e-F_CTORY_BROCHURE

Mitsubishi total automation solution e-F@ctory

Outlining innovative architecture from shop floor to Enterprise!

A winning solution for the manufacturing industry!

A winning solution for the manufacturing industry!

Mitsubishi Elect ric provides piece of mind to all automation related hurdles *The numbers reflect the actual results of Mitsubishi Electric Nagoya Works e-@Factory plants as well as preliminary calculations based on the elimination of PCs and programs.

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Pro

ces

. cipe is . e re uct , th rod now xt p OK the ne for

Job

Productivity is low and defects are high.

Our lead-time is long.

We have much waste in our plant.

Swift response to volume changes, improvements in equipment operation rates, reduction in lead-times, quality improvements, cost reductions . . .

To solve the various issues facing the manufacturing industry shop floor data, digitization and utilization of various types of data in an information system are required.

Offering a wide range automation products, Mitsubishi Electric provides an ideal solution tackling these problems with little disruption to production.

Monitoring factory data in real-time is now second nature providing a truly visual factory.

Inst She ruction et

Easy to link Enterprise systems to the shop floor.

Utilizing Mitsubishi Electric's diverse range of automation products, provides a realization of integrated manufacturing.

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e-F@ctory Solution Operation rate improvement

Process

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Proces

Proce

ess Proc

ss

Quality improvements

Cost reduction ・Delivery ・Inventory ・Work in Progress ・Process

Process Control

Such plants require the

They are in the ×× Process now, so we can ship them today.

Shortened lead-time

Server

Quality Control Production Planning

Control defective parts

No defectiv e par ts

Optimal production plan

Executive

Great! We made production!

When can we finish the products for Company A?

e-F@ctory is the solution to the issues faced in the manufacturing industry!!

e -F@ctory solution.

Quality improvement

Shorter lead-time

Cost reduction *The number reflects the actual results of Mitsubishi Electric Nagoya Works e-@Factory plants.

◆ Work procedures and equipment settings are automatically generated for each product, thereby preventing errors caused by manual labor. ◆ Faulty processes are swiftly detected, enabling prompt response. ◆ Quality information by product and by process is made available online for immediate reference, enabling multifaceted analysis. ◆ The status of partly finished goods and the equipment operation rate by product and by process are made available for reference, enabling the identification and improvement of processes where bottlenecks occur. ◆ Production results are accurately identified for each process and equipment, making improvement possible. ◆ The effects of MES introduction, such as yield improvements due to improved quality, productivity improvements due to a shortened lead-time, and a reduction in partly finished goods and inventory, all lead to cost reduction.

Plant productivity improvement

Increased business efficiency

Effectively Optimizing Production by Directly Connecting Enterprise Systems with Shop Floor.

Instructions from upper management are not communicated.

Onsite opinions and ideas are not utilized.

As a result, production does not run smoothly.

An e-F@ctory plant solves various issues through the direct collection of a wide variety of production site data, such as production and operation performance results and quality information, in real-time from equipment and devices, and the utilization of this data in an information system.

The digitization of the production system solidly aids in improving quality, the manufacturing period and productivity.

Manufacturing Execution System A system that controls the production process, optimizing aspects such as quality, production volume, delivery and costs.

ERP

Enterprise Resource Planning

Enterprise System (Quality control, process control, etc.)

MES

Manufacturing Execution System

MES Interface Control system: Equipment (Mitsubishi FA Product Series)

A means of collating and interfacing all that information between levels

MES interface function (GOT1000: HMI)

MES interface module (MELSEC-Q: PLC)

3rd party controllers

Motion controller

Numerical controller

Electrical Discharge Machine

Laser machine

Robot

CC-Link partner products Mitsubishi Electric CC-Link compatible products

Mitsubishi Electric CC-Link/ LT compatible products AC servo

Inverter

Energy-saving device

The Mitsubishi FA Product Series: Realizing Production Site Digitization on a diverse range of Networks.

