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User Manual - INTEG Process Group

1. All is selected from the dropdown all of the work centers will be included in the report If there are many entries in the parameter dropdown the textbox above it may be used to filter the dropdown to show only items which contain the text in the textbox Below the parameter dropdowns is the new Run Report as Shift checkbox and the Start End Time dropdowns The shift checkbox when clicked uses the start time and end times selected as though they are a shift When a report is run as a shift time all data outside of the selected time range is removed from the report For example when the shift checkbox 1s checked selecting 8am 6 1 2008 through 5pm 6 2 2008 will show all data from 8am 6 1 2008 to 5pm 6 1 2008 and Sam 6 2 2008 to Spm 6 2 2008 All data from 5pm 6 1 2008 to 8am 6 2 2008 will be removed from the report When the shift checkbox is empty the report will show all data from the selected start time to the selected end time The Start Time and End Time selectors are below the shift checkbox The Start Time is default to 1 00 am the End Time is default to the next hour from the current hour of the PC clock Below the time selectors are the day of week checkboxes The day of week checkboxes will include days which are checked and remove days which are unchecked from the report To the right of the Run Report as Shift checkbox and time selectors is the Shift dropdown When a shift is selected from the dropdown the Run Report as Shift chec
2. Release 1 1 INTEG Process Group Inc 4 3 3 Removing an Existing Part To remove a part navigate to the Configure gt Parts page If the part has any routes associated with it remove the routes as described elsewhere Once the part does not have any routes associated with it click the trashcan icon to the left of the part id A confirmation popup will appear asking 1f the part should be removed Clicking OK on the popup will remove the part completely and close the popup By clicking Cancel or clicking the close icon x at the top right of popup the part will remain unaffected and the popup will close After clicking OK the page will reload and the deleted part is removed from the list 4 3 4 Filtering Parts Over time the number of parts that have been created may become large To make searching for a part easier the Configure Parts page includes filters to narrow down the number of parts listed on the page The existing parts can be filtered based on the part 1d part name description and or route name by typing into any of the textbox fields shown at the top of the page The parts list will be filtered to only those parts which contain the text from the textboxes in the related fields 4 3 5 Configuring a Part s Specific Route Step Information Once a part has been made and associated with a route the route can be further configured to give specific operation information for each step in the route
3. The OMS requires a user to login in order to do anything except see the status of the system The functionality of starting a job stopping a job entering job details and configuring the system require some level of privileges gained by logging in There are conceptually two login type pieces of functionality First there is a Log In for the web pages Second there is an Operator Sign In for a work center 1 The web pages Log In is located in the upper right corner of the header of every OMS page This log in allows the proper web pages and web page controls to appear based on privilege level OMS 6 User Manual Release 1 1 INTEG Process Group Inc 2 The work center Operator Sign In allows statistics to be generated for the operator responsible for production at the work center while that operator is signed in NOTE Logging in so that the OMS web pages are set up for the operator requires a username and password However for the Operator Sign In the operator will have the option to select his name from a list or enter their ID number when on a Work Center page The operator of the work center does not have to log in in the upper right corner They just need to sign in on their respective Work Center page Both types of users are set up under the Configure Users tab by an administrator There are effectively four levels of user privileges for the OMS Log In not logged in Operators Supervisors and Administrators
4. available per work center type are listed elsewhere The bottom of the page shows the legend for the status conditions of the work centers background coloring based on operational conditions e _ Goo0d This reflects that a work center is being utilized and is producing at least 80 of the specified target rate e Running Slow This reflects that a work center is being utilized but is producing at less than 80 of the specified target rate e DFlanned Downtime This reflects that a work center is not available and not running e Unexpected Downtime This reflects that a work center is available for production but not producing at all e _ Cornrm Error This reflects that the JNIOR associated with the work center has not communicated with the OMS recently 5 2 Work Center Details To view the detailed status of a work center navigate to the Status gt Work Centers page and select the work center name link for the work center desired At the detailed status page three main viewing panes the Job Details Current Statistics and Machine History are shown The status page also allows an operator to start or end a job at the displayed work center A list of all work centers shows their current status and clicking on the work center name link will navigate to the work center details page for that particular work center OMS 28 User Manual Release 1 1 INTEG Process Group Inc 5 2 1 Job Details The Job Details viewing
5. on the Add Step popup accepts the configuration and closes the popup Selecting Cancel or clicking the close icon x at the top right of popup discards the information and closes the popup After a step has been added the Route Information popup will show the new step under the Name and Description text boxes as shown below At this point the step may be modified by its order in the route or its work center type The add step process may be repeated as many times as necessary to complete a route through a plant factory though a route must have at least one step configured for it Route Information For RAJ R2 x Mare Description RAJ R2 Route 2for RAJ Step Number Operation Work Center Type Delete Bend Brake Press v Update Steps 1 Add Step OK Cancel Apply Selecting OK on the Route Information popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup OMS 14 User Manual Release 1 1 INTEG Process Group Inc The act of adding a step to a route saves that route to the database Creating a new route adding a step to the new route and then clicking Cancel will leave the newly create route in the database with the configured step added to it 4 2 2 Modifying
6. A user can be configured to have any combination of Operators Supervisors and Administrators privileges Without logging in a user will be permitted to navigate to the Status gt Work Centers Status Work Orders and the Help About pages While at the Status gt Work Orders page and Status gt Work Centers page specific work orders and work centers can be selected to see more detailed information However modifying a work order starting a job ending a job and entering job details are prohibited The Operators level login permission allows a user to sign into a work center start and stop a job and enter job details The user is still denied permission to modify existing configuration The Supervisors level login permission allows a user to view OMS reports This login permission level does not allow a user to sign in as an operator on a work center or configure the OMS system The Administrators level login permission allows a user to configure the OMS system This login permission level does not allow a user to sign in as an operator on a work center or to view OMS reports 4 Configuration Configuration of the OMS must be done before the OMS can be utilized Each of the items mentioned in the OMS Terminology section can be configured in one or more ways A little planning at this point would be beneficial for the implementation of the OMS While not necessary things such as consistent naming conventions makes the OMS system easi
7. Orders page Select a work order by clicking the gray red folder icon to the left of the work order name The Work Order Information popup will open with the selected work order s information Parts can be added to or removed from a work order from the Work Order Information popup Adding parts to a work order has been described elsewhere To remove a part from the work order click the trashcan icon 1 to the left of a part listed on the popup The delete confirmation popup will open which asks for confirmation of the deletion Clicking Cancel or the close icon x at the top right of popup on the delete confirmation popup will close the popup and leave the part on the work order Clicking OK on the delete confirmation popup will accept the removal and the Work Order Information popup will refresh with the part removed from the list of parts on the work order The actual deletion of the part from the work order will not be completed until the OK or Apply buttons have been clicked on the Work Order Information popup Selecting OK on the Work Order Information popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup 4 4 3 Removing an Existing Work Order To remove a work order
