F2 Cpy Pt Copy a part s setup sheet to the current job F3 CpyMst Copy a master setup sheet to the current job AS appropriate Press F1 CpyJob Press F2 CpyPt Press F3 CpyMst Enter the sheet number to be copied Press Enter Setup sheets that were copied from master setup sheets defined by the System Manager may have protected cyan and unprotected white fields Setup sheets created in part descriptors or job descriptors are in the unprotected white mode Move the cursor keys to fill in the data field values for the new setup sheet for this particular job When the cursor goes white an alphanumeric character can be entered It is not necessary to press the Enter key after entering a value This is a free form format which means that the cursor keys are used to position to the field that is to be changed After one page of information has been edited to create or edit a second page Press PgDn on keyboard To highlight the p
426. tion follow these steps Press F1 View Figure 3 1 Copyright Screen Press F7 Pgraph Press F1 Sample The system will display the selection screen shown in Figure 3 51 Copyright 2002 MATTEC 3 48 710 0092 ProHelp Millennium A Figure 3 51 Parameter Graphing Selection Screen Sample Enter the desired date Press Enter Enter the appropriate job number Press Enter If you do not know the job number Press spacebar The computer will create a list of all the jobs that are enabled for parameter graphing Move to the Chart Item 1 column Press spacebar Select the first parameter to graph required Press Enter Use the upper boundary and lower boundary fields to limit the scaling of the parameter graph If no boundary is entered value of 0 the graph is scaled to the greatest and least value in the sample base Move to the Chart Item 2 column Press spacebar Select the second parameter to graph optional Press Enter Use the upper boundary and lower boundary fields to limit the scaling of the parameter graph If no boundary is entered value of 0 the graph is scaled to the greatest and least value in the sample base Press F1 Done The chart will be generated Copyright 2002 MATTEC 3 49 710 0092 The name and graph of the first signal requested are always shown in blue If a second signal has been graphed its name and graph will be displayed in red The first graph that
427. tion or remove a real time screen definition to allow room for the current one to be stored Maximum displays already defined Cannot save as named cause An attempt was made to add another display after the maximum number of displays were already defined remedy Either abort the operation or remove a display to allow room for the current one to be stored Maximum number of class defined Cannot add anymore cause An attempt was made to add another class after the maximum number of different classes were already defined remedy Either abort the operation or remove a class to allow room for the current one to be stored Maximum number of departments already defined Cannot Add cause An attempt was made to add another department after the maximum number of departments were already defined Copyright 2002 MATTEC 15 27 710 0092 remedy Either abort the operation or remove a department to allow room for the current one to be stored No active machines cause No machines are defined active remedy Contact MATTEC for assistance No attribute data found cause An attempt to obtain attribute data was performed but failed because there was no attribute data found remedy Check the request entered or abort the operation No data available for requested date cause A date was entered for which no data is currently on the hard disk remedy Verify the entered date No data available for requested job cause A job numbe
428. tion was attempted that required department names to be defined remedy Have the System Manager define departments No display format has been defined cause An attempt was made to save a real time display format to disk although no format had been defined remedy Define a format or abort the operation No Job Descriptors on diskette cause An attempt was made to view archived job descriptors and none were found on the floppy diskette currently in the drive remedy Replace the diskette with the proper one No job on machine Copyright 2002 MATTEC 15 29 710 0092 cause A machine number was specified for the purpose of accessing the job assigned to the machine with no job assigned remedy Verify and enter the correct machine number or access the job via the job number No job schedule found for machine xxxxxx cause A job schedule doesn t exist for this machine remedy Create a job schedule for this machine No machine defined cause An attempt was made to access machine information while no machines had been properly set up remedy Contact MATTEC for assistance No maintenance schedule found for Machine xxxxxx cause A maintenance schedule doesn t exist for this machine remedy Create a maintenance schedule for this machine No maintenance schedule found for machines in Dept xxxxxx cause None of the machines in this department have a maintenance schedule remedy Create a maintenance schedule for all of the
