AUTOMATION AND PROCESS CONTROLManufacturing Execution Systems

THE CONTROL TECHNOLOGY GROUP

FAST SpA has been a leading enterprise in the industrial automation sector since 1982. Besides supplying process control systems, it can also provide software allowing customers to effectively and efficiently switch from plant automation to integrated management of the factory procedures, while guaranteeing complete control of the production processes and in-house logistics.

Specialized in many different fields, FAST excells in the creation of SCADA (Supervisory Control And Data Acquisition) packages, designing MES (Manufacturing Execution Systems) for production operations management, and in planning middleware to support complex distributed applications.

The systems designed and created by FAST allow the different production process tasks to be monitored, controlled and supervised, while the information provided by these systems enables the plant management staff to streamline the production process, from receipt of raw materials through to shipment of the finished goods. The reports drawn up on the basis of information from the various processing stages are of fundamental importance when it comes to planning the production, ensuring complete product traceability, for programmed maintenance and to strengthen the corporate quality system.

Production management solutions

Application Sectors Food & Beverage Automotive Cement Ceramic Chemical Engineering Oil & gas Packaging Iron & Steel

PRODUCTION PLANNING

INTERNAL LOGISTICS & WAREHOUSE

IDENTIFICATION & TRACEABILITY

MES software creates a link between the management area or "brain" (ERP) and the production area (machines and systems): this resolves the problem of correlating factory process and business information with critical information, with which the management is provided in real time.

To provide a complete manufacturing control and execution solution, FAST has come up with a proposal whereby Plant View, the SCADA designed and created by FAST itself, is integrated with MES systems. Plant View acquires the “DATA” from the field, controls and supervises both the individual machines and system. The MES systems pilot the manufacturing tasks and collect, organize and manage the data acquired by SCADA, converting them into “INFORMATION” that can be used for management purposes.

Thanks to MES software, the machine-level of the HMI turns into integrated factory management. In other words, a true centralized control system that connects all the information in each individual piece of machinery to a single management console. FAST supplies the key components for handling operations like:

- production planning - product traceability - machine performance analysis - programmed maintenance - process control - data acquisition

The integrated computer system implemented by FAST not only controls and executes the various manufacturing stages, but also manages the different areas of the logistics chain. This is because the system also includes software modules for:

- end-of-line handling - LGV control - warehouse management

Production management solutions

PROGRAMMED MAINTENANCE

PERFORMANCE ANALYSIS

DATA COLLECTION & ACQUISITION

MES applications Integration with ERP Shop floor HMI Manufacturing reports

Energy Management Factory energy management

Business Intelligence Data collection and analysis to pin-point critical solutions and assess plant productivity

Traceability Collection and aggregation of the data from different production departments so as to trace the process flow of the finished product

Identification and logistics Identification of packages/pallets using RFID/barcode/matrix/labelling

Special communication protocols System integration with non-standard units/packages

TECHNOLOGIES USED Data management with advanced databases MySQL – SQL Server – Oracle - Access

Integrations with corporate ERP systems AS400 – JDE – SAP – Oracle - NAV

Communications in real time OPC – TCP/IP – GPRS - WiFi

Interfacing with process units PLC – HMI – DCS – Scales

Info dissemination on portable devices Hand-held computers – Smartphones – Notebooks - Tablets

Identification technologies RFID – Barcodes – Matrix – Labelling

Interfacing with identification systems Printers – Punches

Production management solutions

Fast Energy Manager

Factory energy accounting system. This software allows the energy consumption of each production department to be monitored, i.e.: - electricity, - gas, - diesel fuel, - water, and displays the incidence of the energy costs of the various processing stages. After due analysis, the system puts the management in the position to decide how to improve the production process and reduce the influence of energy consumption on the cost of the finished product, thereby making this latter more competitive.