8. To configure this navigate to the Configure Parts page Select the desired part by clicking the appropriate gray red folder icon which opens the Part Information popup Select an associated route by clicking the appropriate gray red folder icon which opens the Route Information popup with Strokes Operation Parts Operation and Target Rate textboxes available for each step in the selected route as shown below Alternatively this popup can be reached by navigating to the Configure gt Routes page filtering by part by clicking the Select Part link and choosing the desired part and then selecting a route from the filtered list by clicking the gray red folder icon HF Route Information For PE RTE x Name Description PB RTE BreakPress only Step Number Operation Work Center Type Strokes Operation Parts Operation Target Rate Delete 10 Bend Brake Press v 2 1 80 Update Steps 1 Add Step OK Cancel Apply OMS 19 User Manual Release 1 1 INTEG Process Group Inc The step number and work center type can be modified for the selected route and changing the step number or work center type will change the route information for any part with the associated route The strokes operation parts operation and target rate for each step of the route can be modified for each part route combination and this information is unique per part route combination After modifying any of the fields fo
9. an Existing Route To modify an existing route navigate to the Configure Routes page Select a route to be modified by clicking the gray red folder icon to the left of the desired route The Route Information popup will open with the selected route s information The name and description of the route can be modified by changing the text in the provided Name and Description textboxes To alter the step of a route modify the number in the textbox under Step Number To alter the work center type use the dropdown box under Work Center Type After the step and or work center type have been modified click the Update button to accept the changes Clicking the Delete link to the left of a step will remove that step from the route Selecting OK on the Route Information popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup Any changes to a step that have not been saved to the database via the Update button will be lost if the OK Cancel buttons are clicked 4 2 3 Removing an Existing Route To remove a route navigate to Configure gt Routes page Click the trashcan icon 1 to the left of the route name to be removed A confirmation popup will appear asking if the route shoul
10. and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup OMS 26 User Manual Release 1 1 INTEG Process Group Inc 4 6 3 Removing an Existing Shift To remove a shift navigate to the Configure Shifts page Click the trashcan icon 1 to the left of the shift id to be deleted A confirmation popup will appear asking if the shift should be removed Clicking OK on the popup will remove the shift completely and close the popup By clicking Cancel or clicking the close icon x at the top right of popup the shift will remain unaffected and the popup will close After clicking OK the page will reload and the deleted shift 1s removed from the list 5 Status The status of the system is shown in two ways The work center status is the main way that the system status is displayed showing an overview of the configured work centers The second is work order status which shows the configured work orders 5 1 Work Centers Overview To view the status of all work centers navigate to the Status gt Work Centers page The work centers overview screen shows the work centers currently configured in the system a 3 a iyi Username Password Login ll SR S a and Manemenenice System INTEG P
11. navigate to the Configure Work Orders page Click the trashcan icon 1 to the left of the work order to be deleted A confirmation popup will appear asking if the work order should be removed Clicking OK on the popup will remove the work order completely and close the popup By clicking Cancel or clicking the close icon x at the top right of popup the work order will remain unaffected and the popup will close After clicking OK the page will reload and the deleted work order is removed from the list OMS 22 User Manual Release 1 1 INTEG Process Group Inc 4 5 Users 4 5 1 Configuring a New User To configure a new user navigate to the Configure Users page The Users tab of this page lists the users currently existing in the system as shown below i i f F y Logout admin es Pair sm Your Company Name i Pioni pear mit the Enere katur 1 anton ligar ret ace Hd Work Under i Marke Male i Wurk Center Shile Leer Email Roles Last Login TR alem alar Sin ero rie Aine ali Cet alors pe SOC MEDD UMS AA cheos veholnas even bewper com Acmiivetabor Dporcions Sopire for ii ODE Era MM Go ia ADT iparata A UF rhs MB jo usa miz com Eporziors A EDE MA ia Ea cam iparata SAADAA Ds nH PM f Ji go W Sua eme ema Ia k a 3 gt si SALA integ A A S an IMS Suso prada hitmen un pit CAU bho ALE ELL To create a new user click the Add User link on the bo
12. pane as shown below displays the information for the work order being run and the operator currently logged into the work center Job Details Hide SIM Press Work Order WO 1 One User Running 01 day 01 hour 24 minutes PANA Finished 0 a Logged In 5 29 2008 12 31 PM A 01 day 01 hour 24 Route R PB i cia minutes Step 10 Clicking on Job Details viewing pane s title bar minimizes the viewing pane and clicking a second time will restore it to its normal size The Job Details viewing pane s title bar shows at all times the name of the work center currently being viewed The information shown in the Job Details viewing pane 1s identical for every work center When the Job Details viewing pane is maximized the left hand column shows the following information top to bottom Work Order the work order currently running on the work center Running total time since work order has been running on the work center Finished number of parts made for this work order s part s step Finished the percent of the current step that is finished Required number of parts necessary to complete the work order Route the route that the current work order s part is on Step the step that the current work order s part is on From top to bottom the right hand column in the Job Details pane shows e Operator last name first name and operator number of the currently logged in operator e Logged In Time the timestamp of when
13. pop up contains three rows of data The first row shows the number of parts counted by OMS The second row allows the operator to enter the actual number of parts that were made that were considered to be good The third row allows the operator to enter the number of scrap parts that were made during the Job Click OK to accept the audit and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will discard the audit information and close the pop up and leave the job running Press Brake The End of Job Audit pop up contains three rows of data The first row shows the number of parts counted by OMS The second row allows the operator to enter the actual number of parts that were made that were considered to be good The third row allows the operator to enter the number of scrap parts that were made during the Job Click OK to accept the audit and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will discard the audit information and close the pop up and leave the job running OMS 37 User Manual Release 1 1 INTEG Process Group Inc Slitter The End of Job Audit pop up opens and allows the operator to edit the end product of the job The textboxes for the ID Width I D Sidewall Gauge and Weight of the Master Coil are disabled In the Enter Sidewall Material Left on Drum textbox enter the sidewall height in inches of material left o
14. EE percentage Select a report to use from one of the three dropdowns After a report has been selected the rest of the report filtering dropdowns and selectors become visible as shown below Reports Reports E Summary Availability Full Parts By Work Center v v v Part Work Order Work Center Operator All v All All v a Report Shift Data Only O Report Start Time Report End Time 12 wz 00 AM 3 vito lpm iv OR Select Shift Select Days of Week to Report Sun MI MonM TuesM Wed 4 Thurs M Fri M Sat M lt June 2008 gt Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa 25 26 27 28 29 30 31 25 26 27 28 29 30 31 23 4 5 Be 2 31 4 5 664 8 9 10 11 12 13 14 8 9 10 11 12 B 14 OMS 39 User Manual Release 1 1 INTEG Process Group Inc Once a report has been selected the data to be shown in the report should be filtered down to only the relevant information There are four parameter filters Part Work Order Work Center and Operator Depending on the report selected the parameters available to be selected will change When a parameter is enabled by default All is selected from the dropdown to use all instances of that parameter Selecting a specific parameter will exclude all other instances of that parameter For example if a report allows a work center to be selected and a single work center is selected from the dropdown only that specific work center will be shown in the report However if
