Production Line Monitoring

2/11/2015


A new Operator dashboard for easier navigation and even better reactivity!

The Dashboard available for Operators displays main performance indicators of the production line

  • main figures
  • systematic rejections
  • worst defects
  • last read messages
  • changeable equipment
  • periodical action list
  • ...

 Increase your percentage packed with SILC

With the increase in production machine speeds, the multiplicity of inspection equipment and the light weight of glassware, glassmakers have to supply their Cold End and Hot End operators with a logistical view of their production lines.

With SILC, you are always aware of what is happening on your lines. SILC is the best tool for your operators because it efficiently reduces their reaction times along the lines. It has been proven that the payback is around 6 months.

PRINCIPLE

Production line information is centralized and processed by a SIL server. It is displayed in HE and CE on operator workstations hooked up to the network.

BENEFITS

  • Save time by sharing information
  • Increase the yield by reacting quickly
  • Reduce Customer risk with full traceability


SILC FUNCTIONALITIES

  • Losses along the production lines
    Precise loss recognition on a production line is a necessary part of the total control of the glassmaker process

    Expertise: Our extensive knowledge of inspection machines enables you to efficiently exploit your equipment.
    SILC can be installed on any holloware production line.
    VERTECH' will advise you for the definition and realization of data acquisition that best suit your needs.

    Immediate interpretation: From the long-term trend graph analysis to the display of «real time» values, SILC was designed keeping in mind two basic principles : analysis must be kept simple and interpretation immediate.

    Alarms: As soon as a percentage on a conveyor is over the authorized limit, it is displayed in red.

  • Losses per mould

    The introduction of Mould Number Readers has revolutionized defects analysis by increasing precision. This analysis has also become more time consuming and more difficult. SILC makes it simple.

    Clear visualisation: A color code indicates to Operators the status of each cavity: normal production, exceeding authorized defect rate, rejection of a mould production....

    Detailed analysis: By simply selecting the cavity, SILC displays:
    • the distribution of a defect over the whole machine
    • the list of defects on the mould
    • the comparison of defect rates between control conveyors

    Self training
    The results of any action taken on the IS machine are instantaneously reported to the operator, widening his knowledge base.

  • Messages

    E-mail brings Operators closer together and reduces information transmission time.

    Traceability : On screen or with report print-outs, you keep in memory events which occur during production. For each message the following are recorded : the sender, the content, the hour of transmission and reception.

    Description: An Operator enters messages to be transmitted. A display pops-up on the workstation screen of the Operator who receives these messages. Each message received must be validated individually.

    Reduced reaction time: The system informs Operators automatically of actions taking place on the line :
    • mould change
    • mould rejection with indication of the cause.

    SILC also enables each operator to send messages with his own text. 
  • Lehr exit controls

    Informing Hot End terminals immediately of Cold End sampling results.

    Simple keying: The Operator records the defects observed in his samplings by choosing from a pre-established list. Defects can be assigned cavity by cavity.

    Memorization: Each Operator can consult results of the last controls, for each defect, for each mould, classified by AQL, by value and by percentage.

    Visual display: The results of the latest sampling are instantaneously displayed at the Hot End terminal on a window representing the IS Machine. A corresponding color code enables the Operator to immediately judge the production quality level.
  • Weight

    The control of the gob weight is an important element of the glassmaker process. This function combines easy implementation with the efficiency of the SPC.

    Increased reactivity: You define your own quality parameters for weight and software instantaneously indicates to Operators what corrective actions should be taken.

    Numerous advantages: The control chart of each gob on each feeder provides :
    • better analysis of feeder fluctuations
    • control of defects linked to weight
    • better capacity follow up.

    Implementation: Connected behind the Operator terminal, the scale records automatically the weight of articles placed on it.
  • Internal pressure

    Articles subject to important internal pressure must be tested regularly.
    This procedure is time consuming and fastidious. SILC totally automates this process with On-line SPT machines.
    SILC asks the Mould Number Reader to sample the items to be tested. They are sent to the AGR SPT machine which carries out the internal pressure test. Then, SILC analyzes the results.

    This functionality was designed in partnership with AGR but it may be extended to other machines.

    BENEFITS

    • Automate your controls. SILC automatically selects items to be tested according to sampling frequencies and previous pressure results. The order to reject a mold can also be given as long as pressure results require it.
    • Visualize the results of any type of test thanks to a multi-criteria display: tests, re-tests, breaking period, re-acceptation of a mold.
    • Analyze trends (averages, dispersions…) for different periods thanks to variable time bases.

  • Thickness

    Thickness variations lead to pressure and storage problems as well as high manufacturing costs and waste of bottle material.
    Follow the evolution of the thickness in real time, would give you a better chance of making the right decision in order to reduce variations.

    SILC new Thickness feature enables you to collect thickness data from your inspection machines such as TIM, Veritas and VMA.
    This function was designed in partnership with Emhart and VMA.

    BENEFITS

    • Detect, in real time, thickness problems on your production.
    • See at a glance, in the Hot End, on which level of the bottle the defect appears, with a representation of all the cavities.
    • Make your operators react quickly to main defect causes thanks to statistical analyses and trends.
    • Get the history of thickness rejections over the last 100 rejections.
  • Losses per cavity

    So far, it was possible to check the main defects present on the IS machine, but you didn’t know exactly when a defect appeared.
    Now, this SILC functionality allows you to see the losses evolution over time for one or more defects, and for one or more cavities.
    For this, the data are collected by inspection machines equipped with MNR:
    • Video (MSC Multi, Veritas IB, ...)
    • Check (C0, M1, Fp, TIM, CD, Veritas IM, ...)
    • Hot End (XPAR, ICARE)
    Each MNR gives us the following information for each cavity:
    • The total number of inspected
    • The total number of rejected
    • The number of defects

    BENEFITS

    • See losses history for a MNR type, by cavity. This screen allows you to see the defects evolution over time on the IS machine, or on a particular cavity.
    • See at a glance if a cavity defect is new or exists for a longer time
    • See at a glance if a defect is present on all the IS machine, or just on one or few cavities.

 

VERTECH' - Information Technology for the Glass Industry - Production monitoring system

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