Production Monitoring System with SD Memory Storage User Manual
Contents
1. Run pause production Stop the Production Timer Stop counter Mode Toggle display modes Select various setup choices Select Cycle knob function Display the directory entries on the SD Memory card Table 2 DD 117AB button reference www alzatex com Production Monitoring System with SD Memory Storage Remote Inputs Remote inputs on the RJ 11 connector on the side of the unit Remote Operation Effect on Effect on Effect on Actual Input TAKT Down Count Timer Timer Input 1 Run runs auses None Input 2 Pause auses runs None Input 3 Stop auses auses None Input4 Increment None None Counts by the scale Next factor Table 3 Remote input function reference Alzatex 1 ww cl com The remote inputs are ground closure type The Run Pause and Stop inputs are typically connected to operator buttons The Increment Next button may be a button for the operator or may be connected directly to a machine trigger Serial data I O RS 422 Serial data input for input from additional devices of input from a PLC or computer RS 422 Serial data output for operating displays andon indicators alarms PLC or computer Monitoring Production Statistics The Production Timekeeper can display the current production Data which is available on three screens Momentarily pressing the Mode button toggles between the screens The screen in step one is normally displayed during production m2. following display will appear HH MM SS 00 00 00 Pause HH MM SS Goal nnnnnn The Goal Actual Yellow Blink Yellow Warning and Red Warning counters are set to zero The Actual time and Down time is reset to zero The TAKT time is set to the preset value 6 est E OCActual J Deviation User manual 5 TAK TAKT time in seconds T 6 Time Actual Time since the most recent wigit was started This value is in seconds 7 Red Red warning indicator count This indicator occurs after the TAKT time has expired 8 Yel Yellow warning indicator count This indicator occurs during the TAKT time prior to the red warning indicator When this occurs is user programmable 9 Blink Yellow blink indicator count This indicator occurs during the TAKT time prior to the red warning indicator When this occurs is user programmable 10 Gpre Current static shift goal 11 Scal Current scale factor The following events are recorded whenever one of the remote inputs Run Pause Stop or Next is activated The recording of these events can be individually enabled or disabled using the Setup Event Save menu Event Description ER 12 Run The RUN mode was started The value j l 4 z f f C ency field will be the downtime in seconds 13 Paus The RUN mode was paused The value field will be the actual time in seconds Table
3. NOTE Because all files are stored in the root directory of the SD card only about 500 files can be stored this is an SD card limitation when used formatted for use with MS Windows Alzatex Inc 11 www alzatex com Production Monitoring System with SD Memory Storage Remote Inputs To connect remote inputs to the Production Timekeeper 1 Connect an RJ 11 wall plate jack to the Production Timekeeper remote input jack using either a six conductor modular crossover or a six conductor modular standard telephone cord 2 Connect a momentary or push button switch or switches between the desired remote input and ground using the diagram see installation instructions as a guide The remote inputs are used as follows IN 1 Put the timer into RUN mode This is the same as pressing the RUN PAUSE STOP button e IN 2 Put the timer into PAUSE mode This is the same as pressing the RUN PAUSE STOP button e IN 3 Put the timer into STOPPED mode This is the same as pressing and holding the RUN PAUSE STOP button e IN 4 Increment the Actual Count It also resets the actual count timer This is labeled the Next button on the remote button module Note As the diagram in the installation instructions portrays the individual colored wires on the RJ 11 wall plate jack will function differently depending which six conductor modular telephone cord is chosen Remote Serial Input Remote serial devices may be connecte
4. Turn knob to set goal in steps of 10000 Momentarily press the Mode button The following display will appear Setup Yel Warning 0 00 04 Instructions Sets when the solid yellow occurs during TAKT time Turn knob to set seconds Momentarily press the Select button Turn knob to set minutes Momentarily press the Select button Turn knob to set hours Pi R The yellow warning solid yellow occurs the set time before the TAKT time expires This is measured from the start of the Actual timer which is reset each time the Actual count is incremented For example If the TAKT time is set to 14 seconds and the yellow warning time is set to 4 seconds the solid yellow warning will occur 4 seconds before the TAKT time expires which is 14 4 or 10 seconds into the Actual time Alzatex Inc 8 User manual Momentarily press the Mode button The following display will appear Setup Yellow Blink 0 00 07 Instructions Sets when the blinking yellow occurs during TAKT time 1 Turn knob to set seconds 2 Momentarily press the Select button 3 Turn knob to set minutes 4 Momentarily press the Select button 5 Turn knob to set hours The Blinking Yellow warning occurs the set time before the TAKT time expires This is measured from the start of the Actual timer which is reset each time the Actual count is incremented For example If the TAKT time is set to 14 seconds and the Yellow Blink time is set to 8 seconds the B