15. M 2 40 PM 3 00 PM 1 30 PM 1 50 PM 2 10 PM 2 30 PM 2 50 PM 3 10 PM 5 4 Work Order Details Depending on the work center type starting a job may involve several steps To start a job on any work center click the Operator Sign In button between the Job Details and Current Statistics viewing panes The Operator Sign In pop up will open Enter either an operator name Last First or an operator number After beginning to enter an existing name or number an operator selection grid will expand on the right side of the pop up Optionally the operator can be selected from the grid by clicking Select Click OK to login as this operator and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will abort the login and close the pop up Once an operator logs in the Start Job button becomes visible To start a job on any work center type click the Start Job button The Start Job pop up opens with the work center and operator fields populated and disabled Select the desired work order from the dropdown Once a work order is selected the pop up will expand to allow the operator to select the desired part to be worked on as well as the desired step If only one part and one step exist for the selected work order on the current work center the pop up will alert the operator Click OK to start the job and close the pop up Clicking Cancel or the OMS 35 User Manual Re
16. Parts Good values are determined by operator entry at the job audit screen after stopping a job at a work center The OMS reporting allows the OEE value to be given on a work center operator part and work order basis OMS 5 User Manual Release 1 1 INTEG Process Group Inc 2 OMS Navigation Navigation through OMS occurs mainly through the tabs on the top right of the web screens Depending on the permissions of a logged in user section tabs for Status Analytics Configure Preferences and Help are available Under each of the section tabs one or more page selections can be chosen from For a given page the section tab and page selection that the page falls under is colored when the page 1s up in the browser The following is a screen shot of the main page when logged in as an Administrator 3 F a my Logout rshulkosky Siis Ne gt q N Se A EO Oyo INTEG Process Group Inc Bo Gap between the Plant Floor and the Enterprise Status analytics Configure Preferences Help Work Centers Job Orders Work Centers Overview Filter Y Good M Running Slow M Planned Downtime M Unexpected Downtime Y Comm Error I Info Collapsed Sa Brake Press 1 SIM_Brake Press 2 J0 0001 1 2705 50000 SIM General OEE JO 004 0001 3084 25000 Good _ Running Slow Mi Planned Downtime Mi Unexpected Downtime Comm Error x 3 OMS Login
17. THD Decor quis A aim Sute 207 Ad ins shiha mate A A Fammi rolling roubo 7 um DAMA curly Md E EL FTE Eller ona i E ara TEN Rere A Soler Create New Route e gt Ecry bom ERG BAN Be Bee Tig Ta j cs 1 e AAA LA E ial AN NES Suppt TA Arda Wi Thee ini LE PLL i To create a new route click the Create New Route link at the bottom right of the page The link will open the Route Information popup window as shown below Route Information For New Route gt Name Description AM There are no steps for the selected route Steps O Add Step OK Cancet Apot OMS 13 User Manual Release 1 1 INTEG Process Group Inc In the Name textbox enter a name for the route up to 50 alphanumeric characters long In the Description textbox enter a route description A description for the route can be up to 1024 alphanumeric characters long To add a step to the route click the Add Step link on the bottom left of the popup The Add Step popup will open as shown below Add Step Select Wok Center Type Select a Work Center Type Enter Step Number E A step consists of a work center type where the step will be performed and the step number Select a work center type from the Select a Work Center Type dropdown which 1s populated by the work center types for work centers currently configured in OMS In the Enter Step Number textbox the step number can be entered Selecting OK
18. a Producing signal being Current AIN l i on for that amount of time This translated Producing signal is compared to the amount of time the Available signal is high to determine the OEE percent The closer the translated Producing time is to the Available time the better the OEE percentage This input takes a 10V signal from the 10V module and represents the speed of the slitter For OEE data the amount of time this signal and the Current signal are both above a threshold SE AIN value translates into a Producing signal being on for that amount of time This translated Producing signal 1s compared to the amount of time the Available signal is high to determine the OEE percent The closer the translated Producing time is to the Available time the better the OEE percentage Rolling Mill Footage Available Off On This work center type is specifically for configuration for a rolling mill or similar type continuous operation This work center takes up to three inputs and generates OEE data based the state of those signals Signal Name Explanation Represents the state of the machine for when it should be in operation For OEE data the amount of time this signal is high compared to the amount of time the Producing signal is high impacts the OEE percent Available Off On This input takes a 10V signal from the 10V module that represents the amount of current the rolling mill is drawing For OEE data the amount of tim
19. c Bottles Cancel Apply The Add Route popup lists all routes currently existing in the system A filter at the top of the popup allows the routes to be filtered to only those routes which contain the text OMS 17 User Manual Release 1 1 INTEG Process Group Inc within the filter textbox Click the gray red folder icon next to a route to add that route to the part Click Cancel to close the Add Route popup without adding a route to the part Once a part has been selected the pop will close and the route will be listed in the Part Information popup By default the first route added to a part will be set as the part s default route If more than one route 1s added to the part the default route can be changed by clicking the checkbox under the Default column for the desired route to be default new route can be created from the Part Information popup by clicking the Create New Route link at the bottom of the popup Selecting OK on the Part Information popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup The Clone Part button will do nothing unless the Apply button has already been clicked or the Part Information popup has been reached by selecting a
20. concept of routing allows configuration of the system to link certain parts to certain types of work centers A route is assigned to a part to show the path the part takes through the work centers When it comes time to start working on a particular part having routing configured in OMS allows a limited but relevant set of options to be presented to the operator for the work center he she is at A work order is a number of parts that are to be made on a specified route A user is configured to allow an operator to log into a work center The information generated at a work center is also associated to a logged in operator A shift is a designated time span that can be configured for ease of reporting By selecting a start time end time and a number of days in a given week a report can easily be run to show the data for the configured shift OMS A User Manual Release 1 1 INTEG Process Group Inc Once the appropriate items are configured for OMS the system 1s ready for use The minimum configuration required for OMS 1s the installation of one JNIOR and an appropriate work center set up This allows real time data to be stored and graphed for a work center and provides a basic work center utilization report With full configuration an operator can log into a work center and start a job to produce a part Starting a job consists of choosing the work order part and step that is to be worked on by the operator at the work cen
21. d be removed Clicking OK on the popup will remove the route completely and close the popup By clicking Cancel or clicking the close icon x at the top right of popup the route will remain unaffected and the popup will close After clicking OK the page will reload and the deleted route is removed from the list 4 2 4 Filtering Routes Over time the number of routes that have been created may become large To make searching for a route easier the Configure Routes page includes a filter to narrow down the number of routes listed on the page The existing routes can be filtered by typing into the Filter textbox The text from the textbox will filter the list of routes to only those which contain that text in either the route name or route description OMS 15 User Manual Release 1 1 INTEG Process Group Inc To filter 1n an alternate way click the Select Part link at the top of the routes configuration page This link will open a popup that contains all configured parts By entering text into one of the text fields Part Id Part Name or Description the list of parts can be filtered down to only parts containing the entered text for the appropriate field Select a part by clicking the Part Id link in the popup Once a part has been selected the popup will close Clicking off the popup also closes it The routes configuration page now shows only routes that are associated with the selected part Clicki
