Line Cockpit

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The Line Cockpit

The line cockpit is an aid for production management and our customers' technicians.

In contrast to the line management system, the line cockpit is software which can be installed on any Windows PC. An Ethernet or Internet connection to the line management systems is required so that their data can be evaluated. The line cockpit provides the following functions:

  • A fast overview of how well the last orders were processed by the lines.
  • A size manager for processing sizes and recipes which contain the setting parameters for machines and devices.
  • Order management for entering and processing order data.
  • Administrative functions, e.g. the higher-level user management function.
  • Evaluation functions for the OEE data of the line management systems for analysis of weak points with the objective of improving the OEE.

Figure 8 shows the screen which appears after the line cockpit is started.

 

Figure 8: Start-up screen of line cockpit

The last orders of 2 lines are shown chronologically in the example. Which orders are displayed depends on the filter data set, which is located in the right-hand section of the screen.

The data can be filtered according to periods, orders, machines, sizes or products.

In the screen shown in Figure 8 the "last shift" was selected as a parameter in the time filter. That is why only the orders of the last shift are visible in the left-hand section of the screen. It is apparent that both lines are currently producing and the second order of the first line has not achieved the target output and is therefore shown in red.

If the order marked in red is clicked with the mouse, the system branches off to the screen with the OEE data of the order (Figure 9) 

 

Figure 9: OEE data

The upper section shows from left to right the OEE indicators of the line, the distribution of the losses and a list of the most frequently occurring errors. At the bottom edge of the screen the output of the line over the time axis can be shown, for example in products per minute. This output is measured at a certain point in the line, and not necessarily at the end of the line. It can easily be recognized that the line had no output for approximately 30 minutes beginning at 1 a.m.

The filter settings in the right-hand section of the screen were automatically adjusted with the mouse click.

In order to learn the reasons for the poor output after midnight, the output curve must be clicked with the mouse. Then the screen shown in Figure 10 appears:

 

Figure 10: Operating states

 

The operating states (OMAC states) of the machines are shown on the screen. It is apparent that faults of the palletizer were the cause of the poor output. The faults of the palletizer (shown in red) have led with a time delay to waiting states of the packaging machine (shown in blue).

Clicking on the OMAC states of the palletizer displays its OEE indicators and the most frequently occurring errors (Figure 11) 

 Figure 11: OEE indicators for palletizer

 The screen in Figure 12 shows the causes of the faults which occurred.

 

Figure 12: Causes of faults which occurred

 

The data displayed show that it was not the palletizer, but instead bad pallets that caused the problem.

The line cockpit provides our customers with a powerful tool for analyzing weak points. The line cockpit cannot eliminate the problems, but it does help recognize the cause of the problems with its data and evaluation functions.