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Celltrack ™

Celltrack ™. MIU 01. Machine Interface Unit 01 - MIU 01. Process Setup. Maintenance. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10. Quality not Achieved. Version Change. Tool Change. Box Piece. Machine Fault. Reject. Number Cavities. Oper. Ref.

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Celltrack ™

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  1. Celltrack™ MIU 01

  2. Machine Interface Unit 01 - MIU 01

  3. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator Control Indicators

  4. Control Indicator - Red • Continuous • Machine stop automatically identified (reasons 13-16) or manually by pressing one of the 12 machine state buttons. • Flashing • Machine stopped, but the machine state was not automatic and not identified by pressing one of the 12 machine state buttons.

  5. Control Indicator - Green • Continuous • Machine is in production and cycle time is within defined limits. • Flashing slowly • Cycle time is above maximum limit. • Flashing quickly • Cycle time is below minimum limit.

  6. Control Indicators - Red/Green • Red / Green Alternating • Indicates that the order quantity has been reached and order completed.

  7. Control key • Unlocked • full access to the keyboard and functionality. • Locked mode • limited access, functions not enabled: • Change machine status to number 7-10. • Change the number of cavities (view only). • Change a work order. • Change the cycle limit. • Reset the MIU 01 terminal.

  8. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F1” Cycle Information Elapsed : .60 Tot.Cycles : 61Average : 10.48 Cycles/H : 328Standard : 10.00 Parts/H : 5248Last : 10.05 Open Time :00:13:24Limit : 22.00 Operator:JoeTol +/- : 0.50 Machine :IMM001Mold :Tool_Name JoeStatus :Production v

  9. Cycle Information Elapsed Cycle counter (in seconds) Average Average cycle time for the current work order Standard The cycle time as defined in the current work order Last The last cycle time Limit Maximum cycle limit Tol.+/- Cycle tolerance range Mold The mold name or reference Status Current machine state Tot.Cycles Total number of cycles since the start of the current work order Cycles/H Calculated number of cycles per hour Parts/H Calculated number of parts that could be produced per hour Open time Current production time in seconds Operator The operators name or reference Machine The machine name or reference

  10. Maximum Cycle Limit • Calculated from: • standard cycle time+ upper tolerance limit (defined when creating a work order) + upper alarm limit (defined for machine) • If the cycle time exceeds this maximum value, it triggers a cycle incident alarm

  11. Cycle Tolerance Range • Related to the standard cycle time, for which the system identifies if the process is running slow or fast

  12. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F1” Efficiency Report EFFICIENCY (%) QUANTITIES ^o.e.e. : 98.86 launched : 3200 function: 98.38 produced : 1864speed : 100.94 remaining : 1336quality : 97.75 REQUIREMENTS time : 0h13 material : 1kg

  13. Efficiency Report O.E.E. Overall Equipment Effectiveness function % Time in Production speed Actual production rate compared to scheduled rate quality The % of good parts per total parts produced Launched The requested quanity in the Work Order Produced The number of produced parts Remaining The number of parts remaining to be produced Time The estimated time remaining for this Work Order Material Quantity of material required to finish Work Order

  14. Efficiency Calculation Rate Function = (Total Production Time + Process Setup Time) (Total Time - Scheduled Downtime) “T16” = Total Production Time “T7” = Process Setup Time Rate Speed = Actual Production Rate Scheduled Production Rate Production Rate = Cycletime x Number of Cavities Rate Quality = 1 - Good Part Count Reject Part Count O.E.E = Rate Function x Rate Speed x Rate Quality 100 100 100

  15. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F2” - Machine State Report 01 Maintenance 00:00:0002 Quality Not Achieved 00:00:0003 Machine Fault 00:00:0004 Ancilliary Fault 00:00:0005 Tooling Fault 00:00:0006 No Materials 00:00:0007 Process Setup 00:00:0008 Version/Color change 00:00:00 v

  16. Machine State • If the machine stops running the red LED “!” will flash • The Operator sets the machine state: • Press one of the 12 machine state buttons. • The red LED “!” stops flashing and lights continuously • If the red LED “!” is continuously lit then the MIU 01 has automatically detected the machine state • Optional, 12 additional machine states can be configured and defined by second depression of machine state button

  17. Machine State and Efficiency Calculations

  18. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F3” - Part Reject Report short : 0 flash : 24stains : 0streak mark : 0break ejection : 0deformation : 12out of limits : 0glaze : 0 v

  19. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F4” - Shift Report SHIFT ITEM REPORT : Phone Case Theoretical Parts : 487Good parts : 482Molding rejects : 5 1.03 %Sigalled rejects : 5 1.03 %Boxes/Shift : 0

  20. Shift Report Theoretical Parts Total number of parts produced, whether they are good parts or rejects Good parts The number of good parts produced. Depending on the declaration type the good parts might be counted automatically (when declaration type is Reject or carton) or manually when you have set the declaration type to (good) parts Molding rejects Total number of rejects % molding rejects The percentage of molding rejects ((molding rejects/theoretical parts)*100) Signalled rejects The total number of declared rejects This value is identical to Molding rejects when the declaration type is rejects % signalled rejects The percentage of signalled rejects compared to the number of theoretical parts Boxes / shift The number of boxes declared per shift