22. d on for the displayed work center OMS 31 User Manual Release 1 1 Machine History hide Status Work Order Part Name Route Step Operator Start End Finished Audit Required Scrap ja JO 0001 First Part BrakePress 1 1 00001 6 24 2008 12 16 57 PM 0786 50000 E JO 0002 Part 2 BrakePress 1 0001 6 23 2008 1 15 49 PM 6 23 2008 1 33 33 PM 607 0 20000 Ba JO 0002 Part 2 BrakePress2 1 1 6 20 2008 3 53 27 PM 6 20 2008 4 43 21 PM 1537 o 20000 ez JO 0002 Part 2 BrakePress 1 1 6 20 2008 3 17 46 PM 6 20 2008 3 43 41 PM 1311 0 20000 j Complete au In Progress po Idle pa Stopped Clicking on Machine History viewing pane s title bar minimizes the viewing pane and SIM Brake Press 2 INTEG Process Group Inc clicking a second time will restore it to its normal size The information shown in the Job Details viewing pane is identical for every work center Status Flag that graphically indicates the status of the entry shown Work Order The work order number of the entry shown Part Name The name of the part that was worked on for the entry shown Route The route name of the route that was worked on for the entry shown Step The step number in the route that was worked on for the entry shown Operator The operator number of the operator that worked on the entry shown Start The timestamp when the particular job started for the entry shown End The timestamp when the particular job ended for the entry shown F
23. double clicked to navigate to a screen that allows the time shown on the X axis to be modified as shown below OMS 30 User Manual Release 1 1 INTEG Process Group Inc 6118 2008 Lagins Werk Order DTM Delays j 250 Fl 2000 Rate 100 1 40 PM 2 00 PM 220 PM 2 40 PM 3 00 PM 3 20 PM 1 50 PM 2 10 PM 2 30 PM 2 50 PM 3 10 PM 3 30 PM Select the duration you wish to see 1 hour Select the date and time you wish to view Thursday August 07 2006 e Lao 03 x 007 Pu Back to Current Time When the larger graph loads the default time period is the previous 2 hours The user can use the drop down to change the duration The options are 1 hour 2 hours 4 hours 8 hours 12 hours 16 hours or 1 day The user can also select a specific day and time to start the data graphing for the duration selected This allows the user to go back in time and view any window of data Use the Calendar button to set the date and the pull downs to set the time and then click the Set Start Time If the user left clicks in the graph window and holds down the mouse button and drags the cursor a zoom area 1s created Clicking on the box with the up arrow in the lower left corner of the graph the zero point of the x and y axes returns the graph to the previous time period scale 5 2 3 Machine History The Machine History viewing pane as shown below displays the history of work orders being worke
24. e amount of time this signal is high compared to the amount of time the Producing signal is high impacts the OEE percent Represents the state of the machine when it is making parts For Available Off On OEE data the amount of time this signal is high compared to the Producing Stopped Started amount of time the Available signal is high impacts the OEE percent The closer the Producing time is to the Available time the better the OEE percentage Represents the state of the machine when a piece or part has Piece Made been created A piece is counted when the system sees a low to high transition on the input OMS 14 User Manual Release 1 1 INTEG Process Group Inc Slitter This work center type is specifically for configuration of a slitter machine This work center takes up to four inputs and generates OEE data based the state of those signals Signal Name Explanation This input counts low to high transitions and calculates the number of feet gone by This input does not affect OEE Represents the state of the machine for when it should be in operation For OEE data the amount of time this signal is high compared to the amount of time the Producing signal is high impacts the OEE percent This input takes a 10V signal from the 10V module and represents the amount of current the slitter is drawing For OEE data the amount of time this signal and the Speed signal are both above a threshold value translates into
25. e this signal and the Speed signal are both above a threshold value translates into a Producing signal Current being on for that amount of time This translated Producing signal is compared to the amount of time the Available signal is high to determine the OEE percent The closer the translated Producing time is to the Available time the better the OEE percentage OMS A 12 User Manual Release 1 1 INTEG Process Group Inc This input takes a 10V signal from the 10V module and represents the speed of the rolling mill For OEE data the amount of time this signal and the Current signal are both above a threshold value translates into a Producing signal being on for that amount of time This translated Producing signal 1s compared to the amount of time the Available signal is high to determine the OEE percent The closer the translated Producing time is to the Available time the better the OEE percentage 4 2 Routes 4 2 1 Configuring a New Route To configure a new route navigate to the Configure gt Routes page This page lists all of the routes currently existing in the system as shown below admin Crenthin and Vales een Pils roe baraman ras Pare Heer mih the never Your Company Name Statue analytns Canfiyare Preference Hoty Wurk Under ti urbe Muuler Do ork Cenlera Shile Lore Routes Select Part Select Work Center Gear Selection Filter Route Name Route Descnption 7 mm Monte
26. eces made since the job started on the shown work center The current parts per minute and strokes per minute are shown at the top of the graph Current Statistics Part Number Parts Per Minute Strokes Per Minute 0 Strokes Per _ 6 18 2008 Operation Parts Per a eee Delays Operation gt Target PPM Pieces Made Rate 2 10 PM 2 30 PM 2 50 PM 3 10 PM 3 30 PM 3 50 PM 2 20 PM 2 40 PM 3 00 PM 3 20 PM 3 40 PM 4 00 PM Press Brake The press brake work center s current statistic viewing pane displays the press brake s parts per minute and strokes per minute on the graph as shown below The data on the left of the viewing pane details the part number being worked on the strokes per operation for the current route step the parts per operation for the current route step the target rate for the current route step and the total pieces made since the job started on the shown work center The current parts per minute and strokes per minute are shown at the top of the graph OMS 33 User Manual Release 1 1 INTEG Process Group Inc Current Statistics Part Number Parts Per Minute Strokes Per Minute 119 Strokes Per o 6 18 2008 Operation indie Parts Per Mo Operation Sho Target PPM 200 Pieces Made 150 Rate 100 50 1 40 PM 2 00 PM 2 20 PM 2 40 PM 3 00 PM 3 20 PM 1 50 PM 2 10 PM 2 30 PM 2 50 PM 3 10 PM 3 30 PM Slitter The slitter work center s current
27. ecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup OMS 9 User Manual Release 1 1 INTEG Process Group Inc 4 1 3 Removing an Existing Work Center To remove a work center navigate to the Configure Work Centers page Click the trashcan icon i to the left of the work center name to be removed A confirmation popup will appear asking if the work center should be removed Clicking OK on the popup will remove the work center completely and close the popup By clicking Cancel or clicking the close icon x at the top right of popup the work center will remain unaffected and the popup will close After clicking OK the page will reload and the deleted work center is removed from the list 4 1 4 Managing Work Center Images To add a new image to associate with work centers navigate to the Configure Work Centers page Click the Manage Images link at the bottom right of the page The link will open the Manage Work Center Images page which shows all available images with a checkbox below each From this screen images can be added or deleted To add an image click the Browse button Alternatively type the location of the image to be uploaded directly into the Upload a New Image textbox Once the location of the image has been set click Upload The uploaded image will be added to the top of the page show
28. er to understand and use All aspects of the system show the names of the parts routes work centers and work orders There is not a set order by which OMS needs to be configured There are however some OMS areas that require other areas be configured for example parts have routes associated with them and routes have steps on work centers The most straightforward OMS 7 User Manual Release 1 1 INTEG Process Group Inc way to configure the system 1s to create work centers then routes then parts and finally work orders Users and shifts can be configured at any point and are not dependent on the other portions of OMS 4 1 Work Centers 4 1 1 Configuring a New Work Center To configure a new work center navigate to the Configure Work Centers page This page lists all of the work centers currently existing in the system as shown below E q A is j i i ja A a E Logout admin oa Your Company Name al Ae cape peren che s ia ra terre Status Analytica Gondiqure Preferences tele Werk Orders ii Parte ii Romun Work Centers Seria deere Work Centers Hare Type T E Sit Press Braka Pres E SM Follingaidl Roling Mill o E sw tim Slittar E SM TEME Brake Press T E ci Tester Braka Press E Sw Tetvc siitter Slither E E Siw CEE PE Braka Press E SMCESU Slithar EM SIMCEE RM Rallreg MIL Remove E Select im EEE Hum ERS integ INTEG eei Inc 724 033 9350 a 2319 East Hard
