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ProHelp EPM User`s Manual

1. The following table describes the Schedule From selections that are available on the Rules tab of the Properties dialog Schedule From Properties Tab Description Start Date Rules Allows you to enter a Desired Start Date but not a Desired End Date in the job descriptor A job is late and is colored red if its forecasted start date is later than its desired start date Once the job is running the desired start date is automatically translated by the Job Schedule into a desired end date to permit color coding changes End Date Rules Allows you to enter a Desired End Date but Default not a Desired Start Date in the job descriptor A job is late and is colored red if its forecasted end date is later than its desired end date Copyright 1983 2004 6 117 810 0001 Rev C Mattec Corporation The following table describes the Insert Jobs By selections that are available on the Rules tab of the Properties dialog Insert Jobs By Properties Tab Description Last In First Out Rules Newly created jobs are inserted at the beginning of the machine schedule First In First Out Default Rules Newly created jobs are inserted at the end of the machine schedule Desired Date Rules Newly created jobs are inserted into the Job Schedule according to their desired date A job is inserted as close as possible to the desired date If another job is
2. Shift Report Category Description Cost Reports in this category show cost related information and include the Shift Downtime Cost Report and the Shift Scrap Cost Report Advanced Tip 2 The Shift Overall Equipment Effectiveness Report is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Reference Section 4 3 for additional information regarding this report Advanced Tip 3 You must have appropriate security permissions to view the results of the cost related reports Reference the System Administration Manual 810 0014 for additional information In many of the shift reports if you disable the display of Individual Records you will see only totals for a Machine Department or the entire facility This can change the nature of these reports from detailed reports to big picture reports For example the Daily Production Report normally shows detailed production information for all machines on a shift by shift basis However when Individual Records are turned off this report shows production totals for each department by shift Copyright 1983 2004 4 41 810 0001 Rev C Mattec Corporation 4 2 Job Reports ProHelp EPM offers approximately 15 job reports that show production or process information for a specific machine job part or tool As a general rule these reports show detailed information for jobs Job reports are id
3. Part Cost 245 Group Automotive Percent Regrind fo o aw Color ID o Parts Per Case fi S AS Material ID Polyvinyl Chloride Material Cost ms B e Part Information ees t sS Setup Sheet Comment 1 y S 10139 S Comment 2 SY ST COPPE HINSE T web Setup Document View Document 24 Save Cancel Print T Part ID Edit Facility Copyright 1983 2004 5 62 810 0001 Rev C Mattec Corporation e To edit an existing Part ID locate the desired Part ID using the selection facilities on the left hand side of the display Press the Edit button Modify the Part ID as appropriate Press Save to save your changes e To create a new Part ID press the New button Specify a unique Part Number and fill in the fields on the display as appropriate Press Save to save your changes Alternate Methods You can click on the Edit Part IDs icon on the toolbar to launch the Part ID Edit Facility Part IDs can also be created or modified via the Data Import Export program Reference the Data Exchange Manual 4810 0002 for additional information Advanced Tip 1 A Part ID is associated with a job by being included in a Process Sheet The following table describes the fields that are available in the Part ID Edit Facility Field Description Part Number A unique identifier that identifies the part Description A description for the part
4. Advanced Tip 1 Scrap can be entered by authorized users at the MIU on the Real Time Display or via Edit Facilities Advanced Tip 2 The scrap reasons that are displayed in the Scrap Pareto Chart include all scrap reasons that are configured in the Scrap Map for this machine including reasons from the Advanced Scrap Map and the Simple Scrap Map The Scrap Map is specified in the Machine Configuration program Advanced Tip 3 If you have entered scrap for a scrap reason that is not defined in the Scrap Map that scrap reason will be displayed in the Scrap Pareto Chart Advanced Tip 4 The Scrap Pareto Chart is not available if you are analyzing data for multiple jobs i e SPC By Part or SPC By Tool Copyright O 1983 2004 7 138 810 0001 Rev C Mattec Corporation 7 5 Downtime Pie Chart The Downtime Pie Chart displays the downtime that has been accumulated for the job It quickly identifies the most significant causes of machine downtime and helps you to focus your attention on resolving those problems To generate a Downtime Pie Chart for a job follow these steps e Start the Main Menu and press the Launch ProState icon The Prostate program will be displayed Select the appropriate job as described in Section 7 3 e Press the Downtime Pie Chart icon The Downtime Pie Chart will be displayed Job Downtime Chart x Machine Number INJ 01 1 000 Ton Injection Job Number CAP Lot 419 Job Down