5. counts called Yellow Blink Blnk Yellow Warning Yel and Red Warning Red www alzatex com Production Monitoring System with SD Memory Storage These warnings can be used to indicate whether the actual time is longer or shorter than the TAKT time and determine whether there is a problem with production or whether a particular operator is slower or faster or whether the TAKT time is too long or too short Ideally the TAKT time should be set such that the yellow blink count and the yellow warning count increments the same as the actual count but that the Red warning count always remains at zero The production workers can observe the Green Yellow Red Andon indicators to determine whether they are ahead or behind the expected TAKT time These indicators are great for Slide Lines where several production workers need to synchronize together The Yellow Blink Blnk warning indicates the number of times the Yellow Blink time was reached before the TAKT time expired to complete a production unit If the TAKT time is 100 seconds and the Yellow Blink time is 20 seconds then this count will be incremented if it takes 80 or more seconds to complete a production unit The Yellow Yel warning indicates the number of times the Yellow Warning time was reached before the TAKT time expired to complete a production unit If the TAKT time is 100 seconds and the Yellow Warning time is 10 seconds then this count will be incremented if it
6. takes 90 or more seconds to complete a production unit The Red Red warning indicates the number of times it took longer than the TAKT time to complete a production unit The status field indicates the operational mode of the unit Pause Stopped RunGm Run Yel Run Red One of several error messages may appear on the lower right Alzatex Inc 3 User manual corner of the display SetClock Indicating that the time of day clock needs to be set ClkError Indicating that there is a problem with the TIME of day clock LowBatt Indicating that the battery needs to be replaced The battery can be replaced by removing the rear cover and replacing the battery with a new CR2032 coin cell type battery Goal bad P d P a a G a _ fan es se cooP TYTY a LIT a tottAicce Actua b al ere a Necee Gosso Efficiency Pargo grees eee Ga ka a gt 4 o a gt D e a a Storing and Resetting Production Data The Production Timekeeper will save production data each time the Production Timekeeper is reset The events 0 to 11 shown in table are saved and then the counters are reset to zero and the timers are set to their preset values 1 Press and Hold the History button The following display will appear Save to History and Clear Counters www alzatex com Production Monitoring System with SD Memory Storage 2 Press and Hold the History button again The
7. will appear 2007 01 12 Goal Act Dev 14 03 45 History 12 156 nnnnnn nnnnnn Of nnnnnn Note The first line is the date and time The remaining lines are 3 lines of historical data Turn the knob to scroll through the production history As you scroll the window will show 4 entries in sequence It helps to think of the 4 line display as a sliding window over the history memory that rolls over to the beginning when it gets to the end LOC Display Value Desc 00 Save 76 0l Down 4398 02 TAKT 122 03 2007 10 22 08 22 54 line 1 04 Act 9 03 line 2 05 line 3 Grn 18 mE 06 Act 24 line 4 07 Goal 44 08 Time 4567 09 Down 4422 10 TAKT 288 31 Alzatex Inc 6 User manual Selecting the Static Shift or Running Goal Modes The Production Timekeeper provides two different methods for management of Goal values e Jn the running goal mode the Production Timekeeper calculates the running goal It does this by adding the scale count to the goal count each time the takt time expires e In the static shift goal mode the user enters the desired goal count as a preset value In this mode that value does not change until the user reconfigures it In either mode the DD 117A will display the goal count the actual count the calculated deviation between the goal and actual counts and the calculated efficiency the percentage of actual production versus the production goal The reader board display
