Locally developed production and downtime capturing solution

November 2003 Data Acquisition & Telemetry

AMR Automations was approached by Appletiser to supply them with a solution to enable the operators to log the production details directly in J.D. Edwards. As the company performs nightly backup runs, a separate, full-time server was needed in the plant. Production and stoppages had to be captured and synchronised with the entries.

Two applications written in Delphi:

* A logger application runs as a Windows service on the plant server. It reads the counter values from the Siemens PLC and logs the runtime and stoppages to the Microsoft SQL Server. It also displays the plant efficiencies to an overhead display.

* A downtime capturing application runs on Siemens touch screens, where the operator selects the downtime reason from dropdown menus. The operator can also capture the reject counts from the check equipment. The application calculates and formats the entered data before writing it to the MS SQL Database.

At intervals, the J.D. Edwards system loads new work orders and downtime reasons to the MS SQL database and collects all the production and stoppages information.

The downtime application has the following benefits:

* Recorded production data is accurate, as bottle and can counters are used at the fillers.

* Shift and works order totals are automatically calculated.

* Data is captured during shift and is immediately available.

* Job cards are automatically created in J.D. Edwards for machine breakdowns.

* Operator can view current and previous shift production statistics.

* Operator can view product and packaging specifications as Web pages from the company website.

* The same source of data is used by employees throughout the company (view only).

The maintenance personnel can also view machine events for faultfinding purposes. Efficiencies are calculated by the logger application and displayed on the efficiencies tab and also on the overhead display. The operator can select downtime from the following:

* Shift change - only option on shift change.

* Works order change - select new works order.

* Unplanned stop - breakdowns: mechanical/electrical.

* Planned stop - maintenance, etc.

* Allowed stop - meetings, etc.

For more information contact Henny Keyzer, AMR Automations, 021 534 0838, [email protected] or www.amr.co.za

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