  21. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F5” - Work Order Report W.O. ITEM REPORT : Phone Case Theoretical Parts : 20487Good parts : 20312Molding rejects : 175 0.85 %Sigalled rejects : 175 0.85 %Boxes/W.O. : 0Parts during setup : 24

  22. Work Order Report Theoretical Parts Total number of parts produced, whether they are good parts or rejects Good parts The number of good parts produced. Depending on the declaration type the good parts might be counted automatically (when declaration type is Reject or carton) or manually when you have set the declaration type to (good) parts Molding rejects Total number of rejects % molding rejects The percentage of molding rejects ((molding rejects/theoretical parts)*100) Signalled rejects The total number of declared rejects. This value is identical to Molding rejects when the declaration type is rejects Boxes / W.O. The number of boxes declared per work order Parts during The number of parts produced whilst the production setup process is being optimized (machine state Process Setup is activated)

  23. Ls +12.00|--------------------------------- | * *Cycle Time| * ** * * * |* * * * *My +10.00| * * ** * * | * * * * * | * ** * * ** Li +8.00|--------------------------------- ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F6” SPC/SQC - Average Values

  24. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F6” SPC/SQC - Range Values Lr +1.00|--------------------------------- | * ** * * ** Cycle Time| * ** * * * | * * ** * * | * * * * * | * * |* * * * * 0|---------------------------------

  25. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F6” SQC - Part Dimensions Meas. Sample Lclx Dim1 Uclx 01 01 +6.00 +0000.00 +10.00

  26. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F9” Maintenance Functions MAINTENANCE FUNCTIONS PAGE 1/3reload label table 68 <-reinitialise from server 69display version number 70change language 71fifo display 72display networkinformation 73

  27. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “F10” MIU Functions MIU FUNCTIONS PAGE 1/1send message to server 21 <-change/display cycle limit 22manual tracability 50select vernier/scale xx

  28. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “Reject” - Declare Rejects short : 0 flash : 2stains : 0streak mark : 0break ejection : 0deformation : 4out of limits : 0glaze : 0 v

  29. Declare Rejects • Press “Reject” • Use the arrow buttons to navigate the reject reasons • Enter the number of rejects for the selected reject reason • Repeat until you have declared all the rejects • Validate data entry

  30. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator “Box/Piece” - Declare Good Parts Actual Prod. Box<25 : 5Item Number 1 Code : Syringe_Body

  31. “Box/Piece” - Declare Good Parts • Press “Box/Piece” • Enter the number of Parts or Boxes of Good Parts • Maximum of 25 per entry(parameter defined on server) • Validate data entry • If defined in the BOM, a label is printed on declaration of a Good Box

  32. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator Operator Reference Operator : ID123XYZ

  33. Operator Reference • Press “Operator Ref” • Enter name or operator code • Multiple operators can login and be recorded in the Event Log • Use the operator code to define type of operator or arrival/departure • Basic labor tracking can be achieved by post-processing the Event Log

  34. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator Change Number of Cavities Cav01: 16 Item: Syringe_Body

  35. Change Number of Cavities • Press “Number Cavities” • Enter number of active cavities in Moldi.e. if one cavity in a 16 cavity mold fails, enter 15 • Validate data entry

  36. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator Order Reference W.O. in progress (1) PAGE 1/201) Tool123 Part456 WorkOrder789 +02) 03)04)05)06)

  37. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator Order Reference Tool Code : Tool123Item Code : Part456W.O. No : WorkOrder789Mount/unmount PBRL : + RNumber of cavities : 0016 0015No of Parts/Box : 500Launched Quantity : 20000

  38. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator Job Queue 01) Tool123 Part456 WorkOrder78902) Tool215 Part478 WorkOrder79003)04)05)06)Arrow up/down to moveArrow left/right for detail

  39. Job Queue • Press “Job Queue” • The next scheduled Work Orders are displayed(6 by default, maximum of 15) • Select and Validate data entry • If the current Work Order is incomplete, it is effectively suspended and can be restarted from the Server using the Scheduler functions

  40. MIU 01 1/n • Connect up to 8 machines to a single MIU 01 • Use ? to access machine menu • Limitations • No SPC/SQC support • No multi-job support • Max distance 15m from machine • Or use signal “booster”

  41. ProcessSetup Maintenance F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Quality notAchieved VersionChange ToolChange BoxPiece MachineFault Reject NumberCavities Oper.Ref. AnciliaryFault ToolTrial OrderRef. JobQueue ToolingFault Waiting Engineer NoMaterial Waiting Operator MIU 01 1/n MACHINE SELECTION 1/ IMM001 -> 2/ IMM002 3/ IMM003 4/ IMM004

  42. MIU 01- Dimensions

  43. MIU 01- Standard Machine Cable

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