8. 1 Production data reference 1 a ea PAR mee stop ped The valie field will be the actual time in seconds 15 Wigi A new unit is completed The value field Stored Data will be the actual time in seconds to The following data can be stored The time and date is saved complete this wigit along with each history entry The following events and or data are stored whenever the pier Evens Save to History and Clear Counters command is Event Description executed 16 Save The history memory was saved to the SD Event Description card The value field contains the number 0 Goal Production goal count This can be either a at enice sire running or static goal 17 Clr The history memory was cleared The 1 Act Actual production count This can be valne Held Vong Ahe munner en the history memory at the time it was incremented manually or by machine cleared 2 DOG Deviation enunt Ao dal eee 18 Key A remote KPn command was received 3 Eff Efficiency percent Goal Deviation 100 The n is the value portion of the event 4 Down Accumulated Machine Down Time in 19 Reserved for future use seconds Alzatex Inc 4 www alzatex com Production Monitoring System with SD Memory Storage The following events and or data are stored whenever the Save to History and Clear Counters command is executed The following values are recorded when storing the actual counter values for production lines through production line 10 These actual count
9. Production Monitoring System with SD Memory Storage Production Monitoring With SD Memory Card Storage The Production TimeKeeper TM TAKT timer with production counter and production statistic history storage that will monitor up to 10 production lines simultaneously This reference guide covers the DD 117A0 PROD1 production monitoring system Programmable TAKT Timer and Scale Count Traditionally TAKT time is the time it takes to fabricate and ship one product and is established by dividing the number of orders in hand by the number of working hours in a day In addition to the programmable TAKT timer the Production TimeKeeper M also contains a user settable scale counter which allows the user to set the TAKT time to the time it takes to fabricate product lots Processing lots TAKT times of less than one second do not work well with this system When it takes less than one second to process one production unit it is advisable to setup the system to process in lots In this case set the scale factor to a standard lot size and set the TAKT time to the correct time to process one lot Running or Static Shift Goals The Production TimeKeeper M allows production monitoring using running or static shift goals The running goal is calculated from the TAKT time and scale count while the static or shift goal is easily entered by the user Alzatex Inc 1 User manual Monitor and Save Production Data The Production TimeK
10. Turn the knob until the desired value 0 to 15 appears 00 Running or static goal 01 Actual Count 02 Deviation Goal Actual 03 Efficiency Percent Goal Deviation 100 04 Machine Down Time 05 TAKT Time 06 Actual Time 07 Red Warning Count 08 Yellow Warning Count 09 Yellow Blink Count 10 15 Spares for additional results The second entry is the display address You can use any address here so long as it matches the address that is configured into the display See the display documentation for configuring display addresses The Addresses are in ASCII characters starting at 0 and going up to and including O Output is OFF Digits include 0 9 Characters include A O Special characters include lt gt www alzatex com Production Monitoring System with SD Memory Storage User manual Note For example the DSP1016A display default addresses are A D for lines 1 4 respectively Goal The third entry is the number of digits displayed Actual Deviation Efficiency 0 6 digit display When displaying time values hours minutes and seconds will be displayed 1 4 digit display right justified When displaying time values minutes and seconds will be displayed 2 4 digit display left justified When displaying time values hours and minutes will be displayed Momentarily press the Mode button The following display will appear Setup File Name HISTAOOO TXT The file for
11. arts running www alzatex com Production Monitoring System with SD Memory Storage When the unit is resumed the downtime timer is paused and the TAKT and actual timers are resumed 6 For scheduled breaks or shift changes Stop the TAKT and actual timers without starting the downtime timer pressing the press and holding the Run Stop button or press the remote Stop button remote input IN3 User Programmable Presets The Production Timekeeper can save and recall 8 user programmable setups Each stored setup is labeled from 0 to 7 and contains the following items 1 TAKT time 2 Goal value 3 Scale factor 4 Yellow blink time 5 Yellow warning time 6 Beeper mode To store a setup 1 Press and hold the Recall Setting button The following display will appear Setup Store 3 2 Turn the knob to select the desired 0 to 7 location 3 Press and hold the Recall Setting button again to store the current Production Timekeeper setup into the selected storage location To recall a setup 1 Momentarily press the Recall Setting button The following display will appear Setup Recall 3 Alzatex Inc 7 User manual 2 Turn the knob to select the desired 0 to 7 setup 3 Momentarily press the Recall Setting button again to recall the Production Timekeeper setup from the selected storage location Setting Up the Production Timekeeper The Production Timekeeper contains user programmable t
