Line Management System

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The Line Management System

The Schubert line management system is software for a packaging line which can be installed on a computer, in one of the machines of the line or in an IT room.

With its client-server architecture, the line management system is available to the operators of a line on the touch operator control panel.

Any desired packaging and productions machines can be connected to the line management system. Communication between the machines and the line management system is carried out via Ethernet, OPC and OMAC states.

OPC is an industry standard that describes how data are exchanged between machine control systems and higher-level computers. The OMAC states define the operating states of machines (e.g. production or fault) and therefore specify which data are to be transferred.

The line management system provides the following functions:

• Communication with a higher-level MES or ERP system
• Communication with machine control systems
• Communication with devices, e.g. .labelers, printers cameras or checkweighers
• Archiving and display of camera and scanner images
• User management and audit trail in accordance with CFR 21 Part 11
• Order management for creating and processing orders
• Transfer of parameters and data to machines and devices when starting an order
• Display of machine states
• Display of errors, warnings and current production data
• Display of current OEE (Overall Equipment Effectiveness) data of the line and of the individual machines
• Archiving of a batch log following completion of an order
• Language selection for the user

Figure 4 shows the line overview.

Leitstand_E

Figure 4: Line overview

The operating states of the machines (OMAC states) such as "Production", "Fault" or "Waiting for other machine" are shown in color.

OEE (Overall Equipment Effectiveness)

The OEE indicator of the line management system shows how well the line or the individual machines of the line are operating. Figure 5 explains how the OEE is determined.

Figure 5  

An OEE of 100 percent means that the possible production time has been used optimally. However, due to production losses no line can achieve this in practice.

A distinction is made between types of production losses

Availability losses:
Machine downtimes due to major faults which last longer than 5 minutes, for example component failures, longer stops by the operator, cleaning phases, etc.

Output losses:
Short machine downtimes (shorter than 5 minutes) or losses due to slowly operating machines.

Quality losses:
Losses due to rejected, bad products. This includes, for example, products which are rejected at a checkweigher or products which are not picked up by a picker line.

The following three sub-indicators result from the loss data specified above (in percent, see Figure 5):

The OEE is calculated by multiplying the 3 sub-indicators:

Formel_2

If the OEE value of a packaging line reaches the 80 % mark, this is generally referred to as a functioning line. At the same time, this value shows that 20 percent more output would have been possible in the available time.

Figure 6 shows the OEE screen of the line management system and Figure 7 the screen with the quality losses.

Figure 6 shows the OEE screen of the line management system and Figure 7 the screen with the quality losses.

OEE

Figure 6: Overall Equipment Effectiveness

qualitaetsverluste

Figure 7: Overview of rejected products

The OEE data of the the order being processed can be viewed using the line management system. The line cockpit is required for evaluating the data from orders run previously.