429. tional data that can t be displayed due to a lack of space Click on the drag bar at the bottom of the graph e To print the graph Click on the File Menu and select Print Select the appropriate printer to use and Click OK e To modify the amount of points or zoom in on the graph Click on the Graph Menu and select Control e To modify what type of chart is displayed i e line bar stacked bar or scatter chart or to change the axis orientation of the chart Click on the Graph Menu and select Options e To modify the font size that is used for the graph Click on the Graph Menu and select Size 2 4 Rules of the Keyboard Copyright 2002 MATTEC S 710 0092 This section describes general guidelines for using the keyboard guidelines concerning data entry and the various types of data fields The following are general guidelines for using the keyboard Escape Key Whenever in doubt Press the escape Esc key This always takes you back to the prior level of menu screen and saves any changes you have made If you are in process of entering a data value and have not pressed Enter the Esc key will erase the data value and bring back the previous value After entering data Pressing Esc causes your changes to be saved Passwords All modes of operation are protected by passwords set by the System Manager Each user can have their own password which allows them to enter the functions they have been given access to At th
430. to the next field to be entered Keyboard entry in this mode is also possible so data may be input in the sample by a combination of electronic gages and keyboard entry Values entered from a gage are treated in exactly the same manner as the keyboard so it is possible to enter a value in a field that is not intended for measurements 5 7 3 View Edit SPC Sample Data To view the actual process parameter data automatic or manual samples variable data or attribute data for a job follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F1 View Enter the date to view Copyright 2002 MATTEC 5 28 710 0092 Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To select the data type to view Press spacebar Move the cursor to the desired choice Press Enter The available choices include none automatic parameter data manual parameter data variable data or attribute data Press F1 Done The system will display the first sample recorded on the requested date To display any additional samples recorded on this date Press PgDn To edit the actual process parame
431. to the scrap units and uses one of the ProHelp Millennium serial ports RSU Hardware A scrap station is similar in appearance to a Level 2 MIU The machine number for which scrap is being entered is selected by the top switch The scrap reason is selected by the bottom switch The 16 character LED display shows the machine number and scrap reason being entered Complete information on the RSU hardware is available in the Hardware Installation Manual 710 0050 If all of the machines configured on the RSU are contained within a single department the scrap names assigned to that department will appear at the RSU If machines are from different departments the scrap names that appear at an RSU are the scrap names that are set system wide Setting scrap names is explained in Section 7 14 3 Two items must be configured in ProHelp Millennium for the RSU option to operate correctly e The communication port for the scrap units must be identified and the communications baud rate must be set correctly e Machine names that will be accessed by an RSU must be placed into that RSU s definition file To configure the RSU follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Copyright 2002 MATTEC 7 3 710 0092 Press F3 RSU This key only appears on system with the RSU option The following options are then available FUNCTION KEY DESCRIPTION 1 Add Select the RSU number you wish to configur
432. top of an existing real time screen definition remedy Delete some of the choices from the real time screen Copyright 2002 MATTEC 15 11 710 0092 Error Invalid desired end date cause An invalid desired end date value was entered remedy Enter a valid end date Error Invalid desired end time cause An invalid desired end time value was entered remedy Enter a valid end time Error Invalid field cause An attempt was made to use a field number that did not exist remedy Enter a valid field number Error Invalid Item number must be between 2 122 inclusive cause The item number entered does not fall within the 2 122 range remedy Select the item number and reenter with a valid value Error Invalid machine number in job descriptor cause The job descriptor machine number does not exist remedy Enter a valid machine number Error Invalid PLC Address must be between 0 63 inclusive cause An attempt was made to select a PLC address not within the 0 63 range remedy Adjust the address value to be within the 0 63 range Error Mach Parm low ctrl limit above high ctr limit cause While setting upper and lower control limits an error occurred where the lower control limit is greater than the upper control limit remedy Adjust the control limits so that the lower limit is less than the upper limit Copyright 2002 MATTEC 15 12 710 0092 Error Machine parameter number of decimal places are