5. Advanced Tip 4 The ProHelp EPM system will not forecast that preventive maintenance is due for a specific machine or tool for a specific PM Code unless maintenance history has been entered for that machine tool for that specific code at least one time Thus although the PM Codes are defined system wide they do not necessarily apply to all machines and all tools Advanced Tip 5 The Machine Odometer can be adjusted in the Machine Configuration program The Odometer is used by the Machine PM Due Report to determine when preventive maintenance will next be due for a machine The Machine Odometer is updated automatically and in real time by the ProHelp EPM system Manual changes to the Machine Odometer should be made with care Reference the System Administration Manual 4810 0014 for additional information Advanced Tip 6 The Tool Odometer can be adjusted in the Tool IDs Edit Facility The Odometer is used by the Tool PM Due Report to determine when preventive maintenance will next be due for a tool The Tool Odometer is updated automatically and in real time by the ProHelp EPM system Manual changes to the Tool Odometer should be made with care Reference Section 5 3 for additional information Copyright 1983 2004 4 49 810 0001 Rev C Mattec Corporation 4 5 Operator Tracking and Efficiency Reports Most MIUs allow machine operators and other users to login and logout at the MIU The system records the date time of the
6. Cycles Out Of Spec These fields are red if 5 or more of the cycles are out of Percent Out Of Spec specification otherwise they are green Cycle Efficiency These fields are red if the efficiency falls below 95 white if Yield Efficiency the efficiency exceeds 105 otherwise they are green Percent Scrap These fields are red if the percent scrap exceeds 5 otherwise Scrap Parts they are green Percent Down These fields are red if the percent down exceeds 5 otherwise Run Efficiency they are green Copyright O 1983 2004 3 14 810 0001 Rev C Mattec Corporation 3 2 Filtering Data The Real Time Display can be a valuable tool to many employees throughout your facility in part because employees can easily customize the display to show only those machines that they are interested in This is accomplished by filtering the display To filter the data that is displayed on the Real Time Display follow these steps e Start the Main Menu and press the Launch Real Time Display icon The Real Time Display will be displayed e Click on the File menu and select Filter Data The Real Time Display Options dialog will be displayed Real Time Display Options x Display Real Time Display Standard Display z Refresh Rate 30 Seconds T Multiple Display Refresh Not Recommended Filters Department Jal Departments y Machines Nearing End Of Job Down Reason Jal Machines y I Machines That Are Dut Df Specification
7. Son Job A son job is often referred to as a component job Each son job represents one distinct part that will be created when a family job is run Most data that is collected by the system for a family job is stored to the son job not the father job A son job can be orphaned from a family job When this is done the son job becomes a bachelor job The following offers a brief description of Family Molding features in ProHelp EPM e Each family father job is made up of one 1 or more son component jobs e Each family job can have up to 1 000 total son jobs Of those up to 100 son jobs can be running simultaneously on a single machine e The family is scheduled as a unit but production and process history is stored to each son job individually e The family has a forecasted end date in the Job Schedule and the system will also forecast the end date for each individual son job e Most MIUs allow you to enter scrap parts and packed parts for each individual son job and or for the entire family e You can have different process limits specification and control limits depending on which combination of son jobs is currently running e Mattec s unique Gantt in Gantt Job Schedule allows you to double click on the family job to see a Gantt chart for the individual son jobs in that family job You can then drag and drop the individual son jobs in order to schedule them in a manner that will allow each son job to finish
8. are 0 the chart will automatically chose appropriate values for scaling Lower Boundary X Bar Chart This value controls the minimum value that is displayed on the Y Axis Number of points visible on chart X Bar Chart This value controls the approximate number of points that will be displayed on the chart Additional points can be viewed by scrolling the chart to the left or the right The X Bar Chart the Range Chart and the Standard Deviation Chart use this value Display user defined specification limits X Bar Chart This value controls whether the user entered specification limits will be displayed on the chart Specification limits for Automatic SPC and Manual SPC are entered in the Process Sheet Specification limits for Variable SQC are entered in the Sample Sheet Display user defined control limits X Bar Chart This value controls whether the user entered control limits will be displayed on the chart Control limits for Automatic SPC and Manual SPC are entered in the Process Sheet Control limits for Variable SQC are entered in the Sample Sheet Calculate and display control limits from sample data X Bar Chart This value causes ProStat to dynamically calculate X Bar control limits and display them on the chart Display X Bar for each sample X Bar Chart When selected this value will cause the chart to display the X Bar value for each sample above the sample mar
9. 0 924 0 316x Ea chine WC 24 Job CAP Lot 21 B Part SBC 227280 Bottle Cap Tool SBC 11 GAP DIM B Linear Regression Analysis 2 000 1 807 1 614 1 421 0 843 0 650 0 500 0 557 T T 0 671 0 729 GAP DIM A T 0 614 T 0 786 T q 0 843 0 900 j Print Options Linear Regression Scatter Diagram Interpreting Results Numerous books and articles are available to assist you in interpreting the results of linear regression analysis including the Statistical Quality Control Handbook published by AT amp T Select Code 700 444 As a quick guide however the following are commonly accepted e A Correlation Coefficient of 1 indicates a strong positive correlation between the independent characteristic and the dependent characteristic e A Correlation Coefficient of 1 indicates a strong negative correlation between the independent characteristic and the dependent characteristic e A Correlation Coefficient of 0 indicates no correlation between the independent characteristic and the dependent characteristic e A Significance greater than 3 is considered significant Copyright 1983 2004 Mattec Corporation 7 166 810 0001 Rev C Can I Perform Linear Regression Analysis Between Automatic SPC Data And Variable SOC Data No Linear regression analysis requires the independent characteristic and the dependent character