12. d to the serial input on the Production Timekeeper This unit has 2 choices for serial data input Only one of them may be used at a time If commands are received on both serial inputs at the same time the data will become corrupted and neither command will be processed The DB 9 connector can be used for RS 232 serial data The RJ 45 connectors can be used for RS 422 serial data This unit can be connected to an Alzatex input device PLC Computer or any device having a serial port The data OUT is always the display data The data IN may be used to generate events or to control the unit remotely Some of the options include Connect a remote button module to the RS422 input for generating special events Assign the buttons to specific meanings like paper jam lunch break change over to new product etc Connect the output of a PLC that has a serial output Alzatex Inc 12 User manual or other machine outputs to a ground closure to serial adapter to record specific machine events like door open out of material roller not turning etc The buttons on the DD 117A can be operated remotely using the following commands KPK Save to SD card File Display KPk Press and hold to Save to SD card KPH History Display KPh Press and hold to Save History and Clear Counters KPG Recall Stored Setting KPg Press and hold to Save Stored Sett
13. eeper TM monitors production and conveniently displays the results as a deviation and percentage between the production goal and the amount actually produced In addition to monitoring production the Production TimeKeeper M also tracks down time and other critical time events like the number of times the TAKT time expired All of this data is stored in a conveniently accessible history memory Recording User Events or Reason Codes Sometimes specific events occur that need to be recorded that are in addition to the standard events This system includes an external port to permit special events to be recorded For example Machine jammed out of material lunch break fire drill service door opened or any other event The events can be entered manually or directly from a machine output Buttons and Controls The DD 117A has the following buttons and controls The main unit has 6 buttons and one knob The RJ11 jack on the side of the unit connects to remote buttons or machine inputs for Run Pause Stop and Next e In addition optional remote buttons or machine inputs can be added for special events Front Panel Buttons Button Momentary Press and Press and Hold for 2 Name Release seconds Save Display SD Card File Save History Memory to Name ISD Card History Display history Store history and reset roduction counter to zero Recall Recall stored setting Save stored setting Run Pause
14. ers are incremented when one of the external KPO through KP9 commands are received 20 29 Actual count values for production line 1 20 through production line 10 29 30 Reserved for future use 255 Clearing the History memory To reset the production timers and counters 3 Press and Hold the History button The following display will appear Save to History and Clear Counters 4 Turn the Knob a number of clicks until the Clear History Memory message appears in the display 5 Press and Hold the History button again The following display will appear Clear History Memory Empty The entire history memory is cleared A single message is added Clr 341 where the number is the number of history entries that was in the history memory before it was cleared Alzatex Inc 5 User manual www alzatex com Production Monitoring System with SD Memory Storage Recalling Stored Production Data The Production Timekeeper can recall stored production data The values shown in table 1 are monitored and then stored each time the Production Timekeeper is reset Note The Production Timekeeper has a history memory of 1023 or 4095 entries depending on model This means that the Production Timekeeper can store many days of production data To recall production data 1 Momentarily press the History button A four line display similar to the following display
15. imers and counters Each programmable setting is selected using the Mode button and modified using the Select button and the knob To setup the Production Timekeeper Press and hold the Mode button The following display will appear Setup TAKT Time 0 00 14 Instructions Sets the TAKT timer 1 Turn knob to set seconds 2 Momentarily press the Select button 3 Turn knob to set minutes 4 Momentarily press the Select button 5 Turn knob to set hours Momentarily press the Mode button The following display will appear Setup Goal 0 Instructions Keep at 0 if a running goal is desired If a static goal is desired set this value to the desired goal 1 Turn knob to set goal in steps of 1 Momentarily press the Select button Turn knob to set goal in steps of 100 Momentarily press the Select button Turn knob to set goal in steps of 10000 PtP Sls www alzatex com Production Monitoring System with SD Memory Storage Momentarily press the Mode button The following display will appear Setup Scale NOTE Do not set the scale to 0 If you set the Scale to 0 the Next button will never increment the actual count Instructions The actual count increments by the scale count The running goal calculation also uses the scale count 1 Turn knob to set goal in steps of 1 2 Momentarily press the Select button 3 Turn knob to set goal in steps of 100 4 Momentarily press the Select button 5