433. tor functions of the MIU 10X Missing is the discrete interface capability In normal configuration the MIU 0 XS is used to interface 4 machines in a cell concept All four machines can be monitored simultaneously Selection of the operator interface for each of the machines is done via the main display Four digital input contacts only are provided in order to interface the cycle time contact from each of the machines While the only processing monitoring capability available in the MIU 0 XS is cycle time SPC variable and attribute data entry for all four machines is supported MIU 5 XS The MIU 5 XS includes all operator interface functions of the MIU 10X Missing is the discrete interface capability In normal configuration the MIU 5 XS includes 2 digital input contacts and 1 digital output contact All communication ports are supported Typically the MIU 5 XS is purchased with PLC interface software to provide process monitoring A list of supported PLCs is available in Manual 710 0078 All process parameter monitoring capability is supported in the MIU 5 XS including variable and attribute data entry Copyright 2002 MATTEC 1 16 710 0092 MIU 10X The MIU 10X is a high performance process monitoring Machine Interface Unit It includes a 16 x 40 LCD display for operator interface In its standard configuration it includes 6 true analog input channels for monitoring temperatures pressures and other transducer inputs 8 digital inputs
434. tor the lot size to allow for anticipated scrap The value entered here must be 0 99 for Lo Res systems or 0 0 to 99 9 for Hi Res systems Entering a non zero value modifies the to go values as well TOT PTS RUN HRS and MATL LB are all updated to reflect the additional manufacturing needed to compensate for the anticipated scrap 8 Hour Yield The shift yield is calculated by the system and shows how many parts should be made per shift The number of hours for the yield period is defined by the System Manager Refer to Section 7 3 for additional information 8HRSxCAVSTAND x 1 00 SCRAP CYCLE TIME STAND The values calculated here are also used to generate the yield efficiency values Copyright 2002 MATTEC 4 34 710 0092 FIELD DESCRIPTION Utilization The number entered here is a value used to determine the maximum amount of actual run time that may be expected from this particular job This value is applied to the forecast end date that the system calculates for the actual run time of the job and affects only the forecast end date displayed in the scheduler and on schedule summaries A value of 100 or 0 will disable this function Part Qual Enab Displays whether or not part qualification has been enabled for this part Reference Section 5 9 for additional information Profile Enable Set to Y es to allow use of the optional profile graph storage for this job Non Production Limit The non production limit is the num
435. tor will be displayed in a new window At this point a downtime or scrap Pareto chart can be graphed by pressing a function key Press F1 for current scrap F2 for current downtime F3 for job scrap and F4 for job downtime Press Esc to close this window Help ID Number Click on the help JD number for any machine requesting help and a message will be displayed indicating the type of help that has been requested The message will be cleared in a few seconds or Press Esc to clear the message immediately Machine Number or Job Number Click on any machine or job number and the following menu of available choices will be displayed Copyright 2002 MATTEC 2 5 710 0092 Standards Machine Parameters Scrap Down Time Last 50 Cycles SOC Parameters SOC Variables SQC Attributes SPC ProStat Materials List Machine Schedule Gantt Scheduler Click on the Standards item and the job descriptor standards page will be shown in a new window When you are finished viewing the standards Press Esc to close this window You may select any of the other choices in a similar manner Machine Parameters Click on any of the machine parameters ABCD12345678 and a new window with the last 100 process samples chart for that machine parameter will be displayed Click on the File Menu and select Close to close this window Tool Number Click on the tool number and the first page of the job descriptor will be displayed in a new wi
436. tribute Pareto Chart Pareto charts may be generated for U type attribute data To generate an attribute Pareto chart follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F7 Pareto OR Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F6 Pareto Enter the start and end dates Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist To generate the chart for a part number multiple job runs with the same part number Press F1 Done The system will display the U attribute Pareto chart Copyright 2002 MATTEC 5 45 710 0092 ProHelp Millennium File Graph Figure 5 16 U Attribute Pareto Chart To print the Pareto chart Click File Select Print To exit the Pareto chart Click File Select Close 5 8 7 Linear Regression Analysis ProStat linear regression analysis provides the user with a common set of fundamental tools which can be used to investigate relationships between any two characteristics for which SPC SQC data has been collected With this tool a user may compare data sets from different types of ProStat samples e g autom
