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Using Application Server for Warehousing and Batching

Using Application Server for Warehousing and Batching. Barry Clemence DC Industrial Scanning. Introduction. Working as a system integrator. Have worked with InTouch for many years InTouch 5.6 on Windows 3.11 InTouch 6.0b on Windows NT4.0.

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Using Application Server for Warehousing and Batching

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  1. Using Application Server for Warehousing and Batching Barry Clemence DC Industrial Scanning

  2. Introduction • Working as a system integrator. • Have worked with InTouch for many years InTouch 5.6 on Windows 3.11 InTouch 6.0b on Windows NT4.0. • Specialise in the MES and Track and Trace projects.

  3. Introduction Project Solution Agenda Benefits Considerations Summary

  4. Schaeffler

  5. Schaeffler – 3 Brands Working Together Total sales: approx. € 8.9 Bn. approx. 66,000 Employees Automotive Industrial Aerospace

  6. Schaeffler – Automotive Components Variablevalve timing Finger follower w.hydraulic pivot element Hydraulictappet Dual Mass Flywheel Clutch release system CVT Components • Engine and Transmission Components SAC • Clutch and Transmission components Timing chaindrive Shifting system • Wheel-Modules • Transmissionbearings Overrunningalternator pulley Dual Clutch System dry/wet Sensor - wheel bearing Drawnneedle bearing Strut bearing Torque Converter

  7. Schaeffler – Locations in South Africa • Port Elizabeth (503 employees) Automotive Headquarters Luk Manufacturing Plant INA/FAG Automotive Sales and Warehouse Automotive Aftermarket Warehouse Schaeffler SA Central support functions - F&C,HR,IT • Johannesburg (61 Employees) Industry operational Headquarters Industry Warehouse Automotive Aftermarket Headquarters • Regional sales representatives (5 Employees) Cape Town, Durban, Bloemfontein • Batch

  8. Schaeffler – Port Elizabeth

  9. Schaeffler – Port Elizabeth Founded: 1963 LuK Purchased: 1987 \ 1992 Production Area: 15,404 m² Warehouse Area: 3,680 m² Site Area: 35,806 m² Employees: 450 R&D: 15 Toolroom: 27 Annual Turnover: Eur 40 mil Production - 2007: Facings 2.5 million Clutch sets 1.1 million (OE 34%, AM 66%) Export 51%

  10. Schaeffler – Port Elizabeth Disc Assembly Cover Assembly Capacity : 1.7 Million

  11. Customer Requirement • Warehousing application. • Batch mixing system. • Automated system. • Tracking system. • Reporting system.

  12. Customer Environment – Not Clean • Simple and robust operator interface required.

  13. Introduction Project Solution Agenda Benefits Considerations Summary

  14. Why Wonderware? • Previous system: Wonderware InTouch 6.0 InTrack 3.0 Windows NT4.0 platform Interfaced to a Siemens S5 PLC. Running since 1997 • The customer used the same system integrator as before. • Only problem was that the software and hardware was now obsolete. • For us, it was a natural decision to continue using products from the Wonderware stable.

  15. Topology Client’s Oracle Database Server Existing Clients (Web based reports)Confidential so cannot show. Application Server Galaxy Repository Information Server with Microsoft Reporting Services Application Client (Trolley PC) Application Client(Receiving PC) Stand Alone InTouch(Laboratory PC) Datalogic Skorpio Distributed application with objects running on each client

  16. Client Requirement – Screen Navigation Client required a cost effective soloution that withstood the dirty environment. Easy navigation Create a industrial strength button object.

  17. Object – Button Interface We used standard electrical buttons with separate replaceable contact blocks. This was interfaced with a standard computer serial port. A .net object was written inside ArchestrA to do the interfacing.

  18. Object – Button Usage Operator navigates between the functions. Navigates between the required screens. Progress to the next step. The mouse and keyboard is only used for administrator functions. Demo

  19. Client Requirement – Interact With Database Client required a way to display the data in a list. Operator need to select from the list. Achieved using Wonderware SQL Objects.

  20. Object – SQL Grid • Demo

  21. Object – SQL Object

  22. Client Requirement – Interact With Scanner Client required a way to guide the operator. Allow operator movement ( i.e. wireless) Capture user input (i.e. barcode or keyboard) The solution was a wireless hand held computer with barcode reader.