10. There is no place in the ProHelp EPM software to enter standard control limits for Attributes However the ProStat software is capable of calculating these control limits and displaying them on the related charts Copyright 1983 2004 7 178 810 0001 Rev C Mattec Corporation 7 19 1 Attribute SQC Chart Options A number of options are available to control the behavior of the Attribute SQC charts To modify the behavior of any Attribute SQC Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 Select Attribute soc inthe Data Type field e Press the Options button The Options dialog will be displayed e Press the Attribute tab ProStat Options Ed Production X Bar Chart R MAx Chart s Chart Median Chart Histogram Attribute Upper boundary Lower boundary 0 Approximate number of points visible on chart 50 J Calculate and display control limits from sample data Display horizontal grid lines Display attribute value p np c u for each sample FT Display vertical grid lines FT Display point markers I 3 Dimensional Attribute SQC Chart Options The following table describes the options that affect Attribute SQC Charts Option Options Tab Description Upper Boundary Attribute This value controls the maximum value that is displayed on the Y Axis If both
11. aed 10 22 00 4M E End Date 2 36 00 PM SPC SOC Data Type Data Type Automatic SPC Parameter Cycle Time Cycle Time OK Refresh Options ProStat Overview Tab Advanced Tip 1 When analyzing data for multiple jobs i e SPC By Part or SPC By Tool the Overview tab will show data that is common to all of the jobs being analyzed The Overview tab simply displays information about the currently selected job To select a different job date range or data type and parameter press the Select Data icon Reference Section 7 3 for additional information Copyright O 1983 2004 7 141 810 0001 Rev C Mattec Corporation 7 7 Production Tab The Production tab in ProStat displays job production and material lot data for the currently selected job s To display the Overview tab follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Production tab The Production tab will be displayed Jk ProStat SPC SQC mE x SAHA bel Overview Production Process Alarm X Bar R Chart X Bar s Chart Median Chart Histogram m Production Material Lots Job Total Parts 2408508 Good Parts 2407467 Scrap Parts 1041 Packed Parts 0 Machine Cycles 1786203 Cycles Out Of Spec Se Run Time 895 55 Down
12. 1s the map that the Reclassify Downtime dialog uses The System Manager creates the Down Map and assigns the map to a machine via the Machine Configuration program Reference the System Administration Manual 4810 0014 for additional information Advanced Tip 3 You can not reclassify more downtime or down counts downtime occurrences than have been collected by the MIU Advanced Tip 4 Downtime data is stored internally in seconds not minutes When you reclassify downtime from one downtime reason to another downtime reason 1f you do not reclassify 100 of the existing downtime a best guess algorithm is used to make appropriate changes to the weighted downtime related fields including weighted downtime and weighted down count To directly edit downtime for a specific job follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Downtime Edit The Downtime Edit Edit Facility will be displayed e To directly an existing downtime entry locate the desired job shift and downtime reason using the selection facilities on the left hand side of the display Press the Edit button Make your changes as appropriate and press Save Advanced Tip 5 If you need to edit downtime data you should investigate why What caused the incorrect recording of data in the first place What
13. 78 88 eeM Median Chart Copyright 1983 2004 7 157 810 0001 Rev C Mattec Corporation Advanced Tip 1 If the number of observations per sample for the job equals one 1 the Median Chart will not be displayed However if you have forced ProStat to display a Chart of Individuals and Moving Range chart by selecting Moving Range on the R MRx tab of the Options dialog then the standard Median Chart will be displayed You can double click on any point in the Median Chart to see additional data for the sample including the observations that comprised that sample the date time that the sample was taken and the X Bar Range Standard Deviation and Median for the sample Advanced Tip 2 The Median Chart is available when performing analysis for multiple jobs i e SPC By Part or SPC By Tool Data for the jobs are arranged in chronological order by job starting with the job that ran first You can double click on any point in the chart to see which job is associated with the sample A number of options are available to control the behavior of the chart To modify the behavior of the Median Chart follow these steps e Press the Options button The Options dialog will be displayed e Press the Median Chart tab Copyright 1983 2004 7 158 810 0001 Rev C Mattec Corporation ProStat Options x Production X Bar Chart R MAx Chart s Chart Median Chart Histogram Attribute Upper boun
14. Advanced Tip 1 There is no place in the ProHelp EPM software to enter standard control limits for Attributes However the ProStat software is capable of calculating these control limits and displaying them on Attribute SQC Charts Copyright 1983 2004 Mattec Corporation 7 180 810 0001 Rev C 7 19 2 p Chart A p Chart measures the proportion of non conforming items defects in an Attribute SQC sample Compatibility p Charts are only available for Attribute SQC data They are not available for Automatic SPC Manual SPC or Variable SQC data To display the p Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 Select Attribute Soc in the Data Type field e Press the p Chart tab The p Chart will be displayed ProStat SPC SQC Bi E Proportion of Units Nonconforming E Process Alarm P Chart Chart L u Chart Machine WC 2A Job CAP Lot 21 B Part SBC 227280 Bottle Cap Tool SBC 1115 1407 eL 1 318 2 a A 3 1 204 a T 10 22 2003 10 37 02 10 22 2003 10 53 03 10 22 2003 11 08 38 10 22 2003 11 09 07 10 22 2003 11 11 29 Date ET B Attribute SQC p Chart Copyright 1983 2004 7 181 810 0001 Rev C Mattec Corporation 7 19 3 np Chart An np Chart measures the number of non conforming items defec
