For today, I had the idea that it might be interesting to do a revival of an old project that I did a decade ago. I think it is interesting not only because of the project itself, but also because of the technology used to prepare the presentation. It feels like a century, even though we are talking about 10 years ago. Talking about avatars presenting a project online, I find it difficult even today, let alone back then.
Connecting all plastic molding presses and automatic assembly machines for molded or extruded components is the project in question.
The project was designed to minimize the involvement of production personnel with the ERP. In fact, once the master data was correctly configured in the ERP system, it was sufficient to enter the number of pieces per box and define the locations (accessible only to the quality department personnel) for the pouring of the components during the completion of a box. The automation included the installation of a scale at the end of each molding line, connected to the company's network, which could be used to check any weight variation. By knowing the average unit weight and the number of pieces per box, it was possible to know whether the box had reached the expected quantity.
The system provided for the declaration of the start of a new production order through the use of a special application on a mobile device. By reading a barcode on the order and on each individual production line, the system was able to link the scales, the printer and the production line, so that each time there was a change in weight, it was possible to instruct the system to print a new label and at the same time to pour the components into the appropriate place. Of course, consumption also took place automatically (backlash). Whenever the raw materials operators filled the silos, they were required to declare the items in the system, indicating their quantity and batch.
The same was true for the lines on which the automatic assembly machines were located. These were connected to the system via their PLCs, some of which were very old and did not have Ethernet ports. They were connected via RS232/485 to Wi-Fi converters. Performance was very good considering the average cycle time was less than one second.
Both types of equipment (presses and assembly machines) were able to send all the data to the system, in addition to counting parts, both production data, cycle times/parts produced and quality data, communicating rejected parts, reason for rejection, etc. etc.
I believe that the technologies chosen were the right ones. Considering that, the project was implemented in 2013 and is still ongoing.
Below is the video of the project presentation to the Board of Directors. I am aware that the description of the project is sketchy. My intention is to arouse your curiosity and open a table for discussion.
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