ARBURG host computer system (ALS)

Focus

ARBURG host computer

system (ALS)

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At a glance

Practical productionmanagement: Starting with the simple connection of I/O modules, the modular ALS offers all options for an efficient production organisation.

With the ARBURG host computer sys-tem (ALS), you have at your disposal a standard-setting high-performance, modular fine-planning tool for your injection moulding production. Tried and proven in practice, this Manufactur-ing Execution System (MES) provides all the features required in a modern, efficient and cost-effective production organisation. With hundreds of systems already installed, ARBURG has a wealth of experience. This experience flows into the continuous advancement of ALS on an ongoing basis. Here also, “Made by ARBURG – Made in Germany” stands for quality and our familiar futureproof technology.

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ALS is the central tool for the reliable and cost-effective organisation of your injection moulding production. The possibilities for integrating your machine fleet are virtually unlimited: from the simple connection with I/O modules via standardised interfaces for all makes of injection moulding machine through to the host computer interface for ALLROUNDERs. A wide range of modules (overview on the next page) which can be combined as required allow you to perform each individual task with ease. Because your chosen configuration can be expanded at any time, you can be confident of meeting future demands.

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An efficient information management sys-tem continuously provides you with current online information on your production – centrally and worldwide. Feedback and key figures relating to machines, ongoing or-ders, shifts and production quality are con-tinuously available. This means maximum transparency, wherever, whenever and however you need it: on PC workstations, info screens in production or on smart-phones and tablets. This active information therefore permits you to analyse and make decisions at all times. Set-up operations, as well as mould and machine maintenance can be optimally performed. This is also supported by the central management of all setting data.

Immediate reliable information: retrieve key figures anywhere and on any end devices.

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Fine lannin timum utilisati n a ailable es u es

Automatic archiving: effortless, reliable docu-mentati n

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e i e ula ities in e ti n m uldin -duction, such as machines of different ca-pacities or defective cavities, make reliable detailed planning too complex for conven-ti nal nt l stati ns u need ALS to enable you to complete such tas s inte a ti ely n t e basis nline data, you can optimise batch running times, reduce start-up processes and also set-up times and downtimes when changing or-de s i e ma ine a a ity utilisati n coupled with higher production and prod-u t prod-uality en an es deli e y eliability prod-u use an e fi ient and st e e ti e du -tion organisa-tion with which you achieve si nifi ant time and st sa in s

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With ALS, you can dispense with the time-consuming manual recording of your

ma-ine and e atin data nt y e s a e t e e e eliably e ented n additi n t highly reliable information, you have more time for other value-adding activities such as du ti n lannin el s y u identify potential for improvement and

a y ut ta eted timisati ns n addi-ti nal benefit t e naddi-tinu us and l n term documentation makes audits and

e tifi ati ns substantially easie

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We offer you individual consulting to help you devise the ALS system solution to meet y u needs nstallati n and su t du in the on-site implementation through to the comprehensive training of your employees and administrators are provided as a matter

u se is is t e nly ay t a ie e a simple, trouble-free system implementation, immediately ensuring high acceptance in the company along with the required added

alue is means t at y u in estment ays off from the start and yields the fastest pos-sible etu n

Easy implementation: rapid system introduction

t u essi nal su t

15 minutes of data acquisition per machine/day

Manual recording not required

3 minutes less downtime time per machine/day

Faults immediately identifiable

6 minutes shorter set-up time per order

Online transmission of data records

Business example:

Injection moulding production with 20 machines

Production time 250 h 250 h Working time 1,250 h 250 h

At a glance

Information centre

003/10 Base ALS database, machine and

operating data recording, production overview, mould management

613/01, 613/05 Clients for PC

worksta-tions and laptops, etc.

610/20, 610/21 Mobile ALS for handheld

units and smartphones

613/20, 613/21 Terminal for order

messages or mould provision

610/22 Info for individual info screens in

production

611/08 Web I/O condition Recording of

ambient conditions

611/09 Web I/O alarms Output devices

for central alarm signalling

612/xx Machine interfaces Drivers for

different manufacturers of injection moulding machines and logs

611/1x ALLROUNDER interfaces

Connection of ALLROUNDERs as from year of construction 1984

612/21 Device Connector Data recording

of systems via network

611/0x I/O modules Connection of any

machines and workstations via signals

Documentation/archiving 610/01 Reports Order, item and

machine-based evaluations, data export

610/19 Events Long-term

archiv-ing of event data (alarms, downtimes, etc.) in separate database

610/08 Progression Display of events such

as machine status, shift change and cavity change in chronological sequence

610/15 Production log Permanent

archiving of process parameters

610/10 Set-up log Daily back-up of

SELOGICA set-up log

610/12 Documents Linking of documents

with orders, programs, maintenance and

much more. Production/resource management 610/03 Orders Order planning, graphic

planning chart, schedule monitoring

610/05 ERP interface Linking with PPS/ERP,

adoption of orders, ongoing feedback

610/18 HYDRA interface Data exchange

with HYDRA (MPDV)

