Mitsubishi total automation solutione-F@ctory

Outlining innovativearchitecture from shop floor to Enterprise!

A winning solution for the manufacturing industry!

A winning solution for the manufacturing industry!

*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.

Mitsubishi Elect ric providespiece of mind to all automationrelated hurdles

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.

Easy to link Enterprise systems to the shop floor. Utilizing Mitsubishi Electric's diverse range ofautomation products, provides a realization ofintegrated manufacturing.

e-F@ctory SolutionOperation rateimprovement

Shortenedlead-time

Cost reduction Qualityimprovements

ProductionPlanning

Qualityimprovement

Shorterlead-time

Costreduction

Increasedbusinessefficiency

Plantproductivityimprovement

◆ 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.

Server

Process Process

ProcessProcess

Process

Process

Process

Process

Production

Planning

Quality Control

Productivity is low and defects are high.Our lead-time is long.

We have much waste in our plant.

Such plants require the

e-F@ctory solution.

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

OK now, the recipe

for the next product is . . .

Production

Results

Inventory

Work in

Progress

Job

Inst

ruct

ion

She

et

How much arewe going to

producenext month . . .

Make a productionstatus report.

When can we finish

the products forCompany A?

Uhm . . .

I, ll g

o se

e.

・Delivery・Inventory ・Work in Progress・Process

When can we finishthe products for

Company A?

They are in the×× Process now,

so we can shipthem today.

Optimalproduction

plan

Controldefective

parts No defectiveparts

Great! We madeproduction!

Executive

QualityControlProcess

Control

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

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

Motion controller Numericalcontroller

ElectricalDischargeMachine

AC servo

Laser machine Robot

CC-Linkpartner productsMitsubishi ElectricCC-Linkcompatible products

Mitsubishi Electric CC-Link/LT compatible products

3rd party controllers

Inverter Energy-savingdevice

MES interface module(MELSEC-Q: PLC)

MES interface function(GOT1000: HMI)

ERPEnterprise Resource

Planning

MESManufacturing Execution System

MES Interface

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

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

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

Control system: Equipment(Mitsubishi FA Product Series)

Instructions from upper managementare not communicated.

Onsite opinions and ideas are not utilized.As a result,

production does not run smoothly.

A means of collating andinterfacing all that information

between levels

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.

Gateway PC

MES(Manufacturing Execution System)

database server

Control network(MELSECNET/H etc.)

OverallcontrollingPLC

Resultsmanually entered

orprocessing program

executed byoperator

MES interface

MES(Manufacturing Execution System)

database server

Processing program◆ Data collection◆ Data processing◆ Data communication

Control network(MELSECNET/H etc.)

□

□

□

□

PC not required

* The number reflects preliminarycalculations based on the eliminationof PCs and programs.

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

●Utilizing event driven data management resulting in efficient database

　communication.

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

●Including a data buffering function which ensures data back-up during

　communication errors.

●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.

The New MES Interface:A Simple Low-CostMES (Manufacturing Execution System) toShop Floor Interface!!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.

Accurate identification ofproduction information

System construction simplification

System construction periodand cost reduction

Stable operation

decrease or more in systemimplementation cost!

After MES interface introduction

Standard

I would like to be proactivein the digitization of

shop floor information.But, without the high costs.

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

With <<MES interface>>,

is realized.

　　　　　　　 ◆ Operation performance　　　　　　　　 result data.　　　　◆ Equipment management data.　　◆ Quality control data.◆ Traceability data, etc.

MES InterfaceFeatures and Benefits.

The MES Interface: The Key to Realizing a visual platform e-F@ctory.

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.

The MES interface enables the collection of information from

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

single database.

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

Ethernet

DBDatabase server

PLC Temperaturecontrollers

Barcodereader

MES interfacemodule

GOT interfacefunction

MES Interface Function ListItem Description

Database link function

XML processing function

Time synchronization function

Tag function

Trigger monitoring function

Trigger buffering function

SQL message transmission function (communication action)

Operation processing function (operation action)

Program execution function

DB buffering function

Accesses the database by job.

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

Calculates the tag element value.

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

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)

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

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.