Mitsubishi FA products are compatible with a wide variety of networks, realizing seamless communication from Enterprise to device/sensor level. With Ethernet and CC-Link, connection from the upper system to a wide variety of FA products within devices is possible. FA products realize real-time optimal control as well as onsite information integration.

In addition, MES interface technology transcends any differences in FA product and Enterprise system data formats, enabling direct connection.

The New MES Interface:A Simple Low-Cost MES (Manufacturing Execution System) to Shop Floor Interface!!

I would like to be proactive in the digitization of shop floor information.

But, without the high costs.

The MES interface product group enables direct connection between the MES (Manufacturing Execution System) database and shop floor equipment, without a communication gateway such as a PC. The information collected on the MELSEC-Q PLC is linked by the PLC MES interface module, and the information from existing equipment and 3rd party controllers is linked by the GOT1000 MES interface function.

The MES interface product series links shop floor equipment and MES information simply, with minimum cost.

The MES Interface: The Key to Realizing a visual platform e-F@ctory. ●Provides accurate information in real-time through direct utilization of internal device information. ●Simplifies system implementation by direct;y connecting to database(s). ●Eliminates the need for PCs and programs, greatly reducing costs. ●Improves reliability by changing the gateway PC to a PLC.

MES

decrease or more in system implementation cost!

(Manufacturing Execution System)

database server Results manually entered or processing program executed by operator

* The number reflects preliminary calculations based on the elimination of PCs and programs.

MES (Manufacturing Execution System)

database server

Processing program ◆ Data collection ◆ Data processing ◆ Data communication

Gateway PC

With <<MES interface >>,

Control network (MELSECNET/H etc.)

Sta

◆ Operation performance result data. ◆ Equipment management data.

PC not required ◆ Quality control data. ◆ Traceability data, etc.

Overall controlling PLC

nda

rd Control network (MELSECNET/H etc.)

MES interface

Afte MES Interface Features and Benefits.

is realized.

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S in

terfa

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●Automatically generates SQL based on program-less simple settings, enabling easy, direct connection to the MES database.

ntro

duc

tion

□

Accurate identification of production information

●Utilizing event driven data management resulting in efficient database

□

System construction simplification

communication.

□

System construction period and cost reduction

●Accepts production instructions from MES and transmits and receives time-stamped data.

□

Stable operation

●Including a data buffering function which ensures data back-up during *The number reflects preliminary calculations based on the elimination of PCs and programs.

communication errors.

Diverse range of MES interface functions ideally suited for system implementation and design.

Large-scale production line manufacturing execution system compatible.

Adopting event driven data communication.

The MES interface enables the collection of information from

The MES interface allows you to monitor data and execute data (SQL message) transmission and reception to and from the manufacturing execution system when the data satisfies certain event conditions. Comparing to conventional gateway PCs which use polling method, database communications traffic can be optimized by requesting relevant data only.

multiple production lines of a large-scale production facility into a

Information flow

Enterprise system

MES application

MES application

Database

Database

Database server

■The interface enables transmission of input information, such as two-dimensional barcode reader input data, to a server.

■The interface is provided with a function that transmits messages at the time of alarm detection by the alarm history function, etc.

Ethernet

MES interface module

Event driven communication (SQL)

Upper information system communication processing Data processing (operation processing, logging, etc.)

■The MES interface enables analysis based on operator operation log information (CSV file).

■The interface provides an operation navigation function based on a document display function (PDF, etc.).

single database.

DB

Enterprise system

Multi-faceted system analysis through GOT function and MES interface function integration.

GOT interface function

PLC communication Polling processing

Gateway PC PLC

Communication module

MES interface

Controller (CPU)

Controller/GOT

Temperature Barcode controllers reader

MES Interface Function List Support of a wide variety of cutting-edge functions that ensure data reliability.

