Production Control Systems
Overview
The production control systems provided by DIASYS Netmation support the monitoring and control of production equipment in various fields, realizing higher production efficiency.
In addition, when new equipment is added or changes are made to equipment operation, the customer can make their own modifications to the system, leading to lower system modification costs.
Features
Extensive Range of Monitoring and Operational Features
With the wide array of monitoring and operational features including energy visualization and remote monitoring, combined with management support functions, we enable the efficient operation of production equipment.
Integration with Systems from Other Companies
We are able to easily integrate with systems from other companies, allowing different systems to co-exist without incurring special expenses.
System Configuration
Basic Configuration
| Operator Station (OPS) | This equipment is used for monitoring and operation. This carries out monitoring and operation by displaying graphics and trends, showing alarms, and so on. |
| Accessory Station (ACS) | This equipment is used for data collection. Manufacturing data collected from on-site manufacturing equipment is managed, and the data is output into forms. |
| Engineering & Maintenance Station (EMS) | This equipment is used for maintenance. Maintenance tasks such as the creation and modification of logic and graphics screens, as well as system setup are performed. |
| Compact Process Station (CPS) | Control equipment that performs I/O with instrumentation and other equipment installed on-site at the plant, as well as automated plant control and various computational processing. |
Features
Monitoring and Operational Features
Batch Monitoring
Multiple on-site manufacturing units controlled with programmable logic controllers (PLC) produced by other companies are monitored at once.
Based on the signals read from each PLC, plant operation can be centrally controlled, including the configuration of production plans and reflection in management information.
Alarm Display
When an equipment malfunction occurs, a real-time alarm is displayed on the monitoring screen, supporting early discovery of abnormalities. A per-device history of alarm triggering and restoration can also be displayed.
The system includes an Automated Warning Message Function that displays warning names, trigger and restoration times line-by-line in chronological order on the monitoring screen, and an Error Warning List Screen that displays warning trigger and restoration information for each item chronologically. These functions facilitate analysis of the cause of an error.
Alarm Notification
Through an alarm notification feature that works over the Internet or PHS communications, even when an operator is away from the site, they can quickly take action to address an equipment fault.
Trend Display
Product manufacturing status, equipment operational status and fault signals can be managed through a trend display.
A Per-lot Trend Function that displays trends from lot start to completion is also included, enabling per-lot management.
Management Support Features
Form Features
With daily, weekly, monthly and annual reports, forms are managed in the format best suited to the customer.
In terms of data prepared for form output, by using snapshot CSV and trend CSV files, manufacturing data from lot start to completion and operational data can be summarized in lot forms.
A file listing the warnings generated on a monthly basis can also be created based on the event CSV file.
Production Planning Control
By setting variables such as product model, quantity and work type on a daily, weekly or monthly basis, systematic plant operation can be achieved.
Energy Consumption Rate Control
By applying logical computations to the signals collected from PLCs produced by other companies, specific energy consumption can be managed through graphics and trend displays.
Maintenance Record Display Function
On the maintenance screen of the engineering tool, device information, maintenance details and operating times for each device entered into the system is displayed on a per-device basis. In addition, when the designated maintenance cycle time for each device has elapsed, a warning can also be generated.
Weekly Timer Setting
By setting start-up times for each piece of on-site manufacturing equipment, wasted equipment operation is eliminated.
Optional Features
Energy Visualization Function
With a wide range of monitoring and analysis features including basic unit calculations and energy consumption, CO2 conversion and a comparison of equipment operating statuses with the use of Gantt charts, efficient plant operation and reduced energy consumption is achieved.
Remote Monitoring Function
The Internet-based remote monitoring function allows production status to be verified from a different building inside the plant.
Mitsubishi Power has also developed a communications protocol designed for remote monitoring. Using this protocol, screens can be displayed at the same speed as an on-site Operator Station (OPS), even over an analog telephone line.
