PLS Production Control

              PLS is the central control and information system for discrete manufacturing companies. Bridging the gap between the ERP system and local machine controllers (PLC), PLS provides an integrated data exchange, supports the production scheduling and enables continuous and transparent production flows. Both production managers and operators are informed about the production results, the actual order status and machine conditions and may react quickly in case of deviations.

            For quality control, all production and quality data are stored in PLS and are the sources for various analysis and statistics.

             Usually, PLS receives production orders from the ERP system in advance. The orders may be sorted by production relevant parameters and completion dates. During order processing, PLS records the time and produced quantity of each production step as well as actual stocks and quality data. The production results are reported to the ERP system.

 Functional modules:                                                                                            

            · Production order management

            · Order scheduling

            · Order and material tracking

            · Stock keeping

            · Process visualization

            · Tools management

            · Quality control

            · Reporting and statistics

  QIS Quality Control

      QIS is an online quality control system using production and quality data as well as test results from the laboratory. The main target is to inform the operators immediately if defects are detected or tolerances are violated. The operators may interfere or adapt the process, search for alternative orders or prepare detailed examinations on the concerned material. Thus the waste of production time and material is decreased substantially.

      QIS is designed for various industrial sectors and covers the chemical, process, surface, dimension and visual inspection quality requirements of the material. The quality instructions and rules for each product or customer order are defined by the quality engineer in the QIS or received from the ERP system.

      Quality basic data may be collected automatically from any computer, measurement device or logic controller as well as acquired by operator’s input. The data are measured values (like temperature or pressure), plant conditions (like cooling on/off), test and inspection results. Depending on the customer specific instructions, basic data may be combined and checked against the tolerance ranges.

      The quality basic or result data are allocated to the produced material unit like heat, lot or piece. For long products like coils or wire, QIS allocates the quality data to each position of the piece for a further decision about critical sections.

      The quality data are stored in a quality archive for certifications and statistics.

RSM Roll Shop Management

       Rolls. roll sets and auxiliary equipment are main and cost intensive tools in rolling mills. The quantity and variety of rolls depends on the product range and the characteristic lot sizes.

       The quality of used rolls influences directly the product quality as well as the efficiency and safety of the rolling process. Set up and roll change times may be decreased by optimised arrangements and scheduling.

       RSM supports the purchasing and stock keeping of rolls as well as the management of the roll and grinding shop. Various reports for roll performances, durability and inventory are provided.

        RSM tracks each roll and roll set from delivery to the plant to the point where they become unusable and are scrapped. The roll history records operation times and locations (roll stand), produced materials and overhauling operations.