16. ing KPL Run Pause KPI Press and hold to enter Stopped mode KPA Mode KPA Press and hold to Enter the setup mode KPB Select KPb Press and hold to display Directory Entries K Rotate knob clockwise K Rotate knob counter clockwise KPU Put the unit into RUN mode Remote input IN1 KPV Put the unit into PAUSE mode Remote input IN2 KPW Put the unit into STOPPED mode Remote input IN3 KPX Increment the Actual count and reset the actual timer Remote input IN4 KPY Decrement the Actual count There is no corresponding button on the unit for this command KPO to Increment the Actual count for a specific KP9 production line 1 KPO through 10 KP9 These commands also increment the overall actual count the same as KPX There are no corresponding buttons on the unit for these commands KPO to All other key codes in the range of ASCII 0 KPz Decimal 48 to ASCII z Decimal 122 not listed above generates an event Key xxx where the number will be the corresponding decimal value for the character that is stored in the history memory www alzatex com
17. ion is selected the Red and Green Andon indicators operate differently When the actual count is greater than the goal count the Green andon comes on When the actual count is less than the goal count the Red andon comes on Momentarily press the Mode button The following display will appear Setup Event Save Run Pause Stopped Wigit And Clear Counters Alzatex Inc 9 User manual Instructions Turn the knob until the desired selections appear Save Run event Each time the Run button remote IN1 is pressed an event is stored Save Pause event Each time the Pause button remote IN2 is pressed an event is stored Save Stopped Event Each time the Stop button remote IN3 is pressed an event is stored Save Wigit count event Each time the Next button remote IN4 is pressed an event is stored And Clear Counters is a special feature that causes the counter values to be stored to internal memory at midnight In addition all the counters to be automatically reset at midnight Momentarily press the Mode button The following display will appear Setup Remote Display 00 Addr 1 Mode 0 Various types of information can be displayed on a large display or reader board This configuration menu selects which data is transmitted on the serial port The first entry is the type of data to be displayed The value ranges from 00 to 15 as listed in the instructions below Types of Data Output
18. linking Yellow warning will occur 8 seconds before the TAKT time expires which is 14 8 or 6 seconds into the Actual time Momentarily press the Mode button The following display will appear Setup Clock 0 00 00 DD117A0 V1 00 Instructions Sets up the time of day clock Turn knob to set hours Momentarily press the Select button Turn knob to set seconds Momentarily press the Select button Turn knob to set minutes es aed NOTE If the clock is running slow or fast it can be calibrated to be within 2 5PPM in most cases Contact the factory for calibration information NOTE The product version number also appears on the bottom line of this menu www alzatex com Production Monitoring System with SD Memory Storage Momentarily press the Mode button The following display will appear Setup YYYY MM DD 2007 01 01 Instructions Sets up the date Turn knob to select the desired Day 1 Turn knob to set year 2 Momentarily press the Select button 3 Turn knob to set Month 4 Momentarily press the Select button 5 Turn knob to set Day Momentarily press the Mode button The following display will appear Setup Beep Timer Zero Instructions Sets up the beeper mode 1 Turn knob to select the desired mode The choices are Off Timer Zero On Warnings Actual lt Goal An optional external beeper must be installed for this function to produce an audible sound If the Actual lt Goal opt