610/16 Production variants Material

planning of alternative moulds, taking account of performance of machines

Practical productionmanagement: The individual modules of the ALS can be freely combined and eliminate the need for separate programs e.g. for maintenance.

Set-up log

610/10

Documents

610/12

Maintenance

610/11

Groupwar

e

610/13

I/O-Modules

611/0x

Device

Connector

612/21

ALLROUNDER

interfaces

611/1x

610/17 Resource conflict Monitoring

of moulds for double assignment

610/23 Batch Documentation of batch

changes in order logging

610/13 Groupware E-mail or SMS in the

event of faults or maintenance, cyclical reports

610/11 Maintenance Maintenance plans,

monitoring, due dates, documentation

Quality assurance

610/02 Programs Program management

and transfer between machine and ALS

610/09 Programs plus Parameter lists,

full text search, program comparison

610/04 Quality Statistical process control

(SPC) via actual process values, process sam-ple, interface to quality assurance systems

Info

610/22

Mobile

610/20,

610/21

Programs

610/02

Quality

610/04

Programs plus

610/09

Web-I/O

condition

611/08

Web-I/O

alarms

611/09

Clients

613/01,

613/05

Batch

610/23

Production log

610/15

Reports

610/01

Events

610/19

Progr

ession

610/08

Groupwar

e

Resour

ce

conflict

610/17

Production

variants

610/16

Orders

610/03

ERP

Interface

610/05

MES

interface

610/18

Base

003/10

ALLROUNDER

interfaces

Machine

interfaces

612/xx

Terminal

613/20,

613/21

Powerful information centre

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For ARBURG, “all” really means all! Regard-less of the manufacturer, year of construc-tion and producconstruc-tion process, all the injec-tion moulding machines and producinjec-tion systems can be integrated in the high- performance ALS information centre. The following options are available: • Multi-function terminals for older

machines and manual workstations • I/O modules for simple connection

of any machines and systems

• Standardised interfaces for all makes of injection moulding machine

• Host computer interface for ALLROUNDERs

The SELOGICA machine control system interacts optimally with ALS, in particular when functions such as direct access to screen pages, direct recording of fault causes, exchange of setting data or com-parison with the order list are involved.

Flexible and rapid response to pro-duction requirements is the order of the day. The powerful ARBURG host computer system (ALS) provides you with real-time access to your produc-tion data, worldwide across all your locations, even enabling remote main-tenance. A direct flow of information is ensured through connection to your company-wide production planning system (PPS) or enterprise resource planning system (ERP). You benefit from complete vertical integration from the machine through to material planning, purchasing and sales.

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Record data everywhere: multi-function terminals also integrate manual workstations.

ALS ERP/PPS

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ALS enables the central management of part, mould and material master data. This enables you to perform real-time produc-tion planning down to the minute through the online recording of order statuses, ma-chine states, process parameters and alarm messages. With this precise information, you are able to quickly and flexibly respond to the constantly changing requirements. Optimum cost-efficiency in production is

thus ensured throughout. The combination of machine and production data acquisition (MDA and PDA) allows you make target/ac-tual comparisons, to optimise processes and reduce set-up times. All occurring events are immediately registered via continuous status monitoring.

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Constantly up-to-date production data ben-efits your planning system. Order data is adopted by the planning system, feedback on order progress is provided by ALS. You can choose where, when, how and which information is made available to you: from the smartphone to the flatscreen. This re-sults in significantly fewer internal queries regarding the status of production orders.

Central data acquisition

Comprehensive

data provision

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Integrating all machines

Preventive quality assurance

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ALS facilitates the fast retrieval of the rele-vant data for a certain production combina-tion, such as machine/peripheral/mould/ma-terial. As well as the setting data, setting logs and the corresponding screen pages can be archived simply and reliably.

Furthermore, the creation of parameter overviews from archived setting data is just as quick and easy as the direct comparison between two data records with detailed in-dication of potential differences. Documen-tation of the settings can thus easily be achieved during a batch or a running order.