437. ts and profile graphs are not copied with this copy job function This function is useful for copying the SPC limits from a job to the part descriptor for permanent storage Modify the part descriptor as required To save your changes Press Esc 4 3 5 Delete a Part Descriptor Part descriptors remain active in the system until they are individually deleted Purging the system does not eliminate these part descriptor files To delete a part descriptor follow these steps Copyright 2002 MATTEC 4 37 710 0092 Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F1 Part Enter the part number to delete Press Enter Press F3 Delete To delete the part descriptor Press Y es The part descriptor its setup sheet and its QC sheet will be removed permanently from the system 4 3 6 Setup Sheets Setup Sheets It is possible to create a setup sheet in the part descriptor that can be copied whenever creating new jobs by copying the part To create a setup sheet for a part descriptor follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F5 PtDesc Press F1 Part Enter the part number Press Enter Press F4 Disply A picklist will appear Highlight Machine Tool QC Documents Click OK You will be prompted Press Y to create setup sheet any other key to continue N Type Y es to copy the job s standards to the existing part descriptor The
438. ts for the selected reason Press Enter Repeat this process as many times as required The additional scrap parts are added to the specified category The good parts total is decreased by the amount entered the yield value is changed and the job history is updated Copyright 2002 MATTEC 5 2 710 0092 Negative numbers can be entered A negative number has the effect of reducing the scrap category and increasing good parts You may only scrap up to the number of total parts produced An entry of scrap parts greater than parts made is ignored 5 2 Full Family Production Qualification When a family job is running an operator can indicate that MIU scrap entry applies to the entire family and not just an individual component Entered numbers are not treated as part counts but as cycle counts For example if a family mold contains two cavities for Part A and three cavities for Part B a family scrap entry of 10 would equate to 20 Part As and 30 Part Bs This is available with 10X MIUs 5XS Mis TS MIUs and the PC MIU This same sort of operation can be accomplished at computer consoles within the QC Entry function A Scrap key is added to the menu for Family Jobs and values can be entered for any scrap reason Similarly a Good key exists if Hold Parts are enabled Entered numbers are treated as cycle counts just as at the MIU There is no display of part counts on the Family Job QC Entry screen To access the QC Entry screen Press
439. tup material value is divided according to the ratio of the individual input materials to the total input material and standard regrind percentage and added to the production material requirements If a job is running the setup material does not affect the forecast The dark blue area of the screen the lower left hand corner will display real time material used values for each of the four input materials The MATL LB and MATL HR fields display the total virgin input material that is being used For son jobs the type code units of measure and regrind fields are copied from the father job descriptor and are not modifiable Copyright 2002 MATTEC 4 19 710 0092 To add to the amount of setup material used for a job follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight Materials List Click OK Press F7 SUMatl Enter the amount of setup material that has been used The amount entered includes regrind is divided according to the ratio of individual input materials to the total input material and regrind percentage and is added to any setup material that has already been entered Enter a negative quantity to subtract from the amount of setup material that has been used The standard setup material weight adds to the f
440. ul consideration should be used when determining their location Standby Drive This designates where the standby data is stored Standby data are work files where the need for modification is no longer necessary These files are retained on the system for the purpose of generating reports or viewing data It is not possible to edit standby files The purpose of the Active and Standby files is to reduce the amount of time required to access data By keeping a limited amount of files on the active drive the computer can retrieve data quicker When data is requested the computer first searches the active drive If no data is found the computer then searches the standby drive Active and standby files may be stored on any available hard disk on the network Flexibility is given to the user in specifying a location for the particular type of data Copyright 2002 MATTEC 7 73 710 0092 For example the user may wish to locate the SPC files on the hard drive of the quality control node Since the SPC files are being processed locally at the quality control node there will be less impact on the performance of other computers on the network Any computer storing active files must be turned on at all times or the data will be lost To specify the location of the system data files follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F7 DtaFil Enter the location on the disk drive for each type of da