Item

■The MES interface temporarily stores time-stamped information on a CF card at the time of a communication error or server response failure. The interface automatically resends data upon error recovery, thereby ensuring data continuity.

■The interface provides a data processing function based on statistical processing, four arithmetic operation processing, etc.

Temporarily stores important data on CF card!!

Work schedule

Production instructions

DB Product tracing data

Production and quality control data

Equipment operation information

MES

Accesses the database by job.

Assigns tag element names to device information (control controller memory address), collecting the tag element names in units of tags.

Tag function

■The interface enables time-stamped information transmission (SNTP or PLC internal clock specification).

Database server

Description

Database link function

Trigger monitoring function

Monitors time, tag and other values and starts jobs when the trigger condition changes from False to True (when the trigger conditions are met).

Trigger buffering function

Internally buffers data transmission/reception details when there is a concentrated access load, transmitting and receiving the data at the time the load is alleviated. Load concentration: Temporary delay of database response, temporary concentration of transmission/reception condition satisfaction, etc.

SQL message transmission function (communication action)

Automatically generates SQL messages and communicates with the database. Provides the following three types of SQL messages for selection: Select ／ Update ／ Insert

Operation processing function (operation action)

Calculates the tag element value.

Program execution function

Executes a program on the application server before execution of the first action and after execution of the last action of a job.

DB buffering function

Buffers SQL messages that cannot be transmitted onto a compact flash card at the time of network disconnection or database server PC failure.

Automatically resends the buffered SQL messages to the database after recovery. (Manual operation also possible)

XML processing function

Executes XML format message requests from the user application.

Job one-shot execution ／ Job enable/disable (trigger execution allowed/not allowed)

Time synchronization function

Allows selection of the time information source to be used at the time of data transmission/reception.

Network SNTP server ／ PLC CPU (with GOT: GOT internal clock)

(Manufacturing Execution System)

MES interface

MES Interface Specification List Item

Trigger buffering

128 times, maximum

No. of conditions connectable

Appointed time startup: Starts the job at a specified time (day and time specification or weekday specification) Condition type

Cyclic startup: Starts the job based on a specified cycle (range: 1 to 32767s) Value monitoring startup: Compares the tag elements and constants/tag elements (6 types) At module startup: Starts the job only once at module startup Hardware operation: Starts the job upon request by the PLC CPU

Monitoring cycle

Write destination specified

2 conditions/job, maximum (AND or OR condition selectable)

Product Name MES interface module Compact flash card

Model QJ71MES96

−

Description

Product Name

Setting for executing server program before and after database send/receive

Information link support tool

（ MX MESInterface ）

Model SW＊DNC-MESIF-J

10 actions/job, maximum

Type

4 types (select, update, insert, operation)

Number of communication action fields

8192 fields/project, maximum ●“DB-Tag link setting”: 256 lines/communication action, maximum ●“Select/Update condition”: 8 lines/communication action, maximum

Number of operation actions operable

(20 two-term operations, maximum)/operation action

Operation action operator

6 types (addition, subtraction, multiplication, division, character string connection)

Number of tags

64 tags/project

Number of elements

256 elements/tag (function enhanced) ／ 4096 elements/project

Data types

5 types [signed single-precision integer type (16-bit), signed multipleprecision integer type (32-bit), single-precision floating point number (32-bit), bit type, character string type (1 to 32 characters)]

Statistical processing

6 types (average, maximum, minimum, moving average, moving maximum, moving minimum) Maximum capacity: Compact flash card capacity – 32Mbytes (to 512Mbytes)

GOT1000 MES Interface Function Product Name

Model

Description

MES interface function execution module

ＧＯＴ1000

GT15＊＊-＊＊＊

GT15 series GOT module

Required. 128Mbytes or higher.

