Software Suite Aides Automation

Today's ever-changing and expanding world of manufacturing demands not only timeliness, but lightning speed. Automation has helped companies to increase productivity by streamlining their processes and allowing for less hands-on operator-interaction, thereby decreasing the probability of human error.

"What is just now being embraced in the supply chain is the collection of data and the transformation of that into information that allows the supplier to quickly identify bottlenecks in the production system well before it becomes a critical issue for the product delivery schedule," says Tim Shafer, director of Aerospace Center of Competence at Siemens.

To further benefit the industry and improve automation, Siemens has introduced a software suite called Motion Control Information System (MCIS) that consists of software modules for production machines. These modules support multiple functionalities, including production data management (MDA/PMT/PDA); NC program management (DNC); tool management (TDI); maintenance management (TPM); service management (RCS); and computer interfacing (RPC).

The individual blocks are modular and perfectly matched. This setup allows for easy expansion and a customized fit to any production environment, regardless of size or shape. The suite is compatible with international standards.

MCIS optimizes production and increases productivity by reducing setup times and machine downtimes. It simplifies fault analysis and allows fast, easy integration of production machines. The software suite ensures that the production process is problem free and based on the most up-todate information. MCIS grants access to all relevant data regardless of the operator's location, and modules are available with Web-integrated operator interface for trouble-free coordination of planning, scheduling, and implementation.

Understanding Modules

Production Data Management (MDA/PMT/PDA) – the "MDA Function Package" The MDA Function Package is for machine related data and information; part-related data and information; and order-related data and information.

Machine Data Acquisition (MDA) acquires machine data and machine states, as well as part-specific counters, automatically or manually. A wide array of functions enables flawless analysis and evaluations, and the hard facts and figures verify machine performance and plant parameters such as machining periods and capacity utilization.

Part Maintaining and Tracking (PMT) consists of machining results for mechanical production and assembly, and provides information for parts tracing. In Production Data Acquisition (PDA), setpoint data, such as production orders and feedback data, are exchanged between an ERP system and the production environment. Access to the latest information allows for quick and easy intervention in the production process.

"We have provided full factory integration of the data that connects the shop floor data up to the manufacturing execution system, their maintenance system and even their ERP system," Shafer says.

Direct Numerical Control

The Direct Numerical Control (DNC) cell enables integrated networking of CNC machines. For example, an NC programmer can supply the Siemens SINUMERIK 810D/840Di/840D control with NC programs, therefore taking a considerable load off of production employees.

"MCIS can run on a Siemens 840D control and it becomes a client software, and you have a server software running up on the place network, and it's a seamless way for this MCIS management software to collect data off of the machines on the shop floor," Shafer explains. "MCIS can also collect data from non-Siemens equipment, so it's not a product that only plays in a Siemens factory, but it works in all factories."

The DNC function is user-friendly, and the generated or modified NC data are backed up and archived. The cell is also available in different versions. The DNC Cell is for small production areas, for which a standard PC with network card and serial interface is needed. The CNC Plant, a plant-wide server solution, is better for a large number of CNC machines or several production areas with one another.

MDA offers efficient and modular software packages for managing data from the planning to the production phase.

Tool Data Information (TDI)

The Tool Data Information (TDI) cell can be used with individual machines, flexible transfer lines, or an entire machine park – giving access to all tool data anywhere, any time. An Explorer structure grants user-friendly access to provide a comprehensive detailed overview of tool data for the proper units and tool magazines. The overview gives a list of components from which to choose, with filters to search for specific tools.

The TDI function matches the machine magazine to the list of tools required to produce the part, and results can be transferred to post-processing systems such as tool setting stations or tool management systems. TDI also allows operators to transfer, temporarily store, or forward tool data by means of network or code carrier during both loading and unloading. The main objective of TDI is a closed tool data cycle with as few manual entries as possible.

Total Productive Maintenance (TPM)

The Total Productive Maintenance (TPM) function makes production much less vulnerable to faults by reminding personnel of required maintenance well in advance through an early warning system. The permanently visible traffic signal indicates a pending maintenance task.

TPM works with individual or series machines, master controls, operator panels for transfer lines or the PC in the maintenance department. It is integrated in open SINUMERIK 810D/840Di/840D controls, and enables maintenance on a time-dependent basis as well as in conjunction with freely-configurable PLC states.

The user-friendly characteristics of TPM include the ability to display two documents for each maintenance task at the touch of a button to provide details about the location of the module and the required maintenance. A second-language option is available with one click, and it's possible to configure the maintenance job in MS Excel, making it easy to supplement the directives provided by the machine manufacturer. If the machine is networked, the data can be used universally as well as locally.

More Modules

The MCIS @Event module allows problems and defects to be analyzed and diagnosed from worldwide locations around the clock. This reduces expensive calls and machine downtime, as well as the need for a mechanic to be on-site to fix the problem.

When necessary, the MCIS @Event module sends alarmspecific and recipient-specific messages or emails to an RCS Host and RCS View service management module, making it possible for the authorized service team to make a correct diagnosis.

RPC SINUMERIK is for interfacing the SINUMERIK 810D/840Di/840D control with production control systems. Important CNC data can be interchanged over a defined, open communication interface. Existing systems using current programming capacity are able to be integrated as well.

Faults in your production operation, such as unplanned machine downtime, can be kept to a minimum through consistent use of TPM.

The MCIS Advantage

"The biggest advantage of MCIS is that it's plug-and-play with Siemens controls," Shafer says. "It really takes no configuration. It really is one piece of software here, one piece of software there. It's a low-cost solution to collect data on Siemens CNC controls."

The MCIS software suite is designed specifically to collect the data from Siemens automation equipment, in particular the CNC world, to create an efficient production plan and increase output.