Control station and analysis

AMS ZPoint-CI is a per­fect­ly tai­lored con­trol sta­tion with inte­grat­ed MES func­tion­al­i­ty. All process infor­ma­tion can be record­ed, visu­al­ized and con­trolled company-wide.

Our solu­tions are indi­vid­u­al­ly scal­able and offer a wealth of advan­tages: bet­ter uti­liza­tion and high­er qual­i­ty in pro­duc­tion – at low­er costs.

Seamless detection

MDE / BDE / QDE

Data acqui­si­tion is the core of AMS ZPoint-CI.

Only a detailed recor­dial­sng of the pro­duc­tion data – as an inte­gral part of the machines – shows exist­ing bot­tle­necks con­sis­tent­ly and prompt­ly. This lays the foun­da­tion for a fact-based con­tin­u­ous improve­ment process (CIP).

Machine data log­ging (MDE), pro­duc­tion data acqui­si­tion (BDE) and qual­i­ty data com­pi­la­tion (QDE) allow the data from pro­duc­tion to be record­ed seam­less­ly and made transparent.

Uniform visualization and analysis

Control station / HMI / SCADA / OEE

Trans­paren­cy forms the basis of effi­cient pro­duc­tion. This trans­paren­cy is cre­at­ed with the uni­form visualization.

A con­sis­tent and expand­able visu­al­iza­tion: From the work­er to the pro­duc­tion man­age­ment – from the sig­nal to the ware­house – makes devi­a­tions between ide­al and cur­rent pro­duc­tion imme­di­ate­ly vis­i­ble. Tech­ni­cal process­es can thus be eas­i­ly mon­i­tored and controlled.

Indus­try-stan­dard key fig­ures (e.g. OEE, TEEP, etc.) are clear­ly dis­played and help to avoid or min­i­mize machine fail­ures and mal­func­tions, set­up times, idle times and down­times, reduced speeds, qual­i­ty and start-up losses.

Transparency

Transparency through detail analysis and ad-hoc analysis

Trans­paren­cy forms the basis of effi­cient pro­duc­tion. This trans­paren­cy is cre­at­ed with the uni­form visualization.

A con­sis­tent and expand­able visu­al­iza­tion: From the work­er to the pro­duc­tion man­age­ment – from the sig­nal to the ware­house – makes devi­a­tions between ide­al and cur­rent pro­duc­tion imme­di­ate­ly vis­i­ble. Tech­ni­cal process­es can thus be eas­i­ly mon­i­tored and controlled.

Indus­try-stan­dard key fig­ures (e.g. OEE, TEEP, etc.) are clear­ly dis­played and help to avoid or min­i­mize machine fail­ures and mal­func­tions, set­up times, idle times and down­times, reduced speeds, qual­i­ty and start-up losses.

Quality data under control

TQM / CAQ

Increas­ing safe­ty stan­dards demand a high and con­stant lev­el of qual­i­ty in the pro­duc­tion process.

The legal war­ran­ty and the prod­uct lia­bil­i­ty act oblige machine oper­a­tors to com­ply with exten­sive reg­u­la­tions. This high lev­el of qual­i­ty can be achieved by means of cross-machine sta­tis­ti­cal process analy­sis to opti­mize the process and product.

The com­plete acqui­si­tion and doc­u­men­ta­tion of all qual­i­ty and process-rel­e­vant data is done with AMS QDA-CI. The avail­abil­i­ty of all qual­i­ty data across loca­tions guar­an­tees cost sav­ings, con­tin­u­ous plau­si­bil­i­ty, the abil­i­ty to pro­vide infor­ma­tion and a greater capac­i­ty to act.

Leading recipe management

High vari­ant diver­si­ty, com­plex process­es and chang­ing mate­r­i­al prop­er­ties make intel­li­gent recipe man­age­ment indispensable.