(Mitsubishi Electric or commercial product)

Option function board

GT15-MES48M

MES interface function execution board (extension: 48MB)

Ethernet communication module

GT15-J71E71-100

Ethernet module

MELSEC-Q PLC MES Interface Module Information Link Support Tool

SQL message automatically created by settings

Specifications

Number of actions that can be set

DB buffering capacity

100ms or higher

MELSEC-Q PLC MES Interface Module

Memory address of data to be written specified by tag element name

Action

64 jobs/project, maximum Database link

No. of jobs that can be set

Job

Oracle 8i/9i/10g，Microsoft Access 2000/2003, Microsoft SQL Server 2000/2000 Desktop Engine（MSDE2000）

Action

Connectable databases

Device tag

DB access conditions specified

32 databases/project, maximum

Trigger conditions

Database link

Reduce system implementation costs etc, by using this very simple utility software for setting up the MES interface. No need for difficult programming and debug.

Item

Specifications

No. of connected databases

Job

Easy database connection using intuitive utility software.

Compact flash card

−

Required. 128Mbytes or higher

Description Sets MES interface operation settings, server service settings, etc.

GOT1000 MES Interface Setting Tool (One of the following required) Product Name

*The MES interface sets shipped as of August 2006 will change (switch over) to the above-described product configuration. *The supported function time periods described in the tables may vary with a PLC and GOT. For details, contact Mitsubishi Electric.

Model

GT Designer2 Version2

SW2D5C-GTD2-J

GT Works2 Version2

SW2D5C-GTWK2-J

Description GOT1000 image creation tool for setting MES interface function operation settings, server service settings, etc.

Production plant incorporates high defects and a low yield.

Is there any good way to work toward zero quality loss?

Mitsubishi Electric Nagoya Works very own servo motor factory has achieved a 50% reduction in quality loss and aspires toward numerous "zero targets."

Defect outflow prevention by total automatic data collection and management. ●Manual labor costs significantly reduced by automation of all test result collection and history management.

Test records automatically collected and managed!!

●Defect outflow prevented owing to a system capable of simple data collection, management and analysis.

Before introduction

Making advances toward zero defect outflow!!

After introduction

Lot-based sampling records Notation

Test

Automatic recording of all products

Test

Data entry

e-F@ctory server

Test result data

MES interface

Zero Defect Measures Based on Real-Time Quality Control. ●Defect prevention by real-time status detection by test device

Aspiring toward zero quality loss!!

●Prompt and automatic advance warnings (by e-mail) based on actively monitored bar-charts ●Countermeasures addressing upstream processes by detailed data detection Before introduction

After introduction

Data collected and analyzed manually

Making advances toward zero quality loss!!

Defects prevented in real-time

Control upper limit

Quality data collected and analyzed manually

Warning issued

Control intermediate limit

±0.8A％

Control range ±A%

Control lower limit

Action taken after defect occurs

Cause identification and corrective action based on accumulated data analysis

Production date

Down Time and Prompt Corrective Action at the Time of Defect Occurrence.

Quick notification by e-mail of defect occurrence!!

●Zero initial time with prompt automatic notification (e-mail) to controller when trouble occurs ●Abbreviated corrective action time through past corrective action database utilization

With <<MES interface >>,

Before introduction

Making advances toward zero trouble response time!!

After introduction

Trouble relayed by persons

Automatic notification

Defect!

Line stopped!

Defect!

Line stopped!

Check by worker

Line leader

Branch manager

Section manager Group leader

e-F@ctory server

Line leader

Device

Group leader

Worker (GOT confirmation)

MES interface

Device

Prompt confirmation by e-mail notification (in real-time)

Prevention of Production Stops by Automatic Management of Jig and Tool Information, etc.

Aspiring toward a zero process stop time!!

●Automatic display of warnings based on the number of times a jig, tool or mold is used

has been achieved overall.

●Planned replacement and maintenance based on service life estimation from past results Before introduction

Making advances toward zero production stops!!

After introduction Performance report

Equipment error!

