Extension to the Shop Floor

PC-Topp Machine Terminals provide on-line feedback from every machine

PC-Topp's Machine Terminals extend the PC-Topp system to the shop floor. Mounted right next to the machine, they display the schedule of the next orders to be run as well as the current order and production history. The schedule is constantly kept up-to-date – any changes occurring in Planning, or anywhere else in the plant, are instantly reflected.

On-Line Access to Schedules, Order Data, Drawings

The terminals permit on-line access to the order data right at the machine, including details like printing and cutting dies, ink colors or glue style. They show at all times which of the next orders is actually off the corrugator – just one of the advantages of the permanently up-to-date database that PC-Topp maintains.

The screens are organized by tabs that give direct access to all information and functions. A graphic display realistically shows the order information in relation to the machine. With a finger tab on the terminal's touch screen (optional) the view can be switched to job card, printing instructions etc. In the Order tab, the CAD drawing for the current order pops up automatically, other graphics like the printing instructions are available as well.

Ease of Operation

Everybody at the machine is quickly familiar with the PC-Topp Machine Terminal: Built-in intelligence suggests the right next action automatically, making the terminal very easy to use. The use of a touch sensitive terminal screen makes the interaction even easier and more intuitive.

The terminal suggests the next scheduled order to be run, and the operator either confirms or selects another one by simple point-and-shoot. No more incorrect order numbers due to input errors, no need for barcoded order sheets!

The terminal makes it easy to pull an order forward when necessary, or even re-schedule an order from another machine if a problem arises at night, for example. After any such action, the overall schedule is instantly updated, and Planning (and the other machine's crew) are alerted.

Automatic Capturing of Times and Quantities

The times for Start Setup, Start Run and End Run are sensed automatically, and a Counter (type IVO N214) connected to the machine is used for automatic recording of the quantities processed through the machine. To get the produced count of good items, the terminal asks for input of the number of pallets, the quantity per pallet, and the quantity on the last pallet.

Breakdowns are also sensed and recorded automatically, and the terminal prompts the operator to select a downtime cause from a clearly structured on-screen list. Breaks are also taken into account, as are downtimes occurring during setup. And just as in a handwritten shift report, the crew leader can explain with comments what exactly went wrong.

The terminals prompt for Quality Checks in accordance with predefined rules, and record the results including any measured values that may be required.

Finally, the Machine Terminals can also be used for Personnel Data Entry: Each crew member simply inserts his smart key into the optional chip key reader when coming or leaving, and the system knows at all times who is present, and at which machine.

Downtimes, setups, production counts – all production events are recorded and archived, forming the basis for Comprehensive Production Reports, available instantly and for any period in time. Graphical performance diagrams make it easy to analyze a shift in detail. All production data can also be shared with the host system to replace costly manual data entry.

In a separate section of the terminal screen, On-Screen Performance Indicators show the crew how well they are doing on the current job, or so far during their shift.

PC-Topp.NET Machine Terminal in Action

This is the PC-Topp.NET Machine Terminal in operation on a touchscreen terminal (images courtesy of Ondulati Ghelfi SS).