441. ule for another machine Press F6 Mach OR Press PgUp and PgDn on the keyboard PgUp and PgDn show the next machine in the order the machines are listed on the real time screen Home and End show the first and last machines respectively The following functions are available once a machine schedule has been displayed Copyright 2002 MATTEC 4 42 710 0092 UNCTION KEY DESCRIPTION F1 Add Select to insert a job into the schedule after another job F3 Delete Select to delete a job from the schedule current schedule run hours between jobs F6 Mach Select to view another machine s schedule The PgUp PgDn Home and End keys may also be used F7 MovMch Select to move a job in the current schedule to another machine father job F10 Othr20 Up to 40 jobs may be scheduled per machine however only 20 may be displayed at one time Select F10 Othr20 to see jobs 21 through 40 4 4 2 Modify a Machine Schedule To add a job to a machine the job must not be scheduled on another machine If it is it must be deleted from the other machine s schedule or moved using the move machine key Only new jobs and suspended jobs may be added to the schedule Completed jobs may not be rescheduled unless they are changed to suspended You can add jobs to machines either from the job descriptor or from the scheduler To add a job to a machine schedule from the job descriptor follow these steps Press F2 JobMan
442. uled job the next son job and part number fields are displayed as blanks on the custom real time screen Below is the Real Time Template for the standard MATTEC screen Copyright 2002 MATTEC 7 18 710 0092 ProHelp Millennium Biel x Real Time Display Design screen layout MACH JOB GO OD PR HOURS STD ACT YLD STD ACT MACHINE NUMBER NUMBER gt PR TO GO TO GO SPEED SPEED EFF CAY CAY PARAMETERS peer delete Files H Gcrid A Miconfig Figure 7 12 Real Time Screen Template for Std MATTEC Screen 7 6 1 Create Real Time Displays To create a real time screen follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F5 RITmDf OR Press F2 JobMan Figure 3 1 Copyright Screen Press F7 RITmDf The Real Time Display Design screen layout page will appear along with a new menu of selections UNCTION KEY DESCRIPTION F 1 Insert Press F1 Insert to insert a line into the display F2 Delete Press F2 Delete to delete a line from the display F3 Files Press F3 Files to load an existing display to save the current display or to delete an existing display F8 Grid Press F8 Grid to create a real time graphic layout Reference Section 7 6 6 for additional information Config Press F10 Config to configure default real time screens for all terminals Reference Section 7 7 for additional information To begin inserting data fields onto the screen Press F1 Insert Copyright 2002 M
443. up to the hard disk Backup Type You may select either a full backup or an incremental backup A full backup will copy the entire data directory to the specified directory After the initial full backup has been performed it is possible to save time by using the incremental backup function The incremental backup will only copy files that have changed since the full backup was performed It is recommended that you perform a full backup at least once per week Fill in the interactive screen as appropriate Press F1 Done The backup will be copied to the location on the hard disk that was specified After backing up ProHelp Millennium data to the hard disk it is very important to copy this data to an external device e g a tape for permanent storage Once copied to the external device the original backup on the hard disk should be deleted Reference Section 6 1 for additional information Copyright 2002 MATTEC 6 10 710 0092 6 5 2 Backup Log Report The Backup Log Report is a report that contains information regarding the status of both manual and automatic backups Reference Section 6 6 for information on scheduling the backup program to execute automatically To view the Backup Log Report follow these steps Press F5 FilMan Figure 3 1 Copyright Screen Press F3 Backup Press F2 BkpLog Press F1 VuLog Fill in the interactive screen as appropriate Press F1 Done An entry is made in the log for any event
444. ush button in the Tool Bar area will perform a function already identified in the menu bar No new functionality will be provided by the Tool Bar buttons they will only duplicate functionality provided in the menu bar Push buttons will be provided for the following functions Copyright 2002 MATTEC 12 22 710 0092 Undo Refresh Commit Preferences View Job Description Modify Job Description New Job Description available with Release 2 50 and greater only Toggle Display of the Machine Schedule Area Toggle Display of the Unscheduled Jobs Area Exit Prohelp Millennium ProSched File Edit View Figure 12 27 Tool Bar You will find a description of each button in Section 12 2 2 lof this manual 12 2 2 3 Gantt Area The Gantt Area will consist of scrolling chart area left header top header In the chart area bars will be drawn to represent each scheduled job The chart display will look similar to the chart display of the current ProHelp Gantt chart Outside of the chart area and just to its left will be a left header area In the left header the name of each machine will be displayed and aligned with the graphical view of that machine s schedule in the chart area As the chart area is scrolled vertically the left header will stay synchronized to the chart area As the chart area is scrolled horizontally no change will occur in the left header Just above the chart area will be a top header area In this area
