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Monitoring of manufacturing processes


The presented solution serves for controlling and supervision of specific manufacturing processes in production plants which utilize assembly lines and work in JUST-IN-TIME system (mainly supplying companies providing the production of components). Main demand arising from this situation is the need of traceability recording, but mainly the execution of individual manufacturing process steps for each product. Other requests laid on presented solution is the monitoring of current status of the product within the process and generation of alerts in case of eventual delays or existing extraordinary situations.

Basic System Functions

Acceptance of Orders
Acceptance of orders from the product buyer is realized centrally – by means of an application module on central server. Incoming orders in form of files are scanned by an automatic service, which collects necessary data about the specific order and subsequently stores them into the central database. Further possibility consists of order acquisition from another information system via communication interface based on WEB services.

Order processing continues with assignment of the order to specific manufacturing process category, dependent on required product parameters. The order is then labelled as ready for manufacturing process.


Monitoring of Manufacturing Process
Manufacturing process starts with takeover of the order into manufacturing process. An application module installed on PC of the initiating workplace serves for this purpose. In this workplace an accompanying identification tag is printed for each order. Simultaneously the application module on initiating workplace allows monitoring of raw material and semi-product completeness required for the production of specific product (by barcode scanning or manual confirmation). Scanned data are subsequently recorded in the central database, where they remain stored.

Identification tag further accompanies the product to assembling workplace. The application module installed on PC in this workplace monitors and records individual steps of the manufacturing process. Each step is displayed on monitor also in the form of an illustration picture. The execution of individual manufacturing process steps is recorded by means of signals from any of so-called sensors. The employed work tool (e.g. the screwdriver), the production equipment itself (e.g. the press), barcode scanner, various electronic sensors connected via accessible hardware interface to the specific PC (e.g. a switch for manual operation accomplishment confirmation, micro switches, optical sensors, induction sensors and similar) can serve as sensors.

Individual steps of the manufacturing process are provided with a defined minimum and maximum operation time period. The step can not be terminated (confirm the execution) prior to expiry of the minimum time period. After the expiry of maximum operation time period the system automatically records a downtime and operating staff on specific workplace must enter the reason of the downtime (by a simple choice from defined options) simultaneously with the accomplishment confirmation. After the execution of last production step, the system automatically records the total manufacturing time and labels the specific order in the system as ready for final inspection.

The final inspection workplace is also equipped with an application module. Within the inspection, the scanning of selected barcode modules is carried out, for purpose of product completeness. After accomplishment of the inspection, the system labels the specific order as ready for shipment and stores its data into the registry of realized orders within the central database.

Upon detection of non-reparable deficiency, it is possible to terminate the production process and sort out the product during any step of manufacturing process. System automatically re-initiates the specific order (labels it as ready for manufacturing process) and its realization must start on initiating workplace again. Any production interruption is recorded in the system, and like with downtime recording, it is necessary to state the reason of production interruption.

Evaluation of Manufacturing Process
A separate application module serves for the evaluation of manufacturing process, which shows data recorded during manufacturing process of individual orders. Elementary information provided by this module are
• survey of currently processed orders, providing the current production status of the specific product
• status survey of individual workplaces, providing the actually processed order on given workplace
• occupancy evaluation of individual workplaces
• evaluation of downtime reasons
• evaluation of production interruption reasons

System Administration
Within the scope of application module, it is possible to administer individual registries and configuration parameters recorded in the system, all system users and to review system messages (LOGs from file processing, or from other regular system events).