Fast OEE

The system that streamlines plant efficiency from the productive viewpoint. Fast OEE software is ideal for monitoring performance and includes the following functions and characteristics: • provides accurate information about downtimes (where, when and

why) • provides information about the performance, or non-performance,

of any person in the company without complicating or overburdening the computer systems

• gives the right information to the right people in real time, so as to facilitate decision-making

• it's easy to use and configurable, and can help the customer to discover the reasons for poor performance

Fast Track

The system that manages product traceability and reverse traceability. Functions:

• planning and traceability on production lines

• management of orders and quality system

• management of product packaging article data sheets

Production management solutions

Warehouse Management System

A system that manages automated and manual warehouses. It resolves the typical problems encountered in vertical automatic warehouses, such as correct use of the available space while guaranteeing an optimum performance, or correlation with the manufacturing system (inflows/outflows) and with the administration system (orders/deliveries). Its main functions are: • Management of the stock picking, deposit, inventories and

refilling operations • Consultation of warehouse master data • Consultation of available materials in stock • Statistical analysis of material transfer frequency and historical

data • Manual plant management • Activation of shipment orders • Management of loading bays • Automated management of block storage warehouses using

radio frequency • Integration with robot-supported production lines and with LGV laser

guided vehicles • Interfacing with ERP systems

Starlight Dosing System

This system handles batch production processes with the following functions: • Advanced recipe management • Management of production lots • Manufacturing reports • Interfacing with ERP systems • Interfacing with automation systems This software assesses conformity with the recipe preparation process and is thus the key element in the creation of end products that comply with the corporate quality requirements.

Production management solutions

Maintenance

Software that handles the maintenance required by machines and systems by focusing on the work performed by critical components so as to plan preventive maintenance schedules. You can: • define the plant layout • define, for every system data sheet, the parts or components that

need preventive maintenance • acquire information about the work performed by the components

so as to update the maintenance schedule • obtain an overall view of the entire system from the maintenance

viewpoint • create a log file of the maintenance work performed • display documents (diagrams, manuals) concerning specific parts.

Fast Alarm Messenger Server

Automatic messaging handling system to ensure that problems are promptly and efficiently resolved. The system uses all the options provided by information

technology. The communications are made in accordance with the standards available on the market, i.e.: e-mail, voice calls, SMS, annunciator panels, etc. The application is closely linked to the computer-assisted heart of the process:

it pin-points all intervention needs and informs the personnel how they should act.

Alarm

<STATION><DATE/TIME><DESCRIPTION OF ALARM>

Production management solutions

Production management solutions

FAST offers solutions that stand out for their high-level technological content, with particular care dedicated to customer requirements. Each project is thoroughly analyzed and researched down to the tiniest detail. The goals and existing architecture are assessed during preliminary meetings with the customers. A technical offer, drawn up on the basis of the information acquired, includes flow charts and graphs to illustrate the most suitable solution from the technological and cost allocation viewpoints; a solution which fully complies with the customer's requirements.

Application examples

Unichips

Fast has created a handling supervision and management systemfor the Unichips Group's Novara factory

San Carlo, which belongs to the Unichips group, is a long-standing Italiancompany that, in 1936, became established on the market thanks to arevolutionary speciality: “potato crisps”. Undisputed market leader for thepast 75 years, the company has always paid great attention to developmentand constant innovation

FAST used an advanced MES system. It assures global management of the productionprocesses and internal logistics by expanding with the Unichips computer information system.The system performs two-way data exchanges between the automation system and theinformation systems (JDE, Kompass and Oracle) used by the company.

Packaging Department The automated system acquires the job orders, complete with codesand bills of materials, from the Unichips computer informationsystems and sends the operating data to the machines andsystems. Data acquired by the machines and systems in real time arecollected and stored in the SQL database so as to provide thecorporate management system with the production history.

Raw Material Processing Department The system includes several software modules tailored to thecustomer's specific requirements. They are designed to controlall phases of the process and to communicate with all the otherterminals in the factory. The system takes the scheduledproduction orders from the information system and sends themto the shift supervisor's terminal for execution. Once productionhas been enabled, the data are sent to the terminals and to thepotato processing machines, the conveyors that carry the binscontaining the raw materials and to the packaging lines. Everyprocessing step and operation is checked and recorded to as toensure its traceability and the quality of the finished product. Finished Product Warehouse The system interfaces with the management system from whichit obtains the shipment orders then, after having checked tomake sure that product is effectively available, it transmits the picking details to a mobile device. When the order is closed, allthe information about the products picked from the warehouse isshared with the Unichips management system, which issues therelative transport document and keeps its warehouse aligned.