15. SPC By Tool Advanced Tip 1 ProStat can not analyze data for multiple jobs for the Variable SQC or Attribute SQC data types To select data for multiple jobs for use by ProStat follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed e Press the Select Data icon The Select Data dialog will be displayed e Check the Advanced checkbox Select Data Automatic SPC Cycle Time Machine Cycle Time Select Data Dialog Advanced Copyright 1983 2004 7 135 810 0001 Rev C Mattec Corporation e Select the desired Part Number in the Part Number picklist You can then optionally specify a Tool Number and or Machine Number OR Select the desired Tool Number in the Tool Number picklist You can then optionally specify a Part Number and or Machine Number e To analyze all data that has been collected for the job s press the All Dates checkbox To analyze only a subset of the data that has been collected uncheck the All Dates checkbox and enter the desired date time range for the data to be analyzed e Select the appropriate Data Type and Parameter to be analyzed The Parameter picklist will change depending on the Data Type that has been selected e Press ox The data for the job s will be retrieved from the database and the ProStat program will be displayed You can now view any of the available charts or perform any data analysis as appropriate Co
16. See Expected Parts An optional feature that allows you to monitor production and process information for distinctly different jobs parts that are running on the same machine at the same time A father job is often referred to as a family job A father job is a collection of one 1 or more related son jobs that will be scheduled as a single unit The end date for a job that is forecasted by the Job Schedule The start date for a job that is forecasted by the Job Schedule Parts that are associated with a job that are good or that have been reworked into good parts The number of good parts that need to be produced for a job ProHelp EPM calculates this value in real time A descriptive reason that is entered by the machine operator at the MIU to request help Calls for help can be seen on the Real Time Display A subset of the system wide Help Codes that are available for use for a particular machine The System Manager specifies a Help Map in the machine configuration program 9 191 810 0001 Rev C Histogram Chart Historical Cycle Time Historical Percent Down Historical Percent Scrap Host Computer Hours To Go Job Job Change Job ID Job Number Job Status Copyright O 1983 2004 Mattec Corporation A graphical representation of a frequency distribution of the SPC or SQC sample data The widths of the bars on the chart represent class intervals whose areas are proportional to the corresp
17. This field is frequently displayed throughout the system to help you to identify a part Group A descriptive field to identify a part group The Mattec Customer Service Department can manually configure the names of each group This selection is ignored by the system Color ID The Color ID or other material that is used to make the part Material ID The primary material that is used to make the part Part Information An additional description for the part Comment 1 Descriptive fields used for adding notes about the part Comment 2 Last Update The date time of the last time this specific Part ID was modified by a user Part Weight The estimated total part weight for each part Part Cost The estimated part cost for each part Percent Regrind The estimated percentage of total material that will be used that will be regrind material Parts Per Case The number of parts per case Material Cost The estimated material cost for each part Copyright O 1983 2004 Mattec Corporation 5 63 810 0001 Rev C Field Description Web Setup Document The web address URL of a setup sheet that is associated with this Part ID This web based setup sheet can be viewed using the Document Control Center or by pressing the View Document button Advanced Tip 2 Web based Setup Sheets is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 3 You mu
18. Upper Boundary and Lower Boundary are 0 the chart will automatically chose appropriate values for scaling Attribute This value controls the minimum value that is Lower Boundary displayed on the Y Axis Copyright O 1983 2004 7 179 810 0001 Rev C Mattec Corporation Option Options Tab Description Number of points visible on chart Attribute This value controls the approximate number of points that will be displayed on the chart Additional points can be viewed by scrolling the chart to the left or the right Calculate and display control limits Attribute This value causes ProStat to dynamically from sample data calculate Attribute control limits and display them on the chart Display attribute value for each Attribute When selected this value will cause the chart sample to display the Attribute value for each sample above the sample marker Display point markers Attribute Displays a large marker for each point on the chart This makes it easier to double click on a sample but makes the chart harder to read if you have specified a large number of points visible on chart Display horizontal grid lines Attribute Controls whether horizontal grid lines are displayed on the chart Display vertical grid lines Attribute Controls whether vertical grid lines are displayed on the chart 3 Dimensional Attribute Controls whether the chart is displayed in 2 D or 3 D