445. utomatic scrap purposes Automatic scrap is considered active whenever the down reason identified by the two Switch parameters is selected and any production is automatically counted as scrap for the reason identified by the two Reason parameters Auto Scrap Reason PRI is a number from 1 through 20 and Auto Scrap Switch AUX is a number between from 1 through 10 Note that although down reason settings are used to enable automatic scrap the feature has nothing to do with the machine being down In fact if the machine is down there is no production and therefore no scrap Part Qual Scrap Primary scrap reason applied to part qualification PRI Part Qual Scrap Auxiliary scrap reason applied to part qualification Aux Table 7 2 Miscellaneous Installation Parameters Department 7 12 MIU AIU Installation Parameters To access the MIU AIU Installation Parameters screen follow these steps Press F4 SysMan Figure 3 1 Copyright Screen Press F8 Instal Press F2 MIU The system will display the MIU Installation screen along with a new menu of selections The dark blue area at the top of the display shows items which apply to the entire MIU Any changes made to this area requires a system wide reboot In general when making changes to the MIU AIU configuration it is always a good idea to reboot the system Copyright 2002 MATTEC 7 47 710 0092 The lower portion shows items which apply to a physical group of pro
446. uts extra inputs and process parameter monitoring are not possible on the Level 0 The front panel on this box is almost identical to the Level 2 with a re designation of the functions and an appropriate label overlay MIU 1 The Level 1 MIU has a different face plate than the Level 0 or 2 It has a Machine Status and a Call for Help Switch but has no Keypad or message readout window With the Machine Status Knob you can allocate downtime to a specific reason MIU 2 The Level 2 MIU allows for operator entry of scrap parts and operator login capabilities A keypad and a 16 character alphanumeric data display are included with the Level 2 MIU All functions of the Level 1 MIU can be performed by a Level 2 MIU MIU 3 The Level 3 MIU has all of the capabilities of a Level 2 MIU but has an additional top hat shell in which are mounted the analog circuit board for monitoring temperatures and pressures additional digital input circuits an RS 232 serial board for gage inputs and direct communications with machine controllers and optional warning light interface circuit boards MIU 0 NP 2 NP and 3 NP The suffix after these MIU model numbers stands for New Package The NP is a newer design and replaces the older model MIUs These MIUs have the same functional capabilities as the older style 0 2 and 3 however the interior board and package have been redesigned The physical package of the MIU is gray with a hinged front cover
447. uts to provide cycle partitioning information Signal 1 Back pressure end or cycle start Signal 2 Signal 3 Signal 4 Measurement of digital signals 3 and 4 requires optional digital inputs At the time of automatic sampling the process parameter data is collected by the MIU time stamped and sent to the Host computer asynchronous with other MIU activities The time stamp is used to identify the data during subsequent operations The time stamp consists of the date and time when that sample began Once the data for a sample has been received by the Host computer it may be processed at the Host using ProStat 5 6 3 ProEna Automatic and Manual Enable For automatic and manual sampling each individual process parameter may be enabled for sampling alarm conditions SPC samples and machine parameters and part qualification To enable individual process parameters for automatic or manual sampling alarm conditions and part qualification follow these steps Press F2 JobMan Figure 3 1 Copyright Screen Press F2 JbDesc Press F1 Job enter the job number OR Press F2 Mach enter the machine number of a running job Press F3 Disply A picklist will appear Highlight SPC Settings Click OK Press F7 ProEna Copyright 2002 MATTEC 5 17 710 0092 SPC PROCESS ENABLE Figure 5 5 SPC Process Enable Copyright 2002 MATTEC 5 18 710 0092 The following fields are then available for