Application examples

Packaging Material Warehouse The Packaging Warehouse is managed in the same way as the Finished Products Warehouse: thesystem deals with the receipt, storage and outflow steps in the automatic mode and notifies the Unichips computer information system of the tasks performed.

The Farchioni family processes agriculturalproduce and is one of the longest-standingUmbrian industrialist families.

Benefits that lead to increased competitiveness for the company and clearer perception of thequality of the products by the consumers.

The supervision software was created using Plant View SCADA, result of FAST's know-how,and is integrated into the global management system of the warehouse. It interfaces with thefactory management system. Integration of the various different systems has been achievedthanks to the Internet and wireless technologies.

The information system: - identifies materials and finished products - sends raw materials to the packaging lines - deals with end-of-line logistics - deals with warehouse stock inflows/outflows - handles labelling for traceability purposes - manages shipments directed to the sales outlets

The raw materials and finished products are handled with theaid of LGV (Laser Guided Vehicles) manufactured by Elettric80, a leading enterprise in the logistics sector.

Integrated computer system for warehouse, traceability and logisticsoptimization management.

Farchioni Olii

Application examples

The block storage warehouse management project goals for Farchioni Olii S.p.A.'s new factory are:

- widespread data collection and access to information concerning quality control andtraceability

- efficient, rapid goods handling - optimization of the warehouse space and consultation, in real time, of the effective

availability of material

Atlas Concorde

Fast uses an integrated MES-based approach toautomate ATLAS Concorde's data collection system

Established in 1969, Ceramiche Atlas Concorde is the founder of the Concorde Group, the second largest ceramic tile group in Europe. Atlas Concorde is a major player in the ceramic industry and one of the world's most important and firmly established undertakings.

FAST has created an integrated, modular and configurable factory supervisory system: itproduces production reports, printouts and statistics, thereby monitoring and optimizing plantefficiency. The system monitors and optimizes the manufacturing efficiency of the departments, from raw materialsto mixes, from presses to inward and outward management of the finished products. The system functions synergically with the corporate computer information systems and creates afactory computer system that performs specialistic functions related to the individual manufacturingdepartments as well as interfacing with the company's business management system (ERP).

The MES system fully meets the corporate targets: - Industrial cost control, enabling the Group policies to be planned - Performance monitoring of the individual departments and machines - Reverse traceability of lots

Departments involved Production Laboratory

Maintenance CED

Warehouse

Target functions Lot management

Downtimes Line sizing

Lot production advancement Creation of production statistics

Integration with ERP Inward inventory movements

Preventive maintenance

Thanks to the general supervisor, each production lot can be trackedalong the production line and through the departments, while dataconcerning the previous processes can be traced at any time.

Not only the production parameters of the processing phases aremonitored and analyzed, but also energy consumption. This provides the management with the information required:

• to implement efficient savings policies • to assess the consumption trend over time • to pin-point waste and faults • to optimize each individual production phase

Application examples

These functions must therefore be integrated into acomputer information system.

The structure of the integrated computer informationsystem created by FAST for the companies belongingto the Fontana group can be divided into two mainparts: 1. supervision and collection of the production data

acquired by interfacing with the electronic systems,field sensors, staff members' devices, etc.

2. data entry into the factory's local network, their

management, printouts of reports and statistics,inwards and outwards inventory movements andtheir transmission to the central accounting system(ERP)

FAST created the planning, supervisory and traceability system for the production lines ofBulloneria Fontana Luigi S.p.A. and Industria Bulloneria Speciale (I.B.S.).

Fontana Group

Industria Bulloneria Speciale of Ferriera di Buttigliera Alta(TO) is one of Europe's most important industries for theproduction of standard and special bolts, screws and nuts,mainly used by automotive industries world-wide.

Situated in Verduggio (MI), Fontana Luigi S.p.A. is Italy'smost important manufacturer of high-strength nuts and boltsand one of the world's major industries in this particularsector.

Growing competition and new technological challenges require an increasingly more efficient controlover the capabilities and production quality of companies. Close relations among planning, process control, production parameters, the productivity of themachinery itself (downtimes, maintenance, etc.), industrial accounting, production reports andthe audits required by the ISO quality standards becomes even more essential. None of these issues can be considered separately, since they are all deeply integrated and linked asproduction takes place.

Application examples

Application examples

Fonti di Vinadio S.p.A.

