OSCo Production Data Collection and analysis (PDC/MDC) in the context of MES

• Time synchronous and mix-up free collection of all production data
• Reliable data timeliness and information rapidness
• Confirmation at the point of origin
• Reduction of data collection effort, errors, time and costs
• Goods identification across all business processes according to equal procedures
• Product back-tracing across all production steps
• Direct updating of the fine planning
• User-friendly dialog control with touch screens (OSCo-TouchIN)
• Fast logon and clear identification of users
• Support of the OPC data transfer
• Integration of PDC notifications and DNC program administration
• Centralized in SAP ERP and / or decentralized on SAP WebAs

The OSCo production data collection is composed of modules and can be acquired as a basic module or in full configuration level.

Basic module

The basic module comprehends the possibility of individual logon „on demand“ on pre-defined functions, which can be made dependant of the user and the used screen. Functions can then be SAP standard transactions, self developed functions in the SAP system or a multiple choice on a touch screen with branching possibility to the selected function. The touch screen can also be set as a permanent dialog (see OSCo-TouchIN).

If desired, personal identifications can be derived in different ways, e.g. using corresponding readers. These transfer via magnetic card, chip or OSCo-PIN a personal recognition to the function suited for a robust production area.

You will find a simulation of the OSCo-TouchIN on www.osco.de

The basic module also comprehends the option to use the touch-in functions on a local, autonomous plant server (SAP WebAS). With this, production-related dialogs become independent of the availability of a central SAP ERP.

If the SAP WebAS is used in the OSCo production data collection, data transmissions to the SAP WebAS can be initialized at the same time out of the PP order administration. Then in the SAP WebAS the necessary dataset for plausibility checks is build up redundantly.

Full configuration level

Building on this basic module, multiple further functions can be integrated until a complete production data collection, which can also if desired cover the issues of the classical plant data collection (PDC).

OSCo understands about production data collection in full configuration level the entirety of all data collections and analysis out of the production, including PDC, MDC, labour time and quality data directly at the point of origin and in real-time. The OSCo production data collection is a modular and pre-configured solution integrated in SAP, customizable if desired to individual factory agreements and requirements.

The solution increases the transparency in the production, enables prompt and targeted reactions against plan variances or malfunctions and secures thereby a high quality when realizing customer orders. The timeliness of SAP ERP respectively SAP APO (Advanced Planner and Optimizer) is assured optimally with this real-time method.

Freely configurable touch-screen dialogs for terminals or single work centers with OSCo-TouchIN (SAP-GUI front-ends) facilitate the data collections. The dialogs make it possible to logon and logoff to the work center, to start and finish work orders and operations as well as to make notifications, for example about goods receipts and issue or interruptions (with reasons for malfunction).

Notification types (selection):

• Time and quantities related to the order or operation

• Attendance time in general or related to the work center

• Material flow: goods receipt and consumption, reservations, work in progress, packaging, warehouse, weighing

• Malfunctions with reasons for interruptions

• Transfer postings related to the order or production storage location

• Machine data

• Maintenance

• Quality management

The logon and logoff to the touch screen can be done with magnetic cards, RFID tags or with a pin. It is especially fast using the OSCo-Pin. It has only to be plugged into a corresponding reader to open personnel related entry masks, derived from the respective mini HR master record, in a desired language.

With permanent or temporary verifications (barcode, RFID) at the physical object, goods can already be identified clearly at the supplier, e.g. as batches, handling units or storage units, and tracked across the supply chain. All data (e.g. charges, manufacturing location, personnel) are saved in the OSCo Table of Objects and are anytime at disposal up-to-date and error-free, also for a comprehensive reporting. A back-tracing of the objects in the material flow is thereby secured across all production steps.

If it is necessary to label new goods, the OSCo Form Designer can be used to realize dynamically the derivation of the label content.

References

• Teijin Monofilament, plant in Bobingen
• Wuppermann Group, plants in Herbolzheim, Altmünster, Burgbernheim and Holysov
• Walter AG, plant in Münsingen
• R. STAHL, plant in Waldenburg
• Demag Cranes, plant in Düsseldorf
• BorgWarner Turbo Systems, plant in Kirchheimbolanden