19. 34 3 13 Operator Efficieney Display saicisiccsssscicssscassiees sanccessasassdecvaundcndssacsenease secede ssaeaeveassdantasees 3 35 Dee MOS OS 3 36 3 15 Estnchine Other Applications siii dente ce daa eile is euler 3 37 4 REPOS eeii arna a vancncese soavatns wie A A E RRS a EE A RE 4 38 E 4 39 De A A A ON 4 42 4 3 Overall Equipment Effectiveness OEE Reports ooooonnocccnnoccconocccononccnnnnccnanncnannccnonnnos 4 45 4 4 Preventive Maintenance Reports ii eshdesauaaande de Ratiaess Sotadetaceanadees 4 47 4 5 Operator Tracking and Efficiency ReportS ooooccnnoncccnonccononcnonnnconancconancconnncnnnnnccnnnnno 4 50 O AA TEAL IR CO ORNS a aaa 4 53 4T BS CPV E aga 4 55 4 8 Launching Other Applications sisiccssisccasssestsccvssdccecasncsdneadenacadeacesdedtanuetdacuundecessnccsdasndes 4 57 Oe Edit AG LEI OS AAA A aie a ant ede nek eh a ets tad 5 58 Dell JODADESCTIPLOL eeoa tee eet edie eel eee aetna EEEn 5 60 ze AUR IDEE E EAE E cca hue td tecblaa adeesd pitted da estat ENO 5 62 SS Tool Demneri a aa a a a aaa ea a aE 5 65 54 Sample SMES nl idas 5 69 A Process Sheet mernes aisle pda ct incteceina at aea Aa S sce cies tgp eg eneaeisat aa tease 5 74 5 0 UMachine Maintenance Lo da 5 79 5 7 Tool Maintenance Loe criar ia dial 5 81 Copyright 1983 2004 1 1 810 0001 Rev C Mattec Corporation 5 8 Enter Scrap And Packed Parts util aria inocencia 5 83 20 JOD SEMI NOS ticas 5 85 De WO Material Lot Ed ii 5 87 Didi TO Wee oa 5 88
20. 810 0001 Rev C 7 12 Histogram Chart Capability Analysis A Histogram Chart is a graphical representation of a frequency distribution of the sample data The widths of the bars on the chart represent class intervals whose areas are proportional to the corresponding frequencies Compatibility The Histogram Chart and Capability Analysis data are available for Automatic SPC Manual SPC or Variable SQC Data They are not available for Attribute SQC data To display the Histogram Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Histogram Chart tab The Histogram Chart and Capability Analysis data will be displayed Jj ProState SPC SQC Ela S G S iY a gt Overview Production Process Alarm Bar R Chart Bar s Chatt Median Chart Histogram Histogram for GAP DIM A Variable tachine WC 24 Job CAP Lot 21 B Part SBC 227280 Bottle Cap Tool SBC 111 36 25 o Sigma Individuals i a 0 72 Sigma Estimated 31 0 E G Coefficient Variable 4 Minimum Value 25 89 Maximum Value Cell Width 11 3 20 71 Kurtosis 5 Skewness g E 15 54 Chi Squared Distribution Above USL Below LSL Out of Spec wo aH on ES co Value OK Refresh Options Histogram Chart
21. E Production lt Bar Chart RMR Chart s Chart Median Chart Histogram Attribute Upper boundary 0 Lower boundary 0 Approximate number of points visible on chart applies to Bar A and s charts 50 T Display horizontal grid lines T Display vertical grid lines FT Display user defined specification limits T Display user defined control limits I Calculate and display control limits from sample data J 3 Dimensional I Display X Bar for each sample T Display point markers Cancel X Bar Chart Options ProStat Options x Production X Bar Chart R MRx Chart s Chart Median Chart Histogram Attribute Upper boundary 0 Lower boundary 0 TT Moving Range if sample size equals one moving range is selected by default Observations Per Range 2 Display horizontal grid lines T Display user defined control limits J Calculate and display control limits from sample data I Display vertical grid lines FT Display range for each sample Tl Display point markers 3 Dimensional Cancel Range Moving Range Chart Options Copyright 1983 2004 7 148 810 0001 Rev C Mattec Corporation The following table describes the options that affect the X Bar and Range Charts Option Options Tab Description Upper Boundary X Bar Chart This value controls the maximum value that is displayed on the Y Axis If both Upper Boundary and Lower Boundary
22. Help Call Reason Jal Machines y Machines That Are Not Communicating r Group Filters Machine Class al Groups O Machine Maker fan Groups y Group 3 al Groups o Group 4 al Grous o Cancel Reset All Real Time Display Options Dialog Alternate Methods The Real Time Display s toolbar contains icons that allow you to display all machines any machine that is out of specification any machine that is down or any machine that is calling for help If you press one of these icons all existing filter conditions will be reset and only the new filter condition will be applied Copyright 1983 2004 3 15 810 0001 Rev C Mattec Corporation Advanced Tip 1 The current filter condition is displayed in the lower right hand corner of the Status bar The following table describes the fields that are available on the Real Time Display Options dialog Field Description Real Time Display This field displays the list of all available custom Real Time Displays Several displays shipped with your system and the System Manager can easily create custom displays using the Real Time Display Writer Refresh Rate The field controls how often the Real Time Display is automatically refreshed If the Refresh Rate is 0 the display will not refresh automatically and will only be refreshed when the user manually refreshes the display When in Automatic Paging mode the Refresh Rate is used to d
23. Job Number Part Number Tool Number Customer ID Material ID Color ID Forecasted End Date Desired End Date Forecasted Start Date Desired Start Date Job Duration To change the text that is displayed in the job bar right click in the white area of the display and select Bar Labels All of the available text choices will be displayed Advanced Tip 4 If any son job in a family job is colored red the father job s bar is colored red You can double click on the father job to view the Gantt in Gantt schedule Reference Section 6 5 for additional information Copyright 1983 2004 6 97 810 0001 Rev C Mattec Corporation 6 1 Family Molding Family Molding is a powerful feature in ProHelp EPM that allows you to monitor production and process information for distinctly different jobs parts that are running on the same machine at the same time Definitions Bachelor Job A bachelor job is often referred to simply as a job A bachelor job is any job that produces one distinct part and that is not related to any other job Bachelor jobs can have multiple cavities A bachelor job can be adopted into a family job When this is done the bachelor job becomes a son job Father Job A father job is often referred to as a family job A father job is a collection of one 1 or more related son jobs that will be scheduled as a single unit The father job is the bar that is displayed in the job schedule