  23. Object – Scanner interface Connection status Heading 3 instruction lines Scanner enable/disable Real time interaction Demo

  24. Process Layout – Receiving • Scan Bar Code • Retrieve data for scanned bar code. • Operator enters supplier batch no and manufacture date • System calculates material expiry. • Serialize Material • Each bag given unique serial number. • Barcode printed for each bag • Scan Rack • Destination rack scanned. • System validates • Customer’s System • Given a unique bar code per pallet • Laboratory • Sample passed or failed • Move Pallet • Pallet placed in rack

  25. Process Layout – Make Pre Mix • Scan Container • Each container has unique bar code • Empty container weight retrieved from database. • Mix Material: • Mixed for x minutes. • Weigh Material • Weight based on recipe • Select Recipe • Operator selects recipe. • System checks quantities. • Not Enough Material? • System decides what material based on expiry. • Operator guided by scanner. • Bag scanned and moved • Weigh Container • Empty container weight verified against database weight. • Weigh Material: • Premix into container • Weighed against limits. • Move To Temp. Area: • Containers moved to a temporary storage area • Placed on hold. • Inspect Material: • Premix material is passed or failed. • Move To Rack: • New rack scanned.

  26. Process Layout – Silo Refill • Need a Refill?: • System decides what material based on expiry date. • Operator is guided by the scanner. • Scan A Bag: • The operator scans a bag OR Premix container. • Which Silo: • The scanner informs the operator which silo to go to. • Operator moves to the required silo. • Scan Silo: • Silo is scanned • System validates

  27. Process Layout – Making A Batch • Weigh Material • Material between tolerances. • Select Recipe • Operator selects recipe. • System checks for sufficient stock level in silo’s. • Verify Mix Bin • Certain recipes certain mix bins. • Mix bin scanned • System validates. • Trolley Move • Trolley has PC, scale and operator. • Moves to required silo. • Zero the scale • System validates that the scale is zero.

  28. Weigh Routine – Process Confidential • The materials and quantities used is confidential • As a result, we have censored some screen shots. • Screens are kept as simple as possible. • Interfacing is done using just 3 buttons. Process Layout – Receiving

  29. Weigh Routine – Cycle Start

  30. Weigh Routine – Select Recipe

  31. Weigh Routine – Selected Recipe With Silo Stock

  32. Weigh Routine – Scan The Required Mix Bin

  33. Weigh Routine- Display The Current Recipe

  34. Weigh Routine- Interface To PLC AND Trolley Move

  35. Weigh Routine – Zero The Scale

  36. Weigh Routine – Weigh The Material

  37. Weigh Routine – Weigh The Material

  38. Introduction Project Solution Agenda Benefits Considerations Summary

  39. Benefits / Goals Achieved Automatic system Greatly reduces operator error. The system guides the operator. Warehouse management system Provides instant current stock levels. Know where each bag is and how much is left. Less material loss due to material expiry. Easier operation Wireless scanner prompts. Screen prompts. Button interface.

  40. Benefits / Goals Achieved Mixing Benefits: Prevent wrong material being added. Prevent incorrect amounts being added. Reduce scrap. Traceability: The ability to trace from supplier raw material batch to end product. The ability to trace from end product back to supplier raw material batch. Technology: Replaced obsolete technology.

  41. Introduction Project Solution Agenda Benefits Considerations Summary

  42. Lessons Learned – Specifications We spent plenty of time on the specification.It is worth the effort. We met with IT, Production and Process.We should have spoken more to “Joe”

  43. Lessons Learned – Structure

  44. Lessons Learned – Knowledge / Tools • We did not deliver the project on time. • The training was received about 3 years before the project. It was forgotten. • There was a version change. • The .net SQL functions were difficult to use. • The Wonderware SQL objects were released months after the project started.

  45. Lessons Learned – Summary Specifications. Programmer to meet with Joe if possible. Have the tools and the knowledge to do the project.

  46. Introduction Project Solution Agenda Benefits Considerations Summary

  47. Summary • Re engineered an old application to current technology. • Based on ArchestrA technology. • Created customised objects for the clients requirements. • Used ArchestrA SQL objects extensively.

  48. End Thank you for attending. Any questions or comments?

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