19. mat is always A Z for the first 5 characters and 000 to 999 for the last three characters The numbers will auto increment each time data is stored To change an individual character in the File Name use a momentary press of the Select button to move to the character position then use the Knob to select the character value To change the file type between CSV and TXT press the Select button until cursor is under the file extension Turn the Knob to select the desired file type Instructions Turn the knob to select the desired character Press the Select button to advance to the next character Repeat until the desired file name is entered The data may be stored in one of 2 formats plain text TXT or Comma separated values CSV Alzatex Inc 10 www alzatex com Production Monitoring System with SD Memory Storage User manual Saving History to an SD Memory Card Typical data stored on the SD memory card The history memory can be stored on an SD Secure Digital HISTA023 TXT card 2007 10 10 06 29 57 Time 255 2007 10 10 06 29 49 Down 714 2007 10 10 06 28 49 Save 77 2007 10 10 06 28 42 Scal 1 2007 10 10 06 28 42 Gpre 0 2007 10 10 06 28 42 Eff 55 2007 10 10 06 28 42 Dev 17 2007 10 10 06 28 42 Act 21 2007 10 10 06 28 42 Goal 38 2007 10 10 06 28 42 Grn 6 2007 10 10 06 28 42 Yel 6 2007 10 10 06 28 42 Red 5 HISTA024 CSV 2007 10 10 06 28 27 Paus 241 2007 10 10 06 28 26 Run 539 Save to SD Ca
20. onitoring To display the current production data 1 Momentarily press the Mode button A four line display similar to the following display will appear Alzatex Inc 2 User manual HH MM SS HH MM SS Run Grn HH MM SS Goal Act nnnnnn nnnnnn Dev Eff nnnnnn nnnn Description Line 1 goal count TAKT time count down Line 2 actual count actual time count up Line 3 deviation status run pause stop Line 4 efficiency time of day 2 Momentarily press the Mode button again Another four line display similar to the following display will appear Act BInk nnnnnn nnnnnn HH MM SS Downtime Pause SetClock nnnnnn Yel Red nnnnnn Description Line 1 actual count down time count up Line 2 Yellow blink count Line 3 Yellow warning count Line 4 Red warning count TAKT time expired 3 Momentarily press the Mode button again When counting production from multiple lines simultaneously the actual count for individual lines will be recorded Another four line display similar to the following display will appear Line Actual 1 2345 2 2433 3 9432 Description Line 1 Production Line 2 Line number Actual count Line 3 Line 4 Turn knob to select The individual production line counting feature requires either additional external hardware or connection to a PLC Analyzing and Improving productivity There are three warning
21. rd File 2007 10 10 06 28 26 Paus 240 HISTAO0O 2007 10 10 06 27 49 Save 54 2007 10 10 06 27 10 Time 240 Saved Make sure that the SD card is inserted into the unit Press the Displaying files on an SD Memory Card Save button to see the name of the file to be saved to the SD card Press and hold the Save button to store the contents of The directory listing on an SD Secure Digital card the history memory on to the SD card The history file name will auto increment The name in the display after the save is completed is the name of the next file to be saved You may remove the SD card from the unit and put it into any HISTA000 CSV computer that supports FAT12 or FAT16 type files The Size message Saved will appear once the save is completed Files A single message is added to the history memory Save 227 Make sure that the SD card is inserted into the unit Press where the number is the number of history entries that was in and hold the Select button to see the name of the file on the the history memory at the time the save was executed SD card Turn the Knob to scroll through the list of files on the SD card See the example below for a sample of the saved data When done press any other button to exit this menu NOTE If the SD card is not inserted or if the card is not p 2 formatted properly an error message SD Card Error will appear on the display
22. s the goal count the actual count and the efficiency NOTE To select a running goal the preset goal count must be set to 0 Any non zero preset goal count will remain the static goal value Only a preset goal count of zero changes the goal calculation mode of the Production Timekeeper from static shift mode to running mode 1 When starting a new shift or new production run Press and hold the History button to clear the counters and reset the timers 2 Momentarily press the Run Pause Stop button on the DD 117A unit or press the remote Run button remote input IN1 to start the TAKT and actual timers The TAKT timer will auto restart when it expires 3 Increment the production actual count by pressing the Next button remote input IN4 See the following Remote Inputs section for details 4 For unscheduled production stoppages machine repairs or whenever you want downtime to accumulate pause the TAKT and actual timers by momentarily pressing the Run Pause Stop button on the DD 117A or press the remote Pause button remote input IN2 5 Resume the timers by momentarily pressing the Run Pause Stop button on the DD 117A or press the remote Run button remote input IN1 See the following Remote Inputs section for details NOTE the Run Pause Stop button is labeled as Run Stop on the unit Note Whenever the Production Timekeeper is in the pause mode the TAKT and actual timers are paused and the downtime timer st
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