24. Jobs that will finish on time are colored green jobs that will finish late are colored red Advanced Tip 1 The Job Schedule represents a real time snapshot of your plant Data for running jobs is collected when the Job Schedule is started and is not updated in real time To update the data for running jobs click on the View menu and select Refresh Your schedule personnel can drag a job from one machine to another in an attempt to get all jobs to finish on time If a particular machine does not have a Process Sheet defined that would permit that job to run on the machine an error is displayed and the person is prevented from moving the job to that machine This allows your Process Engineer s to define rules that prevent jobs from being scheduled on machines that aren t capable of running the job Advanced Tip 2 When you click on a job as 1f dragging that job to another machine all machines that have a valid Process Sheet for that job will be highlighted Thus you can quickly determine which machines are capable of running that job and which machines are not capable of running that job This functionality highlighting supported machines when a job is dragged in the Job Schedule can be enabled disabled on the Properties dialog Reference Section 6 9 1 for additional information To launch the Job Schedule follow these steps e Start the Main Menu and press the Launch Job Schedule icon e Select the Machine s that you wish
25. Lot Size pp 0 03 02 2004 03 02 2004 Color ID E Setup Time o fra ial Customer O Active Cavities po 0 Actual Start Actual End Comment 1 fo Parts To Go E NA NA Comment 2 PO Hours To Go NA NA Cancel Epp Job Descriptor Dialog Bachelor Job Yv e Fill in the Job Descriptor page as appropriate Press ox The new bachelor job will be created and added to the machine schedule Alternate Methods You can click on the New Job icon on the toolbar to create a new bachelor job Jobs can also be created and scheduled via the Data Import Export program Reference the Data Exchange Manual 810 0002 for additional information Copyright 1983 2004 6 101 810 0001 Rev C Mattec Corporation The following table describes the fields that are available in the bachelor Job Descriptor dialog Field Description Job Number An identifier that identifies the bachelor job ProHelp EPM allows the user to specify duplicate Job Numbers but each job is treated as a unique unit Machine Number Part Number Tool Number The Machine Number Part Number and Tool Number determine the Process Sheet that will be used by the job When you make a selection in any of these picklists the remaining picklists will be adjusted as appropriate For example if you select a Part ID from the Part Number picklist the Machine Number and Tool Number picklists will automatically adjust to only includ
26. Press the Edit button Modify the Sample Sheet as appropriate Press Save to save your changes e Tocreate a new Sample Sheet press the New button Specify a unique Sample Copyright O 1983 2004 5 69 810 0001 Rev C Mattec Corporation Sheet ID and fill in the fields on the display as appropriate Press Save to save your changes Alternate Methods You can click on the Edit Sample Sheets icon on the toolbar to launch the Sample Sheets Edit Facility Advanced Tip 1 Sample Sheets are related to ProStat ProStat SPC SQC is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 A Sample Sheet is associated with a job by being included in a Process Sheet The following table describes the fields that are available in the Sample Sheet Edit Facility Field Description Sample Sheet ID A unique identifier that identifies the Sample Sheet Description A description for the Sample Sheet Last Update The date time of the last time this specific Sample Sheet was modified by a user Period This field allows you to specify the frequency machine cycles or minutes that you expect a Manual SPC sample Variable SQC sample and or Attribute SQC sample to be taken This field is ignored by the system Number Of Cycles This field is used to define the number of machine cycles that comprise a sample Valid values are 1 to 30 However this v
27. Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Locate the desired machine Double click on a help call related field For example the field HP on the Standard Real Time Display is a help call related field Real Time Display x Help Call Machine Number BMT1 Help Number Help Description SiS ne Teele Start Time 10 31 2003 13 33 AckHelp Retesh f Cancel Help Call Acknowledge Dialog e Press the Ack Help button The help call will be cancelled Advanced Tip 1 There is no feedback at the MIU to indicate to the machine operator that you have cancelled the help call Copyright 1983 2004 3 33 810 0001 Rev C Mattec Corporation 3 12 Additional Functionality The following table describes the selections that are available on the Real Time Displays View menu Field Description Refresh This option allows you to manually refresh the Real Time Display This is especially useful if automatic refreshes have been disabled When the Refresh Rate is set to a number that is greater than 0 the Real Time Display will refresh automatically Reference Section 3 2 for additional information Automatic Paging This options enables disables Automatic Paging mode When in Automatic Paging mode the Real Time Display will automatically page down through multiple pages of machines When in Automatic Pag
28. Refresh button It is safe to press the Refresh button even when automatic refreshes are enabled You can optionally display run time along with downtime You may want to disable the display of run time if the percentage of downtime is very low and thus the display would show mostly run time This is specified on the Options dialog You control the number of slices that will be displayed in the pie When more downtime reasons exist than there are slices to the pie the smallest downtime reasons are accumulated and displayed in the last slice of the pie The number of downtime reasons that were accumulated into that last slice of the pie is displayed in parenthesis By controlling the number of slices in the pie you can minimize the visual impact of having a lot of downtime reasons that have very little downtime accumulated This is specified on the Options dialog You can display the chart as a doughnut chart and display the chart in 2 Dimensions or 3 Dimensions These settings are specified on the Options dialog Advanced Tip 1 Downtime is automatically accumulated by the MIU The user can specify the current downtime reason at the MIU or via the Real Time Display If a mistake is made the System Manager can edit this data via Edit Facilities Advanced Tip 2 Any downtime reason that has accumulated downtime for the job will be displayed in the Downtime Pie Chart Copyright 1983 2004 3 24 810 0001 Rev C Mattec Corp