A steadily increasing turnover and production rate, expansionpotential and far-thinking strategies, business agreementswith the major supermarket chains: these are the factors thatmake Sant'Anna di Vinadio mineral water one of the mostpopular brands in Italy.

The computer system implemented for this customer included several integrated levels: - processing level, where our systems interface with the corporate management system; - MES level, with management of the operating tasks of the various different production phases and

collection, organization and processing of data acquired in real time from the production lines; - logistics level, control of the internal handling operations, storage, stock management and

shipment, plus identification and traceability of the raw materials, semi-finished and finishedproducts.

FAST acted on the company's digital nervous system toachieve close integration between the productioninformation system and the logistics chain. Thisinvolved automating and integrating different operations: - interfacing with the corporate management system - laboratory analysis - management of raw materials - production planning - marking - wrapping - labelling - end-of-line handling - storage and shipment

The complete automation system in the Sant’Annamineral water factory of Vinadio was created byFAST.

The idea was to streamline the link between physical production flow and the flow ofinformation. Achievement of this goal resulted in important benefits, namely: - improved flow efficiency, with materials or information provided in the required quantities,

state and at the right time; - improved flow efficiency, with a view to achieving the lowest overall cost; - reduced time-to-market.

Full access to the process data is thus ensured. The information available is: - useful: for traceability, flow optimization and, more generally, for streamlining the logistics flows - aggregate: data from the individual information subsystems all flow into a single database (WMS) - complete: the system deals with data concerning the entire process flow - up to date: the data are collected straight from the production lines in real time - easily used: the Intranet interface is extremely simple and user-friendly

Application examples

Capabilities that add up to a competitive edge for the company, which can organize all the flows ofmaterials, equipment, semi-finished and finished products throughout the various different processingphases, from the time the raw materials arrive to when the products are shipped.

The raw materials and finished products arehandled with the aid of LGV (Laser GuidedVehicles) manufactured by Elettric 80, a leadingenterprise in the logistics sector. After the LGV were set at work, the cross dockingand warehouse stock inflows/outflows were able tobe performed in a fully automatic way.

Process control is performed by means of PlantView, a graphic supervisory package including aSCADA integrated with the HMIS operatinginterface.

The data from individual information weredirected towards a single system that canbe shared and queried via an Intranet sothat any product can be traced andreverse traced, thereby conforming to thetransparency specifications required bylaw. More specifically, the authorized operator canaccess all the data concerning suppliers,lots, articles and end customers from anyPC station via an Internet browser.

For VM Motori, FAST created a Data Matrix 2D barcodereading system in line that unequivocally identifies eachinjector. The Data Matrix codes are just 3 mm square, are stamped onthe actual injectors and contain information about theproduct's technical characteristics. FAST's system reads the codes thanks to 4 cameras,stores them in the network's database for traceabilitypurposes and prints a barcode label containing essentialinformation obtained from the codes themselves. Theselabels can be read during any phase of the process and areespecially useful for reverse tracing the characteristics of theinjectors, thus for optimizing engine efficiency and configuringthe electrical junction box in the right way.

Module containing themonitoring devices and thedigital cameras that read thecodes on the injectors.

The 4 Data Matrix codes read by the digitalcameras are shown within the red circles. These codes are able to compress a greatdeal of data in small spaces even when thesurfaces are not linear.

Established in 1947, VM Motori specializes in designing andmanufacturing diesel engines for a wide variety of uses.

FAST has created several software modules for VM Motori, thepurpose being to monitor and trace the data from the differentengine processing phases.

The barcode label printedthanks to FAST's readingsystem contains essentialinformation provided by thecodes themselves.

Application examples

VM Motori S.p.A.

Application examples

FAST is involved by VM Motori whenever different systems must be interfaced, especially when thecompany's ERP systems must interact with the production processes.

FAST recently created a system that handlesthe supply of components required for theengine assembly operations along the lines.

Production requirements have highlighted the need to print the list in two consecutive steps, based online running time. The system interfaces with different field devices, such as Beckoff input/output modules (which acquirethe line status signals and then control an indicator light to guide the operator through his tasks) and amultiline LED display that shows the job order advancement data.

