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
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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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we going to produce next month . . .
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e-F@ctory Solution Operation rate improvement
Process
s
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.
r ME
S in
terfa
ce i
●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
Equ
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Quality information Operation information Instruction information
Magnet application
PLC with MES interface
r ato St
e lin on cti u od pr Mold
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
en t
tion
ana
lys
o ol
is t
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.
ly mb se as r to Mo
e lin
：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.