Recovered

e-F@ctory system

MES interface

P la

nn

Service life estimation

Repair

Preventive maintenance

Production stopped

No impact on production

ing

Complete

Specific Case Examples of e-F@ctory.

Mitsubishi Electric Nagoya Works (Japan) operates active e-F@ctory plants.

The active e-F@ctory plants are actual proof of improved productivity and equipment operation rate.

Through the introduction of Mitsubishi FA products which enhance information integration by linking onsite information with business strategies, and the introduction of solutions of partner manufacturers, our plants have made significant steps toward the construction of an optimal production system.

Country/ Region Sales office U.S.A

Mitsubishi Electric Automation lnc.

500 Corporate Woods Parkway Vernon Hills, IL 60061, USA

Tel : +1-847-478-2100 Fax : +1-847-478-2396

Brazil

MELCO-TEC Rep. Com.e Assessoria Tecnica Ltda.

Rua Correia Dias, 184, Edificio Paraiso Trade Center-8 andar Paraiso,Sao Paulo SP Brasil

Tel : +55-11-3262-4759 Fax : +55-11-288-3047

Germany

Mitsubishi Electric Europe B.V. German Branch Gothaer Strasse 8 D-40880 Ratingen, GERMANY

Tel : +49-2102-486-0 Fax : +49-2102-486-1120

U.K

Mitsubishi Electric Europe B.V. UK Branch Travellers Lane, Hatfield, Hertfordshire., AL10 8XB, UK

Tel : +44-1707-276100 Fax : +44-1707-278992

Italy

Misubishi Electric Europe B.V. Italian Branch VIALE COLLEONI 7-20041 Agrate Brianza(Milano),Italy

Tel : +39-039-60531 Fax : +39-039-6053312

Spain

Mitsubishi Electric Europe B.V. Spanish Branch Carretera de Rubi 76-80 E-08190 Sant Cugat del Valles(Barcelona), Spain

Tel : +34-93-565-3131 Fax : +34-93-589-2948

France

Mitsubishi Electric Europe B.V. French Branch 25,Boulevard des Bouvets, F-92741 Nanterre Cedex, France

Tel : +33-1-5568-5568 Fax : +33-1-5568-5685

South Africa

Circuit Breaker Industries Ltd. Private Bag 2016, 1600 Isando, South Africa

Tel : +27-11-928-2000 Fax : +27-11-392-2354

Hong Kong

Mitsubishi Electric Automation(Hong Kong) Ltd. 10/F,Manulife Tower, 169 Electric Road, North Point, HongKong

Tel : +852-2887-8870 Fax : +852-2887-7984

China

Mitsubishi Electric Automaiton(Shanghai) Ltd. 4/F Zhi Fu Plazz, No.80 Xin Chang Road, Shanghai 200003 CHINA

Tel : +86-21-6120-0808 Fax : +86-21-6121-2424

Taiwan

Setsuyo Enterprise Co., Ltd. 6F., No.105 Wu-Kung 3rd.Rd, Wu-Ku Hsiang, Taipei Hsine, Taiwan

Tel : +886-2-2299-2499 Fax : +886-2-2299-2509

Korea

Mitsubishi Electric Automation Korea Co., Ltd. 1480-6, Gayang-dong, Gangseo-ku Seoul 157-200, Korea

Tel : +82-2-3660-9552 Fax : +82-2-3664-8372

Singapore

Mitsubishi Electric Asia Pte, Ltd. 307 Alexandra Road #05-01/02, Mitsubishi Electric Bulding Singapore 159943

Tel : +65-6470-2480 Fax : +65-6476-7439

Thailand

F.A.Tech Co.,Ltd. 896/19,20,21,22,S.V.City Building,office Tower1,Floor 12 Rama Bangkok 10120

Case example of assembly line quality control . . . Servo motor plant (began operation in May 2005)

Quality improvement through real-time quality control!!

The latest case example of MES interface introduction took place at our servo motor plant.

