How you model a production line in the Production Model will be dependent upon the following factors:
- Type of Line (single machine, simple contiguous process, parallel processes, shared cells across lines, complex sub-lines, primary cells, cell groups within cell groups)
- Line Downtime Determination (When is the line considered to be down? All cells, any cells, particular cell)
- How production is scheduled (if parts of a line are scheduled separately from each other, then they may be considered two separate lines)
- Interface to cell (if a cell has no real-time accessible interface, its state and output may be combined with an adjacent cell)
The importance of modelling the line correctly based on the above factors will drive the usability and usefulness of any production data or metrics generated. If a production line of many cells is modeled simply as a single cell, then features provided by the OEE module such as downtime detection methods, cell cycle time, aggregation of machine states by cell, and visual aspects of the OEE components such as the OEE Time chart will all be diminished. Forcing management to schedule production runs on multiple lines that they did not do prior to the OEE implementation, as well as only allowing a single scheduled run on a a set of cells where traditionally multiple schedules existed are signs that the model may not be correct.
In modelling the Line, you will create a Production Model in the Designer that:
- Defines your Enterprises Sites, Areas, Lines and Cells
- Sets up Line Downtime Detection Method to define how line downtime is determined
- Connects states and counts from the equipment PLC interface to the production model
What Is The Production Model?
When any of the core MES modules (OEE, SPC, Recipe, T&T) are installed, the Production Model is added to the Global project resources in the Project Browser window of the Ignition Designer. The Production Model allows you to define your manufacturing process in a tree view form and provides an organized way to configure, control, and analyze your manufacturing activities. It provides the foundation on which the MES modules are built.
Below are the different types of Production Items that can be added to the production model.
|Main||Production model can be enabled and disabled here. Sites can be set licensed in the OEE Downtime 2.0 tab.||All|
|Enterprise||The enterprise is the highest level of the production model and typically represents a manufacturing company. You can rename the Enterprise production item to your company's name. You can only have one Enterprise item in the Production Model.||All|
|Site||A site is a fixed geographical production location that is part of an enterprise. Separating your enterprise into multiple production sites allows for comparing OEE, downtime and production information between them.||All|
|Area||An area is a physical or logical grouping of production lines.||All|
|Line||A line represents a stand-alone machine or a collection of multiple cells and/or cell groups that work together to perform a sequence of process steps. Typically, the product flows from one cell or cell group to the next in sequence until the product, or sub assembly, being produced is complete. Understanding how production execution is managed will help in determining whether cells should be grouped into a line or be considered stand-alone equipment as lines themselves.||All|
|Location||A location item is the place where a sample is collected. This can be placed under an area or a line.||SPC|
|Cell Group||A cell group contains two or more cells. Typically, these cells occur at the same time in the sequence of the line instead of one after another, causing the cell group to act as a single sub process or step within the production.||All|
|Cell||The cell is a single machine, sub process or step required in the manufacture of a product. The product may be a hard product such as used in packaging, adding liquid or powder, etc. Packaging machines are a common example, but a cell applies to processes also.||All|
|Storage Zone||A storage area such as a warehouse.||T&T|
|Storage Unit||A storage unit located inside of a storage zone. For example, you may have a warehouse with bay 1 to 5.||T&T|
Production Item General Settings
The general settings are accessed by selecting the desired production item and selecting the General tab.
By default, the production item is enabled. It can be disabled by un-checking the Enabled setting and saving the project. This will stop the track and trace, OEE, downtime, SPC, recipe and scheduling modules from using the area and any other production items that are underneath it.
|Description||This is an optional description and is just for your reference. |