The engine assembly lines are highly specialized and already equipped with systems for monitoring andcontrolling the functions to which they are dedicated. Generally speaking, these systems do not link tothe corporate management system. As System Integrator, FAST can rectify this by implementing systems allowing the different areas ofthe company to communicate with each other, i.e. the management and the production departments.

All the data are stored in the SQLdatabase and are re-processed anddisplayed via a WEB interface that can beconsulted by the operators in the variousdepartments. Given a production lot, the inflowing serialnumbers and components used for themanufacturing processes can thus bechecked at any time.

This system acquires production orders from AS400 andmakes sure that semi-finished parts conforming to the orderspecifications are imported into the assembly line inflow.The picking list for the components required by the enginein question is then printed, depending on the engine modeland production throughput.

Cooking Station When the products are cooked, the PC station is usedto program the process ovens and to control importantvariables, such as temperature, condensation andcooking time. These variables are not only available in real time, butare also stored in the form of trends.

Leaf bases its business activities on certain fundamentalvalues, like the utmost attention to product quality, a greatrespect for tradition, on-going research into pioneeringproducts and new formulas, the highest regard for thecustomers and their needs.

Moulding Station The lots are run from the two work stations in the moulding department. The different automated phases include, gum melting, paste condensing, the addition of flavourings,filtering and cooking. The barcode allows the trolley of the lot currently being produced to be identifiedwhen the flavourings are added.

In detail, the system comprises 4 PC stations installed in different factory areas. These stations areintegrated into the network with a Server installed in the production managers' office. Thanks to this central station, the managers are able to plan the weekly production schedule, monitorthe process in real time and handle trends and reports. The processing phases are supervised by Plant View. This allows the operators to monitor andcontrol the system from each station, and to acquire all the data required for management tasks fromthe production processes. Flavouring Dosing Station The weekly schedule data are used by the PC in the flavourings department, which is connected to ascale. This allows the relative aromatic ingredients to be dosed for each individual lot. The PC is alsoconnected to a printer, enabling reports to be obtained in real time. Once they have been matched to their respective lots, the aromatic ingredients are placed on trolleysidentified by barcodes.

The system in question is a perfect example of MES. It deals with job orders and creates reportsfrom the different manufacturing phases, which form the traceability structure and are anintegral part of the corporate quality system.

Leaf Italia S.p.A.

FAST created a traceability, process automation andsupervisory system for Leaf Italia S.p.A., in theprovince of Bologna.

Application examples

DOSING Module: provides valid support when thecomponents used to form the batches are dosed in themanual mode. It displays job orders in one of the threemanual stations (medium, activating and acceleratingadditive), checks the weight of each component andrecords each weight in a dedicated table (in the server).

LABEL Module: handles the labelling operations foreach batch leaving the mixers and for the palletsweighed in the stations after the mixers or in the centralweighing station.

REPORT Module: this is the program that logs,displays, finds and prints the production data. The datadisplayed are limited to the selected work area and tothe search criteria specified.

Evercompounds is an industry situated in the Ravenna area that manufacturers rubber and plasticarticles.

Evercompounds

The information system comprises various integrated modules:

BLENDING Module: software that monitors andsupervises the blending process. It allows parametersto be set, manages alarm messages and monitors thestatus of the system.

PRODUCTION MANAGEMENT module: the joborders are uploaded via the interface with thecompany's ERP, after which they are processed andconverted into commands for each individual productionunit, thereby ensuring synchronized execution of themanufacturing operations. The module also identifies both materials and finishedproducts, and deals with the warehouse stockinflows/outflows.

Automation of the production lines, integration with the corporate management system andproduction management are the functions provided by the system that FAST has created forEvercompounds.

The system has reduced time-to-market and has substantially improved the efficacy and efficiency of the production process.

Application examples

Our references

FAST SpAVia Molino Poncino, 4 - 42019 Scandiano (RE) - ITALYTel. (+39) 0522.622411 - Fax (+39) 0522.627194www.fastautomation.it - info@fastautomation.it

TECLAB SrlVia delle Pianazze, 74 - 19136 La Spezia - ITALYTel. (+39) 0187.982747 - Fax (+39) 0187.982790www.teclab.net - teclab@teclab.net

FASTEST SrlStrada Stramutati, 54 - 610203 Piatra Neamt - ROMANIATel. (+40) 333.401129 - Fax (+40) 333.401130www.fast-est.com - info@fast-est.com