The MES interface was introduced under the motifs“meticulously”and“in real-time.”The system configuration, with the MES interface at its core, linked the information system with the control system and related devices.

50% reduction in lead-time

180% increase in productivity

●Operation control ●Quality control ●Real-time QC

*The numbers reflect the actual results of Mitsubishi Electric Nagoya Works e-@Factory plants.

50% reduction in quality loss

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Quality auditor Line leader

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Quality information Operation information Instruction information

Magnet application

PLC with MES interface

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Intermediate testing

Welding

MES database server

Balancing

(operation/quality control system)

Residual c. . unbalance, , et etc ed etc. s, us on s l o cti o u t r Dimension Assessment t nd ins accuracy, result, etc. sa wn jig etc. tdo es u m ti sh Assessment f t Application n ro result, etc. me conditions, be uip um etc. ,n Eq s u at Accuracy, t s e/ etc. tim Encoder ion Mold test rat e conditions, Op Assessment etc. results, etc.

Winding resistance value, etc.

Welding conditions, etc.

Assembly accuracy, etc.

Resistance test

Winding conditions, etc.

Quality control information Operation control information Consumable jig and tool information, etc.

Pre-shipment test

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tion

ana

lys

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Production engineering department Line leader

, ns tio uc str tc. n i t ,e en ns em tio lac ruc ep inst r Jig tup se

Worker

Encode assembly

Average resistance value, etc.

Pressure resistance tes

Winding

ipm

ra o pe

Bolt tightening torques, etc.

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：MES interface

Accuracy measurement

Magnetization conditions, etc.

Assembly

System branch LAN Magnetization

MES interface introduction locations at servo motor plant

Case example of machining line process control . . .

Electrical discharge machine machining plant (began operation in September 2003)

High production efficiency achieved through meticulous process control!!

The e-F@ctory solution was deployed in an electrical discharge machine plant facing issues such as“manual development of production plan” and“network system incompatibility.”By making it possible to comprehend onsite issues directly, the e-@Factory solution increased device and equipment operation efficiency, optimizing the production system. ●Production site scheduling ●Tool information management ●Machining monitor

in equipment 190% increase operation rate

40% reduction in machining time

in manufacturing 60% reduction period *The numbers reflect the actual results of Mitsubishi Electric Nagoya Works e-@Factory plants.

Rd,Bangpongpang,Yannawa,

Tel : +66-2-682-6522 Fax : +66-2-682-6020

Indonesia

P.T. Autoteknindo Sumber Makmur Muara Karang Selatan Block A/Utara No.1 Kav. No.11 Kawasan Industri/Pergudangan Jakarta-Utara P.O Box5045 Jakarta 11050, Indonesia

Tel : +62-21-663-0833 Fax : +62-21-663-0832

India

Messung Systems Pvt.,Ltd. Electronic Sadan NO: Unit No15, M.I.D.C Bhosari, Pune-411026, India

Tel : +91-20-2712-3130 Fax : +91-20-2712-8108

Australia

Mitsubishi Electric Australia Pty.Ltd. 348 Victoria Road, Rydalmere, N.S.W 2116, Australia

Tel : +61-2-9684-7777 Fax : +61-2-9684-7245

Mitsubishi total automation solution e-F@ctory

Tokyo Bldg., 2-7-3 Marunouchi, Chiyoda-ku, Tokyo Japan 100-8310

e-F@ctory is a registered trademark of Mitsubishi Electric Corporation.

All other company names and product names in this document are the trademarks or registered trademarks of their respective owners.

Nagoya works have acquired the certification for Environmental management system ISO 14001 and Quality assurance management system ISO 9001

Safety Precaution To ensure proper use of the products presented in this catalog, be sure to read the relevant manuals prior to use.

EC97J1113

L（NA）16005-A（0612）MDOC

New publication, effective December 2006.

Specifications subject to change without notice.