29. SQC N A To calculate control limits follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Calculate Control Limits icon Calculate Limits Options x SPC 7 SQC Data Type Date Type Automatic SPC y Parameter Jal Parameters y Date Range IV All Dates Start Date 2 36 00 PM End Date 11 22 02 2 36 00 PM Calculation Method Table of Constants Sigma Multiplier 3 E Cancel Calculate Control Limits Data Selection Copyright O 1983 2004 7 168 810 0001 Rev C Mattec Corporation e Specify the Data Type to be used for control limits calculations Specify A11 Parameters Or you may optionally select one specific parameter e You may optional specify a subset of date ranges e Select the Calculation Method and the Sigma Multiplier if needed e Press ox The ProStat software will calculate new control limits X Bar and Range based on the sample data that has been collected The results will be displayed Calculate Control Limits x Current Control Limits New Control Limits X LCL X BarBar X UCL X BarBar X UCL Cycle Time 0 000 0 000 0 000 3 948 4 054 Melt Temp 0 000 0 000 0 000 0 000 0 000 Parm 3 0 000 0 000 0 000 0 000 0 000 WOOO 0 000 0 000 0 000 0 000 0 000 Parm 5 0 000 0 000 0 000 0 000 0 000 Par
30. Time 101 49 Down Count 338 Efficiency Cycle Efficiency 405 0 Yield Efficiency 131 4 Cavities EEE Std Refresh Options Production Tab Alternate Methods Production related information is available in the Real Time Display program This allows you to easily view this data for running jobs Material Lots for a job can be viewed in the Material Lot Report in System Reports Copyright O 1983 2004 7 142 810 0001 Rev C Mattec Corporation Data in the Material Lot display can be sorted by lot number 1 4 or chronologically To modify the current setting press the Options button and select the Production tab Advanced Tip 1 When analyzing data for multiple jobs i e SPC By Part or SPC By Tool the Production tab will show the combined job production data for all jobs being analyzed The Efficiency fields will not be displayed Copyright 1983 2004 7 143 810 0001 Rev C Mattec Corporation 7 8 Process Alarm Tab The Process Alarm tab in ProStat displays Job Engineering data for the currently selected job s This data is automatically collected for all monitored process parameters It includes calculated data including Cpk Standard Deviation Cp and k To display the Overview tab follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7
31. Time Display Options dialog and all of those filter conditions must be met for the machine and related data to be displayed on the Real Time Display Advanced Tip 3 You can easily cancel the current filter condition s by pressing the All Machines icon on the Real Time Display s toolbar Copyright 1983 2004 3 18 810 0001 Rev C Mattec Corporation 3 3 Last 500 Chart The Last 500 Chart displays the last 500 machine cycles for any monitored process parameter in real time Many MIUs are capable of monitoring up to 32 distinct process parameters To generate a Last 500 Chart for a machine follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired machine and select Last 500 Chart The Last 500 Chart will be displayed Last 500 Chart Eg Machine Number wc 24 1 500 Ton Injection he Last Update 01 31 2003 15 48 10 Parameter Cycle Time Machine Cycle Time y Cycle Time WC 2A 15 00 12 00 9 00 6 00 3 00 0 00 481 461 441 421 401 381 361 341 321 301 281 261 241 221 201 181 161 141 121 101 81 61 41 21 1 Average 13 222 Cpk 0 070 Standard Deviation LSL 13 000 LCL Minimum 0 000 Cp 0 157 Cycles Dut of Spec Nominal 13 500 Nominal Maximum 13 400 k 26 445 Percent Dut of Spec USL 14 000 UCL DK Refresh Options E Last 500 Chart Copyri
32. Unit MIU is an industrial strength data collection device that has been designed and manufactured by MATTEC It is used to collect production and process information from the manufacturing machine and transmits that data in real time to the server computer There are a wide variety of MIUs Most have a graphical interface that allows the machine Operator to view data about the current job and input relevant information e g scrap parts Many MIUs have both analog and digital inputs Many MIUs have an optional PLC interface that can be used to extract data directly from supported machine controllers 1 2 3 RocketPort Serial Communication Board And Buffer Box MIUs are connected to the server computer via RS 485 cabling Up to 16 MIUs can be daisy chained together on a single channel Multiple channels can be used in order to reach the maximum 4 096 MIUs per system The Buffer Box is a small device that has been designed and manufactured by MATTEC It is usually located with a few feet of the server computer The Buffer Box converts the RS 485 signal to an RS 232 signal and conditions the signal A channel of MIUs RS 485 is wired into the Buffer Box on one side On the other side the Buffer Box outputs an RS 232 signal that is connected to a serial communication port on the server computer Copyright O 1983 2004 1 5 810 0001 Rev C Mattec Corporation In most applications MATTEC will have installed a RocketPort Serial Communicat