Know-how is virtually priceless. Conse-quently, you should treat your setting data with the greatest of care. The ARBURG host computer system (ALS) provides you with secure collection and archiving of your important data. Only the most recent, optimised and approved change status reaches your machine, the possibility of outdated setting data being used is excluded. Diskettes and memory cards are a thing of the past. You receive fully repro-ducible product quality and minimise complaints – an excellent prerequisite for successful audits and certifications.

Convenient archiving of setting data

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Central access: optimised and approved setting data.

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product quality

The monitoring and documentation of changes in the production process with the recording of the actual process values makes the quality of your production train particular when functions such asin particu-lar when functions such asceable. The prod-uct-specific management of reference val-ues and tolerance bands for the current actual values contributes towards

increased production and product quality. Warnings can be output with regard to im-minent quality deviations. You can then respond quickly and proactively, without having to interrupt production.

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The order-specific archiving of actual process values provides documented evidence of the quality of your production process.

Detailed long-term analyses, statistical evalu-ations and proof of process capability, for example according to ISO TS 16949, can be implemented. Furthermore, close networking with quality assurance systems is possible.

Active improvement of

product quality

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Verifiable process quality

Efficient production and resource management

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Your order planning prompts the provision of the necessary setting data, the relevant mould and the required material. The set-ting data is transmitted directly to the ma-chine when production of the order com-mences. You ensure a high degree of inte-gration, interaction and automation of your production facility while ensuring intelligent production.

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By planning your machine capacity down to the last minute via ALS, you achieve comprehensive time and cost savings: per-fect utilisation of available capacities, pre-cise information on the relevant manpower requirements, minimisation of set-up times and also the co-ordination of necessary in-terruptions in production – all made possi-ble by ALS. The irregular aspects of injec-tion moulding producinjec-tion such as family

The clearly structured order planning and monitoring via the ARBURG host computer system (ALS) enables efficient production management. A high degree of planning reliability is ensured by the direct assignment of orders to machines and by the formation of order queues in the plan table. The proactive fine planning and co-ordination of machine allocation, order situation, production deadlines and unit volumes as well as maintenance work lend transparency to even the most complex production requirements. You are able to man-age the available production resources reliably and with ease. For ARBURG, smooth, automatic data exchange with planning systems such as SAP is a matter of course.

Machine capacity planning

Reliable delivery

Maximisation of availability

Central order management

moulds, defective cavities, mould inserts, master moulds, additional peripherals or machines with different performance can be incorporated into the fine planning. Tar-geted information exchange also supports departments such as warehousing, mould making or service in organising their opera-tions.

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The current scheduling status at a glance: fast and specific order clarification with active display of bottlenecks and potential deadline issues means you can provide information on an ad-hoc basis. Counter-measures can be implemented in good time and production and delivery deadlines can be reliably met. This preventive processing of orders ensures a high degree of customer satisfaction.

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With ALS, you can centrally manage and document your maintenance orders for moulds, machines and peripherals. The continuous monitoring of due dates and automatic reminders for forthcoming work via SMS, e-mail or info screen protect you from unscheduled machine downtimes. In this way, you secure your production quality in the long term through preventive maintenance.

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Comprehensive documentation and archiving

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ALS offers you long-term documentation, reliable and with no effort on your part. Of production sequences with recording of all relevant events. Of order progression with documentation of all events during production of the order, including batch monitoring in the form of an order log. Of parameter changes with recording of all trends and developments in comparison with the specified setting data. These

meas-ures all render your production operations more transparent. ALS therefore provides you with an ideal basis for comprehensive complaints management and seamless quality documentation with regard to all your customers. You are ideally equipped for certifications according to GMP, FDA, ISO TS 16949 and ISO 9001.

Ensure ongoing production optimisa-tion through the continuous identi-fication of potential improvements. Well-founded information forms the basis for professional decisions. This well-founded information is provided by the ARBURG host computer system (ALS) – with all the important key data and statistics, you are always right up-to-date. The fact that the recorded data is presented in a clearly structured manner “at the touch of a button” makes ALS all the more attractive. A significant benefit is that the available data can also be used during the decision-making process relating to capital invest-ments. Knowledge has always been preferable to speculation.

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Well-founded information: data evaluation at the press of a button.

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Targeted analyses become child’s play. Whether the productivity of machines and moulds or the cost-effectiveness of orders and articles are under examination, the modular ALS modular production manage-ment system helps you complete this with a high degree of clarity. For this purpose, a large selection of predefined reports are available.

