Supervisory Control and Data Acquisition (SCADA) uses Programmable Logic Controllers (PLC) to electronically control and monitor production machinery. Many manufacturing companies have installed a PLC on their production machines. But few have learned to take advantage of the raw data the PLC collects.
The Plexus PLC/Machine Integration, Settings/Recipes (SCADA) Module establishes an electronic linkage between the Plexus Online information and your production machines that allows you to finally take advantage of your PLC-equipped equipment.
Monitoring & Reporting: Production machines automatically report uptime, downtime, faults, production counts, and other critical events to Plexus. All machine status changes are recorded in Plexus Online’s detailed Workcenter Log, which drives downtime analysis reports, OEE, labor and production efficiency reports, and other subsystems. This increases accuracy of management reports at the same time it reduces dependency on human labor.
Plexus Online automatically gathers, collects and summarizes pertinent PLC data into useful management information. Plexus Online provides an array of powerful reports.
Controlling: Optionally, Plexus Online can be setup to not just monitor, but control the production machinery. For example, some of our customers configure Plexus Online to automatically pause the machine when the standard quantity has been produced into a bin (preventing non-standard pack sizes) or the job quantity has been fulfilled (preventing over production). Others configure Plexus such that it will not let the machine physically run unless an approved operator has logged in, the correct tools are installed in the machine, the correct raw materials are in place, and the proper quality inspections have been performed.
Plexus Online stores and organizes Machine Setup Recipes. A recipe is a collection of machine settings that will configure the machine to produce a specific part in the most efficient and repeatable fashion. Accessible from the Plexus Online Control Panel, this allows the operator to easily download a standard setup into the PLC at the beginning of a production run, thus auto-configuring the machine in a standard way each time for that specific part. This decreases setup time, reduces variation, improves quality, and increases production.
The Plexus Online Shop Screen Module provides a map-like pictorial view of the overall shop floor, depicting each production machine in a different color and animation depending on its current status. This is a useful communication tool for tooling and maintenance personnel to know what’s happening at all the machines. It also provides a useful supervisory tool for management. The Shop Screen concept is patented by Plexus Systems, LLC.
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