Seiki Systems' Networked Manufacturing System (NMS) is a modular system that comprises of both manufacturing and business intelligence software. At the shop floor level it includes, display of work queues and job data collection (SFDC), machine monitoring, technical data distribution, DNC and probe data collection. The top office analytical suite offers a remote display of machine status and alarms, machine performance analysis, individual job reports, and OEE, the key business tools that are necessary for effective work management information and visibility to maintain a controlled and flexible approach to the manufacturing process.

Managing the critical link between production efficiency and profitability is essential in remaining competitive. The pressure to keep costs low whilst maintaining the high standards demanded by industry and customers is growing. Seiki Systems NMS is aimed at manufacturers looking to maximimse productivity by utilising a complete shop floor system to electronically distribute and collect all manufacturing process data.

Whilst traditional paper based methods can be used to collect and collate data they are often based upon historical data records and are likely to be inaccurate. One of the advantages of a paperless manufacturing environment is that up-to-date manufacturing data is made available at the point of use for viewing by operators on simulation videos, etc. Supportive functions, like toolsetting, can see what's needed, where and when, to ensure everything is ready for start time. The system can also be configured to meet the requirements specified in individual quality standards by recording batch details and changes to NC programs, with audit and traceability records being automatically generated. The SFDC and feedback functionality within NMS enables access to real-time reporting, machine and job performance analysis and OEE on which to base production efficiency and improvement strategies.

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What is it?

• A shop floor management control and communications system
• Work queue display for operators
• Advanced level DNC
• Display work instructions and drawings
• Real-time shop floor data collection (SFDC)
• Real-time NC and manual machine tool monitoring
• Real-time probe data capture
• Remote view of current machine activity
• Machine tool utilisation analysis
• Individual job reports
• Performance analysis and OEE calculation
• Stoppage alerts via SMS messaging, internet or phone

Networked Manufacturing System Modules

Advanced DNC

The Seiki Systems' Advanced DNC module has been developed for users who require a high level, easily managed system for shop floor communications. Advanced DNC can be used by machine operators to navigate for files on a remote server, access complete job information packs containing all manufacturing data relevant to a component or operation and can be configured to meet the requirements specified in quality or operating standards to ensure compete compliance. The system provides file access and status control and can be configured with user prompts for the automatic generation of audit and traceability records. NC programs can be transferred to and from each connected CNC machine via a configurable interface (which includes special RS232 protocols where required) or via CNC based Ethernet interface, in either case shop floor access to the remote server is controlled by Advanced DNC and can be configured as required by the comprehensive access control feature.

This software is also available separately as Seiki Systems Networked DNC

Display of Manufacturing Data

The manufacturing data required for each CNC operation can be combined into a single job information pack. The data can include: NC programs, routing data, tool lists, set up sheets, photographs, NC simulation videos, etc. in any of the recognized formats. The filing structure is categorised to suit and can be either per machine based or component based with sub operations. The job information packs can be filed as folders in Explorer, in Excel spreadsheets or with an SQL database structure, with all the files being viewable on the shop floor, either individually or all simultaneously within our advanced viewer.

Job Queue Management

Work queues can be displayed for each machine or manual resource as a work-to-list. Additionally the work queues can be compiled into a single list for distribution around the site in order to co-ordinate supportive activities to the same set of priorities and time/date requirements. The work queue content can be derived from the Seiki Scheduler or generated as a text list from alternative such as spreadsheets or ERP/MRP. In addition to CNC and manual machine tools, distribution examples can include manual operations, material stores, gauge control areas and tool setting areas. The work queue software incorporates the facility to input information when each supportive activity is complete, which can then automatically update the given resource/operator's screen.

Shop Floor Data Collection (SFDC)

This module is used by the resource operator to advise when jobs are being started or completed with the data being fed back directly to the Seiki Scheduler for automatic updating. The job ID can be selected from the work queue, input manually or read in via barcode scan. The quantity completed can be either incremented, per part or totaled as the job is finished and the software incorporates the facility to enter scrap codes and reasons. For systems not incorporating the Seiki Scheduler, the collected data can be made available for input into any required external system.

Real Time Probe Data Collection Software

The probe data collection module automatically collects in-cycle probing results in real-time from CNC machines equipped with precision probes and a suitable data output facility. The collected data can be routed via Seiki' NMS internal configuration facility (SBS) to create records or feed SPC systems. In turn these external packages can be used to generate records, trigger alarms/alerts and generate SMS or emails. A unique facility is incorporated whereby the software is able to support both DNC and data collection for CNC machines equipped with a single RS232 port.

Probe data collection provides information to support management reporting and can be used to generate valuable warnings of potential problems that may impact production, thus extending a level of confidence in the manufacturing support environment that a process is stable and under control.

Machine Monitoring

Automatic and manual collection of productive and non-productive events occurring on CNC and manual machine tools can be both captured and selected from 64 user definable activities. Each operating condition and status change can be derived automatically (e.g. cycle start or alarm condition) via signals received from the machine or manually entered (e.g. waiting parts) by selecting the defined activity on the local PC screen. All data collected is date and time stamped, including the duration of each event, and can be viewed as an event list or be exported and stored for evaluation purposes using spreadsheets or Seiki Machine Utilisation Analysis and OEE Reports.

Remote Information and Alerts

Seiki Factory Status module can be configured to provide a dynamic real time view of the shop environment showing current machine status and current job information. Multiple licences of the Factory Status module can extend this real time information availability to management or supervisory personnel anywhere in your organisation. In the event of machine alarms and stoppages it is possible, via the Seiki Machine Monitoring solution, to generate automatic status conditions represented as colour coded icons. The system can be configured to utilise these conditions to automatically generate emails and SMS to supportive personnel, i.e. Maintenance.

Performance Analysis

The Seiki Machine Utilisation Analysis and Job Report modules can be used to generate performance reports that act upon the NMS central data repository which hosts the data collected from the Machine Monitoring and SFDC modules. These reports can be presented as simple log files chronologically listing all events by date and time and viewed as pie charts showing machine utilisation and lost productivity with trend analysis and individual job reports detailing the time taken on the various job activities together with a comparison of planned vs actual. The collected log files are also available for export to other external; packages, e.g. spreadsheets, HTML reports, etc.

Analysis of Overall Equipment Effectiveness

OEE data provides a valuable indication of actual resource, groups of resources or site efficiency. This data shows information that can be used to evaluate if processes are correct, highlight resources that are under utilised or identify resources that are suffering reliability problems. It provides the basis on which improvement strategies can be implemented.

The Seiki OEE Analysis software combines the measurements of machine availability, productivity and the quality of parts produced to give a simple measure of how well a machine is being used. The OEE software displays the machine performance results for individual jobs with the additional benefit of providing accumulative results for multiple jobs over a selectable period of time.