29. era mia system Users liners Ambas UserName Operator Supervisar Adminirirator admin El E z Alw Oo O Oo rehulkosky El E Fl ser E O oO liserz El O oO liser3 E oO O Save Rola Changes ntes Boron ERD integ INTEG Process Group Dre 734 999 950 2915 East Hardies Rood eee hit DME Support pemer prup a Gbsoria PA 15044 4 6 Shifis 4 6 1 Configuring a New Shift To configure a new shift navigate to the Configure Shifts page This page lists all of the shifts currently existing in the system as shown below dar Logout admin Ln Your Company Name A eae karawan pie Wan Poar nad the Enero Statur i Analytics Exige lr Lea Work Under i1 aris Muuler do Work Leonera Shifts AB o Mame Days Start Time _ End Time Description jo mi Rocks Shik a plo r 200 PA VEZ A 1 liternowe E Select Create New Shift integ ati Ihas PTET oe A 2010 E22 Hardis Ros pre o ei 5 broma PA A Ween Mib2gog om Hep Soe To create a new shift click the Create New Shift link opening the Shifts popup as shown below OMS 25 User Manual Release 1 1 INTEG Process Group Inc Shifts x Enter an ld Ex SHFT 1 Enter a Name Ex Morning Shift Select the days of the j E sun a Flie al a Dr Dl sat ton Wed week Thu Start Time 12 we 00 PM el End Time 12 we 00 we PM se Description OK Cancel Apply In the Enter an Id textbox the shift
30. he User Information popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup 4 5 3 Removing an Existing User To remove a user navigate to the Configure gt Users page Click the trashcan icon 1 next to the user name to be removed A confirmation popup will appear asking if the user should be removed Clicking OK on the popup will delete the user and the popup will close Clicking Cancel or the close icon x at the top right of popup will leave the user unaffected and close the popup After clicking OK the page will reload and the deleted user is removed from the list 4 5 4 User Roles A user has roles that can be assigned to him her To assign roles navigate to the Configure Users page and click the Roles tab at the top of the page as shown below A user 1s assigned roles by checking the checkboxes in each column for the desired role for the appropriate user Once the appropriate roles have been checked for one or more users click the Save Role Changes button to apply the changes to the database OMS 24 User Manual Release 1 1 INTEG Process Group Inc nS Logout admin Operation aud mainjpanage Spi Your Company Name y Po PA di A o Er E mules at ice Orders o i Parta mt Rostos work Canb
31. i Ma bs ae mteg AO NT ini pd pra ra NEAR AU BOBO E OS Sugg da hela Ha Tee To create a new work order click the Create New Work Order link at the bottom right of the page This will open the Create New Work Order popup as shown below OMS 20 User Manual Release 1 1 INTEG Process Group Inc Create new Work Order p Work Order Number Add Part E Remove ok cancel Appiy In the Work Order Number textbox a work order number can be entered up to 50 alphanumeric characters long To add a part to the work order click the Add Part button and the Add Part popup will appear as shown below Add Part x Patio Search Route Mi Quantity oK cancel In the Part ID textbox a part id to be added to the work order can be entered Alternatively click the Search button to view the part search popup as shown below Select a route from the Route dropdown which is populated with all of the routes associated with the given part id In the Quantity textbox enter the quantity in the provided Quantity textbox and select the units from the dropdown Part ld Part Name Descriptio Part Id Part_Name Description P PE 1 PressBrake part 1 PressBrake part 1 P Rivi 1 Rolling Mill part 1 Rolling Mill part 1 R 5L 1 Shitter part 1 Slitter part 1 The part search popup lists all parts in the system The filters at the top can be used to narrow the list of par
32. id can be entered up to 50 alphanumeric characters long In the Enter a Name textbox the shift name can be entered up 50 alphanumeric characters long Checkboxes can be checked for all of the days on which the shift will be used The start time and end time of the shift can be configured from the Start Time and End Time dropdowns allowing configuration for hours minutes and AM PM In the Description textbox a description for the shift can be entered up to 1024 alphanumeric characters long Selecting OK on the Shifts popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup 4 6 2 Modifying an Existing Shift To configure an existing shift navigate to the Configure Shifts page Select a shift to be modified by clicking the gray red folder icon to the left of the shift id The Shifts popup will open with the selected shift s information Any of the fields can be modified Leaving the shift id causes the selected shift to be modified Changing the shift id to a non existent shift id however results in a new shift being added to OMS Changing the shift id to an already existing shift id results in the existing shift being overwritten Selecting OK on the Shifts popup accepts the configuration
33. ies Rosd Sa z per pa Gibsonia PA 15044 SIMA oem E Super To create a new work center click the Create New Work Center link at the bottom right of the page The link will open the Work Center popup window as shown below Enter Name RAJ 001 PHOTO NOT AVAILABLE Select Type Brake Press E T Available fOff On Select a Device I Producing Stopped Started Select a Device T Piece Made Select a Device cance Apply ox i OMS 8 User Manual Release 1 1 INTEG Process Group Inc In the Enter Name textbox the name for the work center can be entered up to 50 alphanumeric characters long Select a work center type from the Select Type dropdown which is populated with available work center types for the OMS Select a work center image from the Select Image dropdown which 1s populated from the images in the image gallery NOTE OMS includes an initial set of work center types If a specific type of work center is required for your operations INTEG will discuss this with you prior to order placement to define a work center type to be created for your operations This flexibility 1s key to the OMS operation and scalability The image selected from the dropdown will join the specified image to the work center for easier referencing from the work center status overview page If an image is not specified a default image for the type of work center will be automatically assig
34. iguring a Part s Specific Route Step Information 19 es ECOS ea rere en pl RTE ro oe eee eee 20 4 4 1 Contisurine a New Work Order ii 20 4 4 2 Modifying an Existing Work OrderT oocccccccccnnononnccnnnnnnnnnnnnonnccnnnnnnnnnnnnos ZZ 4 4 3 Removing an Existing Work Order csacsi aa 22 4 5 USC PS Senarra AS 23 4 5 1 COMMS UPS a Nem Usados 23 4 5 2 Modif yine am Existo US 24 4 5 3 Removing an E isto Usar a A a 24 4 5 4 SERRO ICS emer re a RO CG AS Rr ee ee 24 AsO SINS cobaia sto aaa Rd ai Da ai 25 4 6 1 Contests a NeW Murio 29 4 6 2 Modifying an EX die 26 4 6 3 Removing an Existing Mya ais 21 A a E T E E NN 2 5 1 Work Centers OvervICM ea e E E ba a 21 32 Work Cener Details 28 A RU NS RA RAT 29 J22 EN O 29 DL Machine Histo us A pa DU GR apr 31 5 3 Work Center SPC CICS unidas eco is asda GRE edo 33 Sd Work Order DELAS seas ae dead ta ra a 35 OMS 2 User Manual Release 1 1 INTEG Process Group Inc o Work Orderiend JOD cata 37 OE MTV AUIS das 38 6 1 REPO e dicos 38 6 1 1 USime REDOR au A 38 O A An ani Aa a a 4 BAC ND o oe QRO PR RR A 4 OMS User Manual Release 1 1 INTEG Process Group Inc 1 OMS Overview The INTEG Operations and Maintenance System OMS bridges the gap between the plant floor and the enterprise OMS provides real time data to the user to gain valuable insight as to the status and effective use of plant equipment Easily configurable to cover one piece of e
35. ing it is now available in OMS as an image for work centers To delete an image check the checkbox under each image to be deleted Once the images to be deleted have been selected click the Delete Selected button under the images and the selected image or images will be removed If an image that has been used for a work center is deleted the image will still remain on the Work Center Status Page but the image will not be available for future work centers being configured If an image is deleted and another image with the same name 1s uploaded the new image will appear on all work centers the old image was associated with Logout admin Your Company Name Status Analytics Configure Preferences Help Work Orders Parts Rovtes Work Centers Shifts Users Manage Work Center Images a a re E gt 1 P y fim O O O O O O O O E O O Delete Selected Upload a New Image Browse Upload integ INTEG Process Group INC 4 933 9350 Boron ER1 2919 East Harches Road a Tm o gt ___ _ _ __ 22 gt User Manual Release 1 1 INTEG Process Group Inc 4 1 5 Work Center Types Several work center types exist for configuration 1n the system Depending on the work center type a variable number of signals can be configured The more signals that are configured the better information the system can give Although the work center types may take the same signals OMS will differentia
