English (UK) 
Česky (CS) Deployment of MES solution in Kasko was motivated mainly by the need to obtain accurate and reliable production information to support in evaluating production efficiency, creating production plans and calculating new projects. The project was designed and implemented from the outset to cover the entire molding shop and related assemblies, with the main emphasis on quality data collection, operator calls with an escalation system, and production visualization.
Key project attributes
| Customer | Kasko, s.r.o. | |
| Used solution |
MES PHARIS | as phar as it goes | |
| Supplier | UNIS, a.s. | Control & Information Systems | |
| ERP |  |
HELIOS |
| Production type |
|
Discrete |
| Manufacturing areas |
|
Production monitoring and control, Maintenance management, Quality |
| Manufacturing classification |
|
Automotive, Plastic & Rubber |
| Integration | |
|
| Essential functionalities |
|
Control & Monitoring of Production, Paperless Production, Production Traceability, Nonconforming Production Management, Production Quality Control, Process Data, Maintenance, Machine Data Collection, Performance Analysis, Production Visualization |
| Year of realization | 2011 |
Main areas supported by MES / MOM system
Production management and monitoring
Production monitoring is based on the system of registration of operators for setting and production by the start-stop method, which assists the system of automated data collection of the machine operation to ensure high quality of such collected information. This system was supported by equipping each workplace with its own production terminal with touch screen and also with a comprehensive visualization system - see the chapter Production Visualization.
Integration
Kasko accepts orders, generates work orders and plans production in the ERP system. Thus, already created and scheduled work orders from the ERP system are sent into the PHARIS system, then they are released for production. In addition to the transfer of work orders, persons, product definitions, materials, basic code lists such as downtime types, codes of nonconformities, the structure of production model, etc. MES, on the other hand, sends production registrations with data about duration, number of produced products, number of NOKs and downtimes to the ERP system.
Paperless Production
Thanks to the use of a separate production terminal at each workplace, it was possible to implement so-called paperless production, at least in the area of work instructions, packaging requirements and support for visual quality check of products. The documentation is primarily managed in the ERP system and it is transferred to the PHARIS system with a link to the objects of product definitions and operations. The operators then always have the latest version of the production documentation available at their workplace, precisely for the currently running production.
Data Collection
Data collection was a key topic for the project, both data collection from operators and automated data collection from machines. Specifically, for the collection of data from machines, the most important parameter collected was the production cycle of the machine, but it was equally required to achieve the collection of technological data on as many machines as possible.
Due to the diverse machine fleet, both in terms of machine age and manufacturers, several types of machine communication have been implemented.
For the oldest machines with the least readiness for communication, digital input cards were used to collect the machine's production cycle.
For slightly newer machines, the supplier chose a non-standard approach to data collection. This approach uses a machine interface designed to print a quality table while using a connected printer. However, instead of the printer, there are specially prepared converters, which are able to automatically transform the data into readable form for the MES system. It is an inexpensive solution for collecting data from the quality table (approx. 8 to 30 parameters). In Kasko, all print ports were connected to serial (RS232) or parallel (LPT) communications.
For the newest machines, the latest communication method via the Euromap 63 protocol was chosen. This method allows collection of all machine parameters as well as the upload and download of machine control programs.
Generally speaking, collecting the machine production cycle is absolutely essential for improvement of the quality of data collection from operators and the related methods of increasing efficiency. On the other hand, the collection of technological parameters (either through printer ports or standard Euromap 63 communication) is increasingly required in the field of automotive industry to document the conditions under which production was performed.
Data collection was a key topic for the project, both data collection from operators and automated data collection from machines. Specifically, for the collection of data from machines, the most important parameter collected was the production cycle of the machine, but it was equally required to achieve the collection of technological data on as many machines as possible.
Due to the diverse machine fleet, both in terms of machine age and manufacturers, several types of machine communication have been implemented.
For the oldest machines with the least readiness for communication, digital input cards were used to collect the machine's production cycle.
For slightly newer machines, the supplier chose a non-standard approach to data collection. This approach uses a machine interface designed to print a quality table while using a connected printer. However, instead of the printer, there are specially prepared converters, which are able to automatically transform the data into readable form for the MES system. It is an inexpensive solution for collecting data from the quality table (approx. 8 to 30 parameters). In Kasko, all print ports were connected to serial (RS232) or parallel (LPT) communications.
For the newest machines, the latest communication method via the Euromap 63 protocol was chosen. This method allows collection of all machine parameters as well as the upload and download of machine control programs.
Generally speaking, collecting the machine production cycle is absolutely essential for improvement of the quality of data collection from operators and the related methods of increasing efficiency. On the other hand, the collection of technological parameters (either through printer ports or standard Euromap 63 communication) is increasingly required in the field of automotive industry to document the conditions under which production was performed.
Tool Management
An injection mold is a crucial element in every molding shop. It is so important, that it is absolutely necessary to keep track about the position of the mold and the number of production cycles done on the mold. This information is collected via Tool Management module of the MES solution deployed in KASKO. More precisely, it reports each movement of the mold (placing the mold to a machine, mounting it on the machine, putting it in a warehouse, moving it in a tool shop for a repair or maintenance…). This reporting is done thanks to RFID chips placed directly on the mold and via RFID readers located on production terminals and mobile devices.
Furthermore, the MES system automatically starts counting the production cycles for the mold that is in the status "mounted on the machine", providing reliable predictive maintenance - see the chapter Maintenance.
Production Visualization
Kasko has decided to build operational management of production on the basis of information provided by visualization screens. The first necessary step was the installation of large-scale (160 cm) LCDs. They are visible from everywhere in the production hall, from setters’ workshop, master's office, maintenance workshop and from central granulate drying cabinet. In total there are 15 LCDs. Thanks to LCDs, Kasko built a very effective system of reporting of current events at individual workplaces to all key employees. Each group of workers got their own custom-built visualization screen. E.g. the screens for operators show the current status of work in progress, calls from machines, etc. The screen for setters shows the time until the next injection mold should be (un)mounted, or the calls from operators, who require setter’s presence at their workplace. Visualization screens dedicated to material preparation show the time until material exchange at each site.
The visualization screen module was delivered to the customer with a custom screen editor / builder, which allows the customer to adapt individual screens or create new layouts.
Maintenance
Maintenance module of MES system was deployed in Kasko with the intention to achieve smart alerting of upcoming mold and machine maintenance. This alerting is based on the real number of cycles counted on the machine. This maintenance module enables custom definition of conditions based on so called data tags. These tags represent the real number of production cycles of each machine.