Executes XML format message requests from the user application.Job one-shot execution ／ Job enable/disable (trigger execution allowed/not allowed)

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

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)

MELSEC-Q PLC MES Interface ModuleProduct Name Model Description

MES interface module

Compact flash card

QJ71MES96 MES interface function execution module

Required. 128Mbytes or higher. (Mitsubishi Electric or commercial product)

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

GT Designer2 Version2 SW2D5C-GTD2-J GOT1000 image creation tool for setting MES interface function operation settings, server service settings, etc.

GOT1000 MES Interface FunctionProduct Name Model Description

ＧＯＴ1000

Option function board

Ethernet communication module

Compact flash card

GT15＊＊-＊＊＊ GT15 series GOT module

MES interface function execution board (extension: 48MB)

Ethernet module

Required. 128Mbytes or higherMELSEC-Q PLC MES Interface Module Information Link Support Tool

Product Name Model Description

Information link support tool

（ MX MESInterface ） SW＊DNC-MESIF-J

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

－

－

Info

rmat

ion

flo

w

MES interfaceCommunication module

Controller (CPU) Controller/GOT

Pollingprocessing

PLC communication

Upper information systemcommunication processing

Gateway PC

Database

MES application

Enterprise system

Database

MES application

Enterprise system

MES Interface Specification List Item Specifications

Connectable databases

No. of connected databases

No. of jobs that can be set

Trigger buffering

No. of conditions connectable

Condition type

Monitoring cycle

32 databases/project, maximum

64 jobs/project, maximum

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

128 times, maximum

100ms or higher

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

JobD

atab

ase

link

Trig

ger

cond

ition

s

Item Specifications

Statistical processing

DB buffering capacity

6 types (average, maximum, minimum, moving average, moving maximum, moving minimum)

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

Data types

Number of elements

64 tags/projectNumber of tags

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

Maximum capacity: Compact flash card capacity – 32Mbytes (to 512Mbytes)

Dev

ice

tag

Dat

abas

e lin

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

4 types (select, update, insert, operation)

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

Number of communication action fields

Number of operation actions operable

Operation actionoperator

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

Act

ion

Job

Act

ion

Type

10 actions/job, maximumNumber of actions that can be set

DB

MES (Manufacturing Execution System)

Databaseserver

Workschedule

Productioninstructions

Productionand qualitycontrol data

Producttracing data

Equipmentoperation

information

MES interface

Temporarily storesimportant dataon CF card!!

Data processing(operation processing, logging, etc.)

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

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

■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.

*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.

GT15-MES48M

GT15-J71E71-100

SW2D5C-GTWK2-JGT Works2 Version2

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.

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

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 startupHardware operation: Starts the job upon request by the PLC CPU

Eventdriven

communication(SQL)

Adopting event driven data communication.

Support of a wide variety of cutting-edge functions that ensure data reliability.

Easy database connection using intuitive utility software.

DB access conditions specified

Setting for executing server program before andafter database send/receive

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

SQL message automatically created by settings

Write destinationspecified

Large-scale production line manufacturing execution system compatible.

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

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

●Manual labor costs significantly reduced by automation of all test result　collection and history management.

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

Test records automatically collected and managed!!

Lot-based sampling records

MESinterface

e-F@ctoryserver

TestTestNotation

Test resultdata

Data entryMaking

advancestoward

zero defect outflow!!

Before introduction Automatic recording of all products

Afterintroduction

●Defect prevention by real-time status detection by test device

●Prompt and automatic advance warnings (by e-mail) based on　actively monitored bar-charts

●Countermeasures addressing upstream processes by detailed data detection

Aspiring toward zero quality loss!!

Action takenafter defect occurs

Quality data collected and

analyzed manually

Productiondate

Warningissued

Control upperlimit

Control intermediate

limit

Control lowerlimit

Control range ±A%

Cause identification and correctiveaction based on accumulated data analysis

±0.8A％

Data collected and analyzed manually

Makingadvances

towardzero quality

loss!!

Before introduction Defects prevented in real-timeAfter

introduction

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

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

Prevention of Production Stops by Automatic Management of Jig and Tool Information, etc.Aspiring toward a zero process stop time!!

MESinterface

Before introduction After introduction

Equipment error!