36. inished The number of parts the OMS has calculated to have been completed for the entry shown Audit The good amount in the audit popup for the entry shown Required The amount needed for the part listed on the work order for the entry shown Scrap The scrap amount entered in the audit popup for the entry shown The bottom of the Machine History viewing pane shows the legend for the status conditions of the work order status flags OMS co mplete This status reflects that a work order has been completed E l E M In Progress This status reflects that a work order 1s currently being worked on EE Idle This status reflects that a work order has not been worked on at all En M Stopped This status reflects that a work order has previously been worked on but is currently not being worked on 32 User Manual Release 1 1 INTEG Process Group Inc 5 3 Work Center Specifics Some of the above mentioned details differ based on specific work center These differences are discussed below General OEE The general OEE work center s current statistic viewing pane displays the work center s parts per minute and strokes per minute on the graph as shown below The data on the left of the viewing pane details the part number being worked on the strokes per operation for the current route step the parts per operation for the current route step the target rate for the current route step and the total pi
37. ion while trying to run multiple reports 7 Preferences System preferences can be modified by navigating to the Preferences Status Box page This brings up two items that can be configured The number of columns or machines that can be displayed per row on the work center status overview page can be configured This number can be chosen to be between 5 and 10 columns 8 Help The Help About page shows the currently installed versions of the pieces of the OMS OMS 41 User Manual Release 1 1
38. kbox Start Time End Time and day of week checkboxes are disabled and they are reset to match the selected shift s start time end time and days of week If a shift is wrongly selected from the Shift dropdown or the user wishes to return to manual time selection to re enable the Start Time End Time and day of week checkboxes select the from the Shift dropdown Using the shift dropdown is the most convenient way to show data for a specific time slot To fully use this function be sure to set up shifts refer elsewhere for instructions on creating a shift before running reports Below the Run Report as Shift checkbox Start Time End Time selectors day of week checkboxes and shift dropdown are the calendars for selecting the start and end dates of the report By default the start and end day 1s set to the current day except if the hour of the PC is 11 00pm or greater the end day will move to the next day To select a different day use the arrows to the right and left of the month to change months then click on the day to select it Light gray on a day denotes the current day while dark gray on a day denotes it has been selected OMS 40 User Manual Release 1 1 INTEG Process Group Inc After the report parameters timespan shift and day have been selected the report is ready to be run To run a report click the Run Report button to the right of the calendars When the Run Report button has been clicked the report page wil
39. l expand vertically and the actual report will be displayed under the report controls The report viewer has several controls at its top These controls enable the user to move through the pages of the report export the report to a file and refresh the report To navigate through the report pages click on the directional arrows Clicking a double arrow will navigate to the first or last page while a single arrow will move to the next or previous page A report page can be navigated to directly by typing the page number into the page textbox To export the report to a file first select the type of file to be created Choosing Excel will create a xls file and be opened in MS Excel Selecting Acrobat PDF file will create a pdf file and be opened in a PDF viewer The default viewer is Acrobat Once a file type has been selected clicking the Export link to the right of the file selection dropdown will send the file and open it Clicking the refresh icon on the report viewer control bar will refresh the current view only The report will not be re sent to the database and no new information will be refreshed into the report To refresh completely and ask for new data from the database re run the report by clicking the Run Report button again Once a report is run the shift checkbox start time end time start day end day days of week and overriding shift will be remembered from report run to report run to minimize user interact
40. l mil Rollagi 7 E wim Mala cranes ro Ihe ita Sollee 1 Borre E Sela Create Part rias Ecry um ERG ES AMES AO a mi a TO sal A fi SAren MS Support pra rma timia aa q i ASAP EJE HAN baaa User Manual Release 1 1 INTEG Process Group Inc To create a new part click the Create Part link on the bottom right of the page This link will open the Part Information popup as shown below Part Information For New Part gt x Part ID Description Part Mame OK Cancel Apply Clone Part In the Part ID textbox the 1d for the part can be entered up to 50 alphanumeric characters long In the Part Name textbox the name for the part can be entered up to 256 alphanumeric characters long In the Description textbox the description for the part can be entered up to 1024 alphanumeric characters long The Filter textbox allows the routes to be filtered to only those routes with names that contain the text entered into the textbox To add a route to the part click the Add Route link at the bottom of the popup to open the Add Route popup as shown below Add Route x Name Filtes Route Name Route Description E R 100 Route 100 Description Al R 200 Route 200 E Slitter1 Slitter route E Rollingmilh rolling mill route E RM RTEI RM only E SL_RTE1 Slitter only E PE _RTE1 BreakPress only E RAJ R3 Route 1 for RAJ E RAJ RZ Route for RAJ E PLBottles Plasti
41. lease 1 1 INTEG Process Group Inc close window icon on the top right of the pop up will discard the information and close the pop up Depending on work center type the operator may wish to enter more detailed information about the job to allow for more detailed tracking of production once it has started To enter this information click the Job Details button between the Job Details and Current Statistics panes if itis visible The Enter Job Details pop up will open General OEE There is no further information for this work center The Job Details button is not visible Press Brake There is no further information for this work center The Job Details button is not visible Slitter The slitter s Enter Job Detail pop up contains the following fields Master Coil ID Width LD Sidewall Gauge Weight Destination Drum I D and number of Mults Enter a Master Coil ID up to 50 alphanumeric characters the width of the Master Coil in inches I D inside diameter of the Master Coil in inches Sidewall height of the Master Coil in inches and Gauge of the Master Coil The Weight is automatically filled once the previous fields have been entered Now enter the Destination Drum I D and select how many Mults will be produced from the dropdown After the number of Mults have been selected the pop up will expand to allow the Operator to enter the specifics for each Mult Enter the Width and Sidewall into the appropria
42. n existing part 4 3 2 Modifying an Existing Part To modify an existing part navigate to the Configure Parts page Select a part to be modified by clicking the gray red folder icon to the left of the desired part The Part Information popup will open with the selected part s information The selected part s name and description can be modified by changing the text 1n the appropriate field s textbox The Part Id cannot be changed Associating a route to a part is done as elsewhere described A route can be removed from the part by clicking the Remove Association link to the right of the route Alternatively a route can be removed from a part by deleting the route itself However this method will remove the route from any part that 1s associated with it Selecting OK on the Part Information popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup Selecting Clone Part on the Part Information popup will open a small popup The popup asks for a new Part ID After entering a Part ID clicking OK will create the cloned part in the database close the popup and return to the Part Information popup Clicking Cancel will abort the clone and close the popup OMS 18 User Manual
43. n the master coil drum The weight of the master coil that is left is automatically calculated and displayed in the Weight textbox The final product dimensions for each mult can be entered in the provided textboxes Whether a mult was scrap can be specified by clicking the checkbox The scrap weight is automatically calculated by adding the weight left on the master coil drum plus any mults marked as scrap This field can be further edited by typing into the Total Weight of Scrap textbox which overrides the calculated value and uses whatever was typed in Click OK to accept the audit and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will discard the audit and close the pop up Cancelling or closing the pop up will also leave the job running Rolling Mill Once a job has been ended on a rolling mill the End of Job Audit pop up will open The End of Job Audit popup allows the operator to edit the final product of the job The id width inner diameter sidewall gauge and weight of the master coil is given The sidewall height of material left on the master coil drum can be entered in the Enter Sidewall Material Left on Drum textbox The weight of the material left on the drum is automatically calculated and displayed Click OK to accept the audit and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will discard the audit and close the p