448. vailable at the host by clicking on a process parameter field of the Real Time Display Copyright 2002 MATTEC 7 56 710 0092 Primary Process Parameters Any 20 from the total of 96 are eligible as primaries For each machine 20 are selected at system configuration time A different set of 20 may be selected for each machine and the 20 selected for a particular machine can be altered Naturally any reconfiguration of a machine or its parameters should be done with care This is especially true if any sense is to be made of data collected both before and after a change In addition to the capabilities described for auxiliary parameters primary parameters possess the following capabilities FIELD DESCRIPTION Process Parameter This is the ProHelp Systems traditional Parameter recording reporting Graph and Parameter report and charting SPC recording All normal SPC functions are present including reporting and e Control Limits calculation and checking charting SPC Trending SPC Composite Chart Xbar R Chart Histogram X MR Chart 7 12 3 Create Delete an MIU AIU Each monitoring node on the ProHelp Millennium network can monitor a maximum of 64 machines This requires one 4 channel RocketPort board with 16 machines per channel Anytime an MIU is added or deleted you must reboot all nodes on the system for the change to take effect To create an MIU follow these steps Press F4 SysMan Figure 3 1 Copyright S
449. w set to Y es goes below the specification limit CNTRL set to Y es and Hi set to Y es goes above the SPC control limit CNTRL set to Y es and Low set to Y es goes below the SPC control limit Copyright 2002 MATTEC 5 58 710 0092 The system will count parts as scrap in scrap reason 10 every time the MIU contact is closed If Part Qualification is set to N o in the job descriptor the MIU output contact will close during the next cycle if in the current cycle any signal with Hi set to Y es goes above the specification limit or if any signal with Low set to Y es goes below the specification limit in the job descriptor The system will NOT count parts as scrap when the MIU contact is closed 5 9 4 Release 1 3 Part Qualification In ProHelp 1000 Release 1 3 and earlier part qualification is based on the settings in the MIU setup screen and on the Part Qualification switch in the job descriptor The MIU setup variable Alarm Output Lo High can be selected for use with each machine signal for part qualification Utilizing Release 1 3 part qualification rules the system functions as follows If Part Qualification is set to Y es and SPC is disabled the MIU output contact will close during the next cycle if in the current cycle any signal with Hi set to Y es goes above the specification limit or any signal with Low set to Y es goes below the specification limit The system will count parts as scrap in scrap reaso
450. wever two examples are as follows Copyright 2002 MATTEC 77 710 0092 ProHelp Millennium Iof x Figure 7 5 Shift Configuration The schedule in Figure 7 5 Shift Configuration defines three 8 hour shifts per day with Saturday and Sunday inactive N o in the Act field The weekly shift progresses through each tag number until it reaches the last one At this point it returns to tag 1 and repeats itself indefinitely By specifying a start point of 2 16 92 at 00 00 hours we are telling the system to start the first tag which we have defined as shift 3 to start at midnight Note screens are for example purposes only YA 00 00 Y A 00 00 Y A 00 00 Y A 00 00 YA 00 YB 12 00 B 12 00 VB 12 00 B 12 00 Y B 12 Figure 7 6 Shift Configuration The schedule in Figure 7 6 Shift Configuration defines two 12 hour shifts per day 7 days per week However we have designed a swing shift that alternates back and forth from week to week We have defined shifts A B C and D Shifts A and B work 4 days on Copyright 2002 MATTEC 7 8 710 0092 one week and 3 days on the next week rotating with shifts C and D This pattern repeats itself every other week Tag s 1 through 28 represent a two week period 2 shifts day 7 days week 2 weeks 28 By specifying the shift date as start of shift we are indicating that shift B and D will be saved according to the day those shifts started Note screens are for example purposes only To
451. will appear Then the message Preprocessing data for regression analysis point MM is displayed while matching sample points are collected A second message Regression analysis in progress is displayed immediately before the chart is displayed To print the chart Click File Select Print To exit the chart Click File Select Close ProHelp Millennium File Graph Figure 5 17 Linear Regression Analysis The calculated values displayed use standard formulas The Pearson product moment correlation coefficient formula is Copyright 2002 MATTEC 5 48 710 0092 The correlation significance formula is t 4n 5 8 8 P U Charts The P U chart function allows the user to display a P U chart of attribute data at a computer terminal To generate a P U chart follow these steps Press F1 View Figure 3 1 Copyright Screen Press F5 ProStat Press F9 P U OR Press F3 QC Man Figure 3 1 Copyright Screen Press F5 ProStat Press F8 P U Enter the start and end dates Press Enter Enter the job number from the SQC directory If you do not know the job number Press spacebar The available job numbers for that particular date are shown Move the cursor to the desired job Press Enter The selection is now made This selection only consists of jobs in the active directory standby files will not be displayed in the picklist Press F1 Done The selected chart s will be displayed Scali
