Real Time Declaration of Production in Manufacturing Plant

barcode

Project Title: Real Time Declaration of manufacturing and assembly

Scope: Transmission, Hydraulic, Engine, & Aggregate Assembly

Brief about Real Time Declaration:

IT solutions for Real time declaration of the assembly of a part and its related aggregates in production. Production management also includes the capability to manage and change entity status as well as the control of the manual operations needed during production. This solution covers both primary and secondary production phases and is designed to be easily integrated with 3rd party systems such as SAP.

The real time declaration can be done by using SCADA or Bar code system which later on sync with the SAP server at particular intervals which is given to the server.

SCADA:

SCADA stands for Supervisory Control And Data Acquisition which generally refers to Industrial Control Systems (ICS). This system helps to reduce the manual intervention and to maintain the quality standards as per the requirement.

SCADA system has the complete programming in “C” Language

A SCADA system usually consists of the following subsystems:

  • A human–machine interface or HMI is the apparatus or device which presents process data to a human operator, and through this, the human operator monitors and controls the process.
  • A supervisory (computer) system, gathering (acquiring) data on the process and sending commands (control) to the process.
  • Remote terminal units (RTUs) connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system.
  • Programmable logic controller (PLCs) used as field devices because they are more economical, versatile, flexible, and configurable than special-purpose RTUs.
  • Communication infrastructure connecting the supervisory system to the remote terminal units.
    Various process and analytical instrumentation.

HMI – Human Machine Interface usually collects the data from the Supervisor (Computer) and passes on the data to the operator and automatically programs the apparatus which reduces the human intervention and helps to maintain the quality requirements. After the completion of the program the data will be sent to RTU (Remote Terminal Units) which will match the actual and the stored data.

Barcode System:

Everyone is having an apt knowledge about the barcodes which is available in almost all the products available in market, right from Consumables, Foods, and now a days on the vegetables sold in supermarkets.

The barcode system can be implemented in the assembly line in any manufacturing industry.

At the starting of the line we will place a barcode on the product which will run through the line. The barcode will have the data of the variant, model and finished part number. Each and every apparatus on the line will have the barcode reader which will read the barcode and program automatically with the requirement of the quality standards. Even we can program the engine and the transmission testing equipment through barcode and the RFID will read the product at the end and will help in the right quality and the complete data on real time basis.

REAL TIME DECLARATION IN THE ERP

As the process completes either through SCADA or Barcodes then the data will be converted through OPC (Open Process Control) servers. This software application acts as an API (Application Programming Interface) or a Protocol Server.

The data as soon as it enters the ERP system it will automatically helps the back-flushing of the components.

BENEFITS OF REAL TIME DECLARATION

  • Reduce non-added value time
  • Reduce human error during production
  • Reduce manual operation during production
  • Automate production execution
  • Increase production data visibility
  • Improve business decision making
  • Facilitate procedures standardization
  • Enable real-time monitoring of productivity, yields and throughput
  • Eliminate the need for the partners to declare material production/consumption in the ERP systems

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