44. ned to the work center The user can also import images of their work center Once a work center type is selected the Work Center popup will expand vertically to show the signal setup Depending on the type of work center chosen in the Select Type dropdown the list of configurable signals for that type of work center appears for configuration For each signal select a device a JNIOR and the associated channel Be sure that the correct device and channel supply the desired signal type or data collected from that signal will be unrecognizable by OMS Selecting OK on the Work Center popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup 4 1 2 Modifying an Existing Work Center To configure an existing work center navigate to the Configure Work Centers page Select a workcenter to be modified by clicking the gray red folder icon to the left of the work center name The Work Center popup will open with the selected work center s information All fields on the popup are editable including the name field Selecting OK on the Work Center popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Sel
45. ng the gray red folder icon next to a route will bring up the Route Information popup The Route Information popup when shown after using the Select Part filter 1s shown in a way which allows the part s specific route step information to be configured The final way to filter the routes configuration list is to click the Select Work Center link at top of the page A dropdown filled with work center names appears under the link after the link is clicked Selecting a work center from this dropdown will filter the list of routes down to only those which use the selected work center type After a filter has been applied to the list clicking the Clear Selection link will remove the filtering and the full list of routes will be displayed 4 3 Parts 4 3 1 Configuring a New Part To configure a new part navigate to the Configure gt Parts page This page contains all of the existing parts currently existing in the system as shown below Logout admin e PARE SEE a ao Your Company Name Statur anubetna Conyers rreberenter made Work Drder d urbe Moule i Work Cenere shiii ie Parts Pal Til Pail Marne Desa ripiliori Rewile Warne Hiter Fart ld Fart Hame Description Routes A Ho ETH ProceBra pati az PZ STE ATA molan AN quarto ala HAL RIII a CERs EUR parti ial SL RTEI 7 Bo ee Bari UHE Bard UD ees alin TAS rm PIO PID Decarlosion R 02 2 tig i am Aula Hati al TES a E OLUKONI cos cos trom hz ro
46. nteg process group inc OMS Operations and Maintenance System User Manual Release 1 1 INTEG Process Group Inc 2919 E Hardies Rd First Floor Gibsonia PA 15044 PH 724 933 9350 FAX 724 443 3553 Email www integpg com Support http support integog com Copyright 2008 All Rights Reserved Software Version Carbon Last updated on August 7 2008 INTEG Process Group Inc TABLE OF CONTENTS OMS OV Gt V1 Wind Ta lagos ss idas alada seis na asas atas aaa 4 1 1 OMS Teran ai a 4 122 ONIS Dias RD talc aie eaten 5 E A EN 6 2 OMS EO o crias e A A ee 6 A CONSUMO sua Bacias enw Gia ig ad sas a venom a Meals 7 4 1 WOK Contenido odo 8 4 1 1 Coniisumme a New Work Center sii hee nee SS 8 4 1 2 Modifying an Existing Work Center ooooccccnccccccnonoccnnnnncnnnnnnnncnnnnnnnnnnnnnnnos 9 4 1 3 Removing an Existing Work CenteT ooooonnnnnnccccncnnoooncnnnnnnonnnnnnnncnnnnnnnnnnnos 10 4 1 4 Mand cine Work Center IMAGES on as 10 4 1 5 Work Center TN CS ass pura a etna tava entbetiaaseateerwedtaa ts 11 A ER QUICS Sra i doa RO E Ra 13 4 2 1 Contieurine New ROME usas assi au Tod a ee esi D tees 13 4 2 2 Modyo an Existine ROME sra iia acen 15 4 2 3 Removine an Existino Route iia a 15 4 2 4 Erlterins Rot a a a sa gay irei 15 4 3 Gia o 5 AE TR 16 4 3 1 Contistrins a New Part eee AE e 16 4 3 2 Modityme an Existine Parto E T EN 18 4 3 3 Removing an Existino Patton dai ld 19 4 3 4 Endterme Pasaasi a 19 4 3 5 Conf
47. op up Cancelling or closing the pop up will also leave the job running 6 Analytics 6 1 Reports Navigate to the Analytics Reports page to view the data collected from the plant floor The Reports give an overview of operations by looking at Work Center utilization All collected data can be displayed in the Reports in one way or another allowing a User to view plant efficiency from one place 6 1 1 Using Reports When the Reports page is first opened the only visible objects are the three Report selection dropdowns Summary Basic and Full as shown below OMS 38 User Manual Release 1 1 INTEG Process Group Inc Reports Summary Rasic Full Y E x i fe am a Haren 141 eg G Process Group Inc a Int 2919 East Hardios Road Met rats el OME support OME Aire o no a H 4 m 4 e 3 4 sa To prep rr Gibsona PA 15014 The Summary reports are the simplest reports showing very basic data to allow an operator to quickly view the progress for a given time span Most of the Summary reports give data back in terms of Parts Made Availability reports become a little more complex and include an OEE calculation Availability reports rely on the available and running signals from a work center If a work center does not have those signals there will be no data for 1t The Full reports contain the most data possible These reports use all signals available running and parts made from a work center to calculate an O
48. quipment or a whole plant the OMS can look at a range of signals to determine the operating efficiency OMS can track data by work center and if desired by operator work order and or part The data is stored in database files for viewing and reporting via the OMS web based interface The open database structure enables the data to be utilized directly by higher level enterprise systems such as ERP and MES 1 1 OMS Terminology There are several concepts for the OMS that must be understood in order to appreciate the range of utility of the product A JNIOR is INTEG s Ethernet input output I O device that enables the real time data signals to be received by OMS The JNIOR can handle both digital and analog signals The user connects the appropriate signals from a work center to the JNIOR and the JNIOR acts as a data buffer as well as a seamless link to OMS running on a PC A work center represents the place where work is done This can be a machine that makes widgets a machine that performs a process without any widget like output or an area where packaging or assembly occurs Currently the work center can be configured to take inputs that are wired to a JNIOR These inputs can be anything from an existing machine electrical signal to something like a button that is wired into a JNIOR A part is an item that is made at a work center A route consists of one or more steps that are performed at a specified work center type The
49. r a step click the Update button to save the changes to the database This must be done as each step is modified as updating one step will cause all other step data to revert to what is in the database Selecting OK on the Route Information popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup Any changes to a step that have not been saved to the database via the Update button will be lost if the OK Cancel buttons are clicked 4 4 Work Orders 4 4 1 Configuring a New Work Order To configure a new work order first navigate to the Configure gt Work Orders page This page lists all of the work orders currently existing in the system as shown below Logout admin eee i La go de ta mi Drenthe and Vakrari Fee a i Dele o rar karpan piv Your Company Name Mane Hor iid the Eris ere Statur Analytics tanline preberem mp Work Urduri i urbe Mouler co Work Centers Shill ase Work Orders Status Work Order Part ld Comp Archivod 1a Ff Wiel eile ia Wo Jl Hi iia ST D igs Bug 1a WAT sm i E Eobtes tdi 104 Es Ci a ey Create New Work y z TS Complete In Progress Idie Pending archive f n o MDG E 24 l era i feta Bee ban
50. rocess Group Inc gt ging the Gap between the Plant Floor and the Enterprise Status Help Work Centers Job Orders z a Work Centers Overview Filter Y Good M Running Slow M Planned Downtime M Unexpected Downtime Y Comm Error I Info Collapsed amp TTY ms Brake Press 1 SIM Brake Eress 2 JO 0001 1 4505 50000 SIM_General OEE JO 004 0001 4884 25000 Good _ Running Slow Mi Planned Downtime Mi Unexpected Downtime Comm Error gt SSS SSS User Manual Release 1 1 INTEG Process Group Inc At the top of the Work Centers Overview page are checkboxes that allow the work centers to be filtered By checking or un checking the various checkboxes the list of work centers is narrowed to only those which meet the checked status conditions Each work center is shown in a box with a graphic and a colored background reflecting the current status of the work center The work center name is shown as a link and clicking the link will bring up the work center details page as discussed elsewhere The current work order for the work center is also listed as a link and clicking the link will navigate to the work order details page as discussed elsewhere The current operator user logged in at that work center 1s also listed Additional information shown in the box for each work center varies by the work center type The different types of information