452. within a department 7 14 6 Network Setup To setup the server node configuration Press F4 Sysman Figure 3 1 Copyright Screen Press F8 Install Press F9 Network This will display the Server Node Configuration setup screen prohelp Add Belete Eserver es a E Figure 7 32 Server Node Configuration Screen Copyright 2002 MATTEC 7 69 710 0092 The choices are as follows F1 Add Server number to add 1 64 F2 Delete Will delete the current server F3 Server Will take you to the server setup that you request To add a server Press F1 Add Enter in the name of the server Select the type by pressing the spacebar and selecting one of the following e None e Monitoring Node 64 e PCMIU Cell Control Type in the Physical Channel Typical choices are as follows dev term r0a dev term r0b dev term r0c dev term r0d For each Physical Channel select the type the choices are e None MIU Machine Interface Unit Simulated RSU Remote Scrap Unit DIU Display Interface Unit To save your changes Press Esc 7 14 6 1 Manually Monitored Machines This feature allows machines to be defined which have no MIU attached All production data for these machines is entered through Manual Entry of Production Section 3 10 or Data Import refer to ProHelp Millennium Data Exchange Manual 710 0085 This feature gives the user the ability to select Manual as a node type Manual M
453. ws the Job Manager or QC Manager to manually introduce production data not collected through an MIU This function actually produces a set of Production Data Import records as described in the ProHelp Millennium Data Exchange Manual 710 0085 Data is entered via a spreadsheet style interface The first three columns of each row contain e Job Number e Date e Shift Tag The remaining columns contain various production values The default spreadsheet includes all possible scrap and downtime columns A new System Manager function allows up to ten named configurations of different column sets to be maintained Any of these configurations may be selected for use The full set of available fields is listed below in the left to right order The order may not be changed but any item beyond the first five may be omitted Job Number Shift Date Shift Tag To setup a template for a specific department before entering the Manual Production Entry Screen Press F4 Sysman Figure 3 1 Copyright Screen Press F8 Install Press F10 more Press F3 ManEnt The following screen will display Copyright 2002 MATTEC 11 1 710 0092 X ProHelp Mileniun Isi Millennium X ProHelp Mileniun Isi E A Delete Wi Figure 11 1 Manual Production Entry Template Screen In the Enable column Enter Y es or N o based on whether this information should appear in the final Manual Production Entry Screen To access the Manual Pr
454. y Report before resetting the log and file the printed copy for future references Copyright 2002 MATTEC 6 20 710 0092 7 System Manager The System Manager plays a very important function for ProHelp Millennium The System Manager must be involved at the system installation time in order to e Set the shift times and days e Set the machine numbers e Allocate machines to departments e Set the scrap part names e Set the downtime reason names e Set the help call names e Set the process parameter names e Define users rights and passwords e Configure all system terminals e Create master setup sheets e Set preventative maintenance codes e Create real time screens e Set MIU and Miscellaneous installation parameters e Enter help and downtime voice synthesizer messages Many of the functions the System Manager performs are ongoing If new machines are added to the plant the System Manager tells ProHelp Millennium User passwords need to be changed periodically Shift times and workdays may change In many companies it is very practical for the System Manager and the File Manager to be the same person Both responsibilities require an organized reliable and knowledgeable person to perform them For additional information on advanced System Manager commands reference the ProHelp Millennium Software Installation Manual 710 0067 7 1 Define ProHelp Millennium Users The System Manager can define users of the ProH
455. ys to select the language to copy Press Enter If the language to copy is not on your system a Language not available error message will appear If the language is available the entire translation will be copied into the User Defined file After it is copied it may be modified or edited and all changes will be Copyright 2002 MATTEC 7 64 710 0092 saved to the User Defined language This translation is now available for display on any terminal on the ProHelp Millennium system 7 13 3 Switching Terminal Language For ease of operation a top level function is available for quickly switching the language that a terminal displays With this facility a user may walk up to any terminal and easily change the display to the language of their choice provided that the desired language has already been defined To change the language of any terminal follow these steps Press F10 Lang Figure 3 1 Copyright Screen A picklist of available languages will appear Use the arrow keys to select the language you wish to use Press Enter To save your changes Press Esc When the copyright screen is again displayed it will be in the new language the user has selected NOTE Language configuration is selected on a per terminal basis so selecting a different language for this terminal in no way affects other terminals on the system 7 14 Set System Names ProHelp Millennium has the ability to set unique machine signal nam

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