Repair

Production stopped

Complete

Preventive maintenance

No impact on production

e-F@ctory systemPlanning

Service life estimation

Performance report

Recovered

Making advancestoward

zero productionstops!!

●Zero initial time with prompt automatic notification (e-mail) to controller　when trouble occurs

●Abbreviated corrective action time through past corrective action database utilization

Quick notification by e-mail of defect occurrence!!

Device

Defect!Line

stopped!

Defect!Line

stopped!

Line leaderCheck by worker Group leaderDevice

e-F@ctoryserver

Sectionmanager

Group leader

Line leader

Worker (GOT confirmation)

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

MESinterface

Trouble relayed by persons

Making advancestoward

zero trouble response time!!

Before introduction

Automaticnotification

Afterintroduction

Branchmanager

Production plant incorporateshigh defects and a low yield.

Is there any good way towork toward zero quality loss?

With <<MES interface>>,

has been achieved overall.

Defect outflow prevention by total automatic data collection and management.

Zero Defect Measures Based on Real-Time Quality Control.

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

increase in productivity180% reduction in lead-time50%

reduction in quality loss50%

Magnetization

Assembly

Mold

Encode assembly

MES database server (operation/quality control system)

Quality control informationOperation control informationConsumable jig and tool information, etc.

Windingconditions, etc.

Assessmentresults, etc.

Assessmentresult, etc.

Assessmentresult, etc.

Accuracy,etc.

Average resistancevalue, etc.

Stator productio

n line

Rotor productio

n line

Motor assembly lin

eWeldingconditions, etc.

Applicationconditions, etc.

Dimensionaccuracy, etc.

Residualunbalance,etc.

Windingresistancevalue, etc.

Moldconditions,etc.

Equipment shutdo

Equipment shutdown in

structio

ns,

wn instru

ctions, etc.

etc.

Operation tim

e/status, number of ti

mes jigs and to

ols used,

umber of ti

mes jigs and to

ols used, etc.

Equipment shutdown in

structio

ns, etc.

Jig replacement in

structio

ns,

setup instru

ctions, etc.

System branch LAN

Magnetizationconditions, etc.

Assemblyaccuracy, etc.

Bolt tighteningtorques, etc.

Encodertest

Quality analysis tool (Q

C tool)

Line monito

r

Equipment operation analysis tool

Worker

Quality department

Quality auditor Line leader

Production engineeringdepartmentLine leader

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

Case example of machining line process control . . . Electrical discharge machine machining plant (began operation in September 2003)

： MES interface

MES interface introductionlocations at servo motor plant

PLC with MES interface

Quality information

Operation information

Instruction information

Specific Case Examples of e-F@ctory.

●Operation control ●Quality control●Real-time QC

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

increase in equipmentoperation rate190%

reduction in machining time40%

reduction in manufacturingperiod60%

Magnetapplication

Rotorassembly

Balancing

●Production site scheduling●Tool information management●Machining monitor

Intermediatetesting

Winding

WeldingPressure

resistance tes

Resistancetest

Accuracymeasurement

Pre-shipmenttest

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.

Quality improvement through real-time quality 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.

High production efficiency achievedthrough meticulous process control!!

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.

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

Operation tim

e/status, number of ti

mes jigs and to

ols used, etc.

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

Germany Mitsubishi Electric Europe B.V. German BranchGothaer Strasse 8 D-40880 Ratingen, GERMANY

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

U.K Mitsubishi Electric Europe B.V. UK BranchTravellers Lane, Hatfield, Hertfordshire., AL10 8XB, UK

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

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

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

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

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

France Mitsubishi Electric Europe B.V. French Branch25,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 200003CHINA

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

Indonesia P.T. Autoteknindo Sumber MakmurMuara 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

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

Brazil MELCO-TEC Rep. Com.e Assessoria Tecnica Ltda.Rua Correia Dias, 184, Edificio Paraiso Trade Center-8 andarParaiso,Sao Paulo SP Brasil

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

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

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

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

Mitsubishi total automation solution e-F@ctory

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.

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

Safety Precaution

L（NA）16005-A （0612）MDOC

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

EC97J1113

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

New publication, effective December 2006.Specifications subject to change without notice.