Dynam­ic and ver­sion­able recipe man­age­ment gets the vari­ety of prod­uct vari­ants and the diver­si­ty of pro­duc­tion process­es under con­trol. The trans­par­ent man­age­ment of man­u­fac­tur­ing para­me­ters (e.g. force, tem­per­a­ture, pres­sure etc.) and illus­tra­tion in assem­bly groups ensure max­i­mum repro­ducibil­i­ty of man­u­fac­tur­ing processes.

Trace­able man­u­fac­tur­ing process­es are the start­ing point for con­sis­tent part qual­i­ty and the basis for suc­cess­ful process analysis.

Traceability

Traceability, tracking and tracing

The qual­i­ty require­ments are con­stant­ly increas­ing. An impor­tant basis is to avoid future mistakes

The near-real-time trace­abil­i­ty func­tion of AMS MES-CI can not only deter­mine the caus­es of errors, but also make pro­duc­tion process­es more trans­par­ent. It deter­mines at light­ing speed whether the prob­lem is a prod­uct, process or batch error.

Com­plete trace­abil­i­ty can be ensured by link­ing batch and process data and by assign­ing the process para­me­ters to an indi­vid­ual com­po­nent. Inte­gral data acqui­si­tion and ver­sion­able recipes from the back­bone of trace­abil­i­ty – whether upstream or down­stream tracing.

Bidirectional ERP / PPS communication

In order to build an effec­tive infor­ma­tion infra­struc­ture, the inte­gra­tion of exist­ing ERP/PPS sys­tems is nec­es­sary. Their syn­er­gies are opti­mal­ly used when they func­tion syn­chro­nous­ly and seamlessly.

Intel­li­gent soft­ware solu­tions con­nect the busi­ness and pro­duc­tion lev­els. Infor­ma­tion is exchanged bidi­rec­tion­al­ly and processed in defined process­es. ERP con­nec­tors ensure that data is always con­sis­tent and redun­dan­cy-free across sys­tems and through­out the entire busi­ness process.

Numer­ous already imple­ment­ed con­nec­tion solu­tions and the prob­lem-free expand­abil­i­ty guar­an­tee prob­lem-free com­mu­ni­ca­tion with stan­dard and pro­pri­etary ERP/PPS solutions.

Alarm management, smart alarming and hall mirror

With effi­cient alarm man­age­ment inte­grat­ed into the con­trol sta­tion, risks in pro­duc­tion lines can be reli­ably con­trolled and min­i­mized. This makes oper­a­tion not only safer, but also more economical.

The flood of infor­ma­tion in pro­duc­tion is increas­ing and must be brought under con­trol. The goal is the bet­ter han­dling of alarms and mes­sages. Con­cen­tra­tion to the essen­tial to inform the user again.

With the alarm solu­tions the user can focus on the essen­tials again. Dif­fer­ent esca­la­tion lev­els, clear­ly defined events and max­i­mum avail­abil­i­ty. The alarm man­age­ment life­cy­cle is sup­port­ed by CI-Watch or SMS or e‑mail mes­sages or hall mir­ror. By reduc­ing response times and reliev­ing the user, pro­duc­tion effi­cien­cy is increased.

Process data

Live Analysis and Condition Monitoring

Con­tin­u­ous con­di­tion mon­i­tor­ing and per­ma­nent mon­i­tor­ing of machines and process­es increas­es machine effi­cien­cy, reduces set­up effort and increas­es safety.

The biggest lever for increas­ing pro­duc­tiv­i­ty is high machine avail­abil­i­ty. With live analy­sis, pos­si­ble error sources can be iden­ti­fied ear­ly on and nec­es­sary main­te­nance work can also be car­ried out preventively.

User ben­e­fit sev­er­al times over by increas­ing machine avail­abil­i­ty, avoid­ing unplanned down­time, reduc­ing oper­at­ing costs, increas­ing oper­a­tional safe­ty, opti­miz­ing process para­me­ters and ensur­ing prod­uct quality.