Moreover, data exchange for the further processing of recorded production data using standard software tools is of course always possible. This allows even highly specific evaluations to be made simply, quickly and reliably.

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ALS provides fast access to production- related documents, such as work instruc-tions, test schedules, parts lists and draw-ings. Through direct linking to master data, setting data and orders, the current availa-bility of documents and the absence of pa-perwork, you receive an efficient informa-tion management system. Comprehensive and always centrally available.

Continuous recording

of data

Targeted analysis

Central document

networking

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Application examples

Individual info screens: free selection from various widgets provides for on-site transparency.

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From smartphone through to large flatscreen in production: with ALS, you can configure customised info screens – browser-based and completely platform- independent. Depending on the location and purpose of use, any number of differ-ent info screens can be combined, e.g. for alarms as a machine control station, for increased reject rates as a quality chart or for orders as a production overview. In addition, a wide range of graphic design options allows you to present the collated information in your corporate design.

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ALS is the ideal tool to help you retrieve all important production data for your world-wide locations. A standard network connec-tion is all you need to be able access fault messages, downtime causes, production progress, key figures such as OEE, availabil-ity and qualavailabil-ity rate at the “touch of a but-ton”. And not only for ALLROUNDER injec-tion moulding machines, but for all produc-tion systems! However, remote access via ALS is also a useful service tool. Quick assis-tance from ARBURG Customer Service is therefore instantly available to you.

ALS offers you a wide variety of func-tions to enable you to implement your specific requirements for an efficient and economical production organisa-tion. Thanks to the flexible, modular concept, precise adaptation to differ-ent applications is comprehensively ensured. This may involve quantity recording, simple connection to I/O modules, detailed fine planning of available capacities or management of the mould store. And you can be sure of one thing: ALS considerably simplifies your data handling and allows you to optimise your production in a targeted manner, including time and cost saving.

Worldwide networking:

ALS is available in numerous languages.

ALS modules in use:

• Web I/O alarms • Info

• Progression

ALS modules in use:

• Mobile • Programs • Reports

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Interactive checklists:

a useful aid so that nothing is forgotten.

Validated processes: production release via handheld unit.

Automatic mould provision list: direct feedback via touch terminal.

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With ALS, you can document the event his-tory of machines, moulds, peripherals and other equipment in the long term and ex-tremely reliably. Shot counts, operating hours, set-up processes etc. are determined automatically and directly recorded. Due dates for maintenance work are constantly monitored – you receive advance warning in good time via SMS or e-mail. In addition, ALS supports you in the performance and documentation of maintenance work, e.g. instructions, checklists, reports or electronic signatures can be stored.

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Even at the order planning stage, ALS takes account of the storage location and availa-bility, including master mould, inserts and accessories. Current provision lists are auto-matically generated. Mould management, a touch terminal for stock movements and scanner support are also provided. Moulds can therefore be provided particularly quickly and efficiently. ALS transfers the data record of the next order online to the SELOGICA machine control. Set-up person-nel are therefore provided with the mould and data record in good time on the ma-chine and can start the set-up immediately.

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On the basis of a central machine control, you can use ALS to define production com-binations (e.g. machinery-peripheral-mould-material) for order planning. This means that there is only one validated data record for each production combination. You can control production release via user identifi-cation with an RFID card and an ACTUAL-TARGET comparison via a scan. ALS then offers you GMP-compliant process docu-mentation at virtually no extra cost: from the continuous logging of process parame-ters and seamless batch tracking through to long-term archiving of set-up logs and recalibrations.

ALS modules in use:

• Terminal • Programs • Orders • Reports

ALS modules in use:

• Maintenance • Groupware • Documents

ALS modules in use:

• Mobile • Programs • Orders • Quality

© 2014 ARBURG GmbH + Co KG

The brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG.

All data and technical information have been compiled with great care. However, we are unable to guarantee its correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine.

ARBURG GmbH + Co KG

Postfach 11 09 · 72286 Lossburg · Tel.: +49(0)7446 33-0 · Fax: +49(0)7446 33-3365 · www.arburg.com · e-mail: [email protected]

With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia,

Spain, Czech Republic, Turkey, Hungary | Asia: People’s Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates | America: Brazil, Mexico, USA For more information, please go to www.arburg.com.

523904_EN_GB_092014 ·

Subject to alterations Printed in Germany

ARBURG GmbH + Co KG