51. statistic viewing pane displays the slitter s current and speed on the graph as shown below The data on the left of the viewing pane details the master coil 1d width side wall inside diameter gauge and weight The number of mults mult inside diameter mult coil 1d mult width mult sidewall and mult weight are also detailed on the left of the graph The speed and current are shown at the top of the graph Current Statistics SIM Slitter Master Coil Speed 1 Current 2 ID LE 6 24 2008 Width EEE Lagins Job Orde Side Wall Daas Inside y dia Diameter Gauge Ee E Weight lbs Target Speed O Er 5 E m un Number of Mults 4 Inside Diameter 2 a 1 20 PM 1 40 PM 2 00 PM 220 PM 2 40 PM 3 00 PM 1 30 PM 1 50 PM 2 10 PM 2 30 PM 2 50 PM 3 10 PM User Manual Release 1 1 INTEG Process Group Inc Rolling Mill The rolling mill work center s current statistic viewing pane displays the rolling mill s current and speed on the graph as shown below The data on the left of the viewing pane details the master coil id width side wall inside diameter gauge and weight The actual speed and current are shown at the top of the graph Current Statistics SIM_Rolling Mill Master Coil Speed 1 Current 0 ID 123 456 789 6 24 2008 Width 30 Logins Side Wall 24 Inside Diameter 3 Q Gauge 0 5 Weight 30022 lbs Target Rate Speed Wua 1 20 PM 1 40 PM 2 00 PM 2 20 P
52. te amongst them for routing purposes starting a job job details end of job audit and a variety of other features General OEE This is a generic work center type available for configuration for a number of scenarios This work center takes up to three inputs and generates OEE data based the signal state Signal Name Explanation Represents the state of the machine for when it should be in operation For OEE data the amount of time this signal is high compared to the amount of time the Producing signal is high impacts the OEE percent Represents the state of the machine when it is making parts For Available Off On OEE data the amount of time this signal is high compared to the Producing Stopped Started amount of time the Available signal is high impacts the OEE percent The closer the Producing time is to the Available time the better the OEE percentage Represents the state of the machine when a piece or part has Piece Made been created A piece is counted when the system sees a low to high transition on the input Press Brake This work center type is specifically for configuration of a machine making discrete parts such as a stamping press press brake etc This work center takes up to three inputs and generates OEE data based the state of those signals in the same way as the General OEE work center Signal Name Explanation Represents the state of the machine for when it should be in operation For OEE data th
53. te textboxes and the Weight will automatically be calculated Click OK to accept the details and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will discard the details and close the pop up OMS 36 User Manual Release 1 1 INTEG Process Group Inc Rolling Mill The Rolling Mills Enter Job Detail pop up shows the following fields Master Coil ID Width I D Sidewall Gauge Destination Drum I D Enter a Master Coil ID up to 50 alphanumeric characters the width of the Master Coil in inches I D inside diameter of the Master Coil in inches Sidewall height of the Master Coil in inches and Gauge of the Master Coil The Weight is automatically filled once the previous fields have been entered Finally enter the Destination Drum I D Click OK to accept the details and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will discard the details and close the pop up 5 5 Work Order End Job To end a job click the End Job button between the Job Details and Current Statistics viewing panes After clicking the End Job button the Job End Confirmation pop up will appear Click OK to end the Job and close the pop up Clicking Cancel or the close window icon on the top right of the pop up will cancel the job end After clicking OK the Job Audit pop up will open General OEE The End of Job Audit
54. ter Normal work center operation is then done Once the job has been finished the operator stops the job entering the audit information as necessary The audit information includes how many pieces were actually made and how many pieces of scrap were generated 1 2 OMS Data The purpose of OMS is to gather real time information about a work center store the data and generate appropriate statistical information and reports on the utilization of the work center With the appropriate signals connected for the work center one of the goals of OMS 1s to be able to calculate the Overall Equipment Efficiency OEE OEE data can take many forms and has many definitions the scope of which far exceeds this manual The OMS however utilizes the following equations for its calculations OEE Availability X Efficiency X Quality Availability Time Running Time Available Efficiency Parts Made Parts Theoretically Possible Quality Parts Good Parts Good Scrap The italicized words above represent data gathered from signals connected to the JNIOR and configured for the work center Time Running comes from the Running signal Time Available comes from the Available signal Parts Made comes from the Stroke signal and knowing how many strokes it takes to make a part The Parts Theoretically Possible value is determined by knowing the theoretical rate of production for a given part and is calculated for a given time span The Scrap and
55. the current operator logged in e Elapsed the time that has elapsed since the operator has logged in 5 2 2 Current Statistics The Current Statistics viewing pane as shown below displays I O data as well as other information that is work center specific for the displayed work center OMS 29 User Manual Release 1 1 INTEG Process Group Inc Current Statistics Part Number Parts Per Minute Strokes Per Minute 119 Strokes Per _ 6 18 2008 Operation findi Parts Per Work Order RO rrrrr n VE m Delays Operation SR AA Target PPM Pieces Made 1 40 PM 2 00 PM 2 20 PM 2 40 PM 3 00 PM 3 20 PM 1 50 PM 210 PM 2 30 PM 2 50 PM 410 PM 3 30 PM The Current Statistics viewing pane s information shown differs entirely based on work center the details of which are discussed elsewhere Unlike the Job Details viewing pane the Current Statistics viewing pane cannot be minimized A graph of incoming data specifics of which are dependent on the work center being viewed 1s also shown on the Current Statistics viewing pane The graph displays the last two hours of data for the signal shown The red line on the graph illustrates the target rate associated with the part for the relevant data The area above the graph details what operator which work order and what part has been worked on during the time shown If the top area 1s white or a color missing then a part or operator were not entered The graph can be
56. ts to only those containing text for the field which was entered To add a part to the work order click on the part 1d link in the popup Selecting a part closes the popup and populates the Add Part popup with the selected part id and the part s default route Clicking off of the part search popup also closes it and no part information will be populated in the Add Part popup Selecting OK on the Add Part popup accepts the configuration and closes the popup Selecting Cancel or clicking the close icon x at the top right of popup discards the OMS 21 User Manual Release 1 1 INTEG Process Group Inc information in the Add Part popup and closes it After clicking OK the work order configuration page will reload and the configured part is added to the list After a part has been added the Create New Work Order popup will expand and list the configured part on the work order Clicking the expander icon E next to a part shows detailed information about the part and its route Selecting OK on the Create New Work Order popup accepts the configuration and closes the popup Selecting Apply on the popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup 4 4 2 Modifying an Existing Work Order To configure an existing part navigate to the Configure gt Work
57. ttom of the Users tab This link will open the User Information popup as shown below User Information For New User gt PHOTO NOT AVAILABLE In the User Name textbox a user s user name can be entered up to 256 alphanumeric characters long In the Password and Confirm Password textboxes the same password OMS 23 User Manual Release 1 1 INTEG Process Group Inc must be entered in each and must be minimally 5 alphanumeric characters long The Operator Number First Name Last Name and Email textboxes allow up to 50 alphanumeric characters The Active checkbox is set by default which allows a user to login Selecting OK on the User Information popup accepts the configuration and closes the popup Selecting Apply on the User Information popup applies the settings to the database but the popup will remain open Selecting Cancel or clicking the close icon x at the top right of popup discards any changes not saved to the database and closes the popup 4 5 2 Modifying an Existing User To configure an existing user navigate to the Configure gt Users page Select a user to configure by clicking the gray red folder icon to the left of the user name The User Information popup open will open with the selected user s information All fields except the user name on the popup are editable Selecting OK on the User Information popup accepts the configuration and closes the popup Selecting Apply on t

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