The MDE software on the left-hand screen provides current production data in real time. The timeline on the monitor on the right provides a complete overview of a system's performance over a specific period. © Proxia

A series machine with little set-up effort was used for the pilot operation. Proxia provided a BDE loan terminal for operation. All modules were activated for the trial operation of three months. All machine and production data acquisition (MDA/PDA) times were entered into the data acquisition software. During the three months of test operation by Penn key users, the MES proved itself on the pilot plant. Due to this success, Fabian decided to roll out the system to other plants as well. In cooperation with Proxia, those responsible specified the overall project: in the first step, the MES was to include automatic machine data acquisition (MDA) and production data acquisition (PDA).

Communication as the key to success

The Proxia MDE was extended to all new series machines with low set-up effort. Proxia BDE production data acquisition was introduced for manual workstations. To shorten the familiarization phase, the employees were given their own manual explaining how to operate the MES. In addition, various roles with corresponding rights were defined in the system. Depending on the application, the machines were equipped with tablets or PCs for recording data. Newer systems provide the digital signals for an MDC as standard; older machines had to be upgraded accordingly by the technicians. Proxia received messages regarding signals and IP addresses in order to adapt the system communication accordingly. Where this was not possible, Penn worked with Proxia to develop an independent configuration, including a hardware concept with PLC. A total of 19 machines were then connected with MDE software. For production data acquisition, the machines were equipped with 12-inch tablet PCs, which are connected to the company network via WLAN. Fabian explains his decision in favor of the mobile solution as follows: "Everyone has tablet PCs at home, the employees know how to use them. And even the older ones know it from their grandchildren." Andreas Fabian was also able to allay employees' fears of being completely monitored: "What we evaluate, we also show here. The visualization is visible to everyone on the info boards. Anyone who needs additional information can access further data at any time. That's how we handled it from the very beginning and that was the key to success."

MES promotes CIP: reject rate below 1.5 percent

Penn uses hardware-independent PDA software to manually record operating data. Different hardware solutions - from stationary PCs and laptops to tablet PCs - are used for the different areas of application. © Proxia

As the data was accessible to everyone, a small competition arose among the employees as a positive consequence. As soon as someone fell significantly below the average, the system helped them to find and rectify the reasons in the shortest possible time. In addition, employees were able to play an active role in configuring the system: If an employee needed a certain button in the software, he came to Fabian's colleagues with the suggestion and they set it up for him. This also promoted acceptance.

Proxia-MES user interface. © Proxia

The positive results were not long in coming: as soon as a fault occurs, maintenance and production management are automatically notified by email. In this way, the causes of faults can be localized, evaluated and, above all, rectified more quickly, so that the systems are up and running again within a very short time. This has enabled Penn to increase its machine availability to 97 percent. The automatic evaluation of machine data has helped to integrate newly commissioned systems into productive operation more quickly. As machine and production data is not only automatically recorded but also evaluated, working time in the organizational area has been reduced by around 50 percent. Set-up times have also been significantly reduced. All of this has contributed to a significant reduction in production and process costs. But it was not only the purely economic aspects that played a role. The active involvement of employees in the design of the MES has led to the fact that employees are now driving the continuous improvement process (CIP) at Penn with their own suggestions, which is reflected in the quality of the products: The reject rate is below 1.5 percent. This puts Penn below the expectations of car manufacturers, who consider a value below 2 percent to be ideal. The calculated OEE (Overall Equipment Effectiveness) of around 90 percent also speaks volumes. Now that working with Proxia's MES has led to a consistently positive development, Penn is planning to expand the system: the entire mechanical production with around 50 systems and machines will be fully integrated into the MES, communication with the ERP system will be expanded so that employees can call up all order data and scrap figures electronically via their PC terminals at the machine. The process data of the systems, for example vibrations or temperature, are to be continuously and automatically monitored so that faults can be detected and rectified even sooner. In addition, the MDC and PDC modules are to be supplemented by the Proxia detailed planning and personnel resource planning modules. With these measures, Penn is well positioned to further reduce throughput times and increase its own competitiveness.

According to documents from Proxia