33. X Bar values The Lower Control Limit for X Bar See Lower Control Limit The Lower Specification Limit for X Bar See Lower Specification Limit The Upper Control Limit for X Bar See Upper Control Limit The Upper Specification Limit for X Bar See Upper Specification Limit The ratio of the good parts made compared to the standard parts that should have been made YE Good Parts Expected Parts See Expected Parts Yield Efficiency in ProHelp EPM differs slightly from the same calculation in ProHelp Millennium ProHelp EPM uses Total Time Standard Percent Up 100 in calculations for Expected Parts whereas ProHelp Millennium uses the monitored Run Time A job in ProHelp EPM would have a higher Yield Efficiency than a job in ProHelp Millennium if that job had less downtime than the standard downtime in the Process Sheet A job in ProHelp EPM would have a lower Yield Efficiency than a job in ProHelp Millennium if that job had more downtime than the standard downtime in the Process Sheet In both cases the job in ProHelp Millennium would have the same Yield Efficiency 9 202 810 0001 Rev C
34. and press the Launch System Reports icon e Select the report that you wish to execute Fill in the report data selection interface as appropriate Press ox The selected report will be displayed Advanced Tip 3 Mattec provides an optional Web Reporting feature with ProHelp EPM This feature allows system reports to be run through a supported web browser The user interface for these reports differs only slightly from the user interface in the standard System Reports program Advanced Tip 4 Web Reporting is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 5 If you have purchased the Web Reporting option the installation program will configure your computer to launch either the Web Reporting interface or the standard System Reports interface when you press the Launch System Reports icon on the Main Menu Copyright 1983 2004 4 38 810 0001 Rev C Mattec Corporation 4 1 Shift Reports ProHelp EPM offers approximately 20 shift reports that show production or process information for a specific machine job part or tool As a general rule these reports show detailed information for jobs by day and by shift Shift reports are ideal if you would like to view data for a very precise time range To generate a Shift Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon
35. boundary 0 I Calculate and display control limits from sample data FT Display standard deviation for each sample Display point markers Display horizontal grid lines FT Display vertical grid lines I 3 Dimensional s Chart Options Options that affect the X Bar Chart are described in Section 7 9 The following table describes the options that affect the Standard Deviation Chart Option Options Tab Description Upper Boundary s Chart This value controls the maximum value that is displayed on the Y Axis If both Upper Boundary and Lower Boundary are 0 the chart will automatically chose appropriate values for scaling Lower Boundary s Chart This value controls the minimum value that is displayed on the Y Axis Number of points visible on chart X Bar Chart This value controls the approximate number of points that will be displayed on the chart Additional points can be viewed by scrolling the chart to the left or the right Calculate and display control limits from sample data s Chart This value causes ProStat to dynamically calculate standard deviation control limits and display them on the chart Display standard deviation for each sample s Chart When selected this value will cause the chart to display the standard deviation value for each sample above the sample marker Display point markers s Chart Displays a large marker for each point
36. channel that is used for cavity pressure transfer and monitoring in the Machine Configuration program Labor Hour Factor This field allows you to identify the number of machine operators that are required per shift This field is ignored by the system Copyright O 1983 2004 Mattec Corporation 5 76 810 0001 Rev C Field Description Labor Cost This field allows you to specify the standard labor cost for the machine operators that are required per shift This field 1s ignored by the system Comment 1 Descriptive fields used for adding notes about the Process Comment 2 Sheet Web Setup Document The web address URL of a setup sheet that is associated with this Process Sheet This web based setup sheet can be viewed using the Document Control Center or by pressing the View Document button Specification The fields on this tab represent the process parameters that will be monitored by the MIU The System Administrator defines these process parameters in the Machine Configuration program Specification limits lower nominal and upper are specified on this page Control Control limits lower nominal and upper monitored process parameters are specified on this page Advanced Tip 3 Web based Setup Sheets is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 4 Cavity Pressure Transfer is an optio
37. click on the Audit Trail menu and select the desired report Fill in the report data selection interface as appropriate Press ox The selected report will be displayed Pile Ea pa System Reports ITCHY Login Failure Report File Shift Job Planning Application Help 09238154890 4 1011 ma ele foo J Toas 100 Login Failure Report Mattec Corporation Loveland Ohio Selected Range frora 02 03 04 to 03 04 04 All Machines Mach Date Time SH LoginID i Description of Failure Department Auto Automobile Paris INJ 01 2 4 04 4 07 48 PIM A 1234 Operator Tracking INJ 01 2 4104 4 02 09 PM A 1234 Operator Tracking INJ 01 2 4104 4 07 23 PM A 1234 Operator Tracking Department Injection Injection Moding RM 75 2 16 04 2 23 30 PM 1 12345 Operator Efficiency Login Failure 2 16 04 2 24 21 PM 1 12345 Operator Efficiency Login Failure 1 1 2 16 04 2 25 00 PM 12345 Operator Efficiency Login Failure MAMA 9 54 20 PMA inky Nmavatar Ffficioners T amin Failnva Login Failure Report Copyright 1983 2004 4 53 810 0001 Rev C Mattec Corporation Alternate Methods Some Audit Trail data can be viewed from within the applications that created the Audit Trail For example Process Sheet related Audit Trails can be viewed by pressing the Audit Trail button in the Process Sheet Edit Facility SPC SQC related Audit Trails can be viewed by pressing the Audit Trail button in ProStat Sample Data Edit Advanced Tip 1 Audit T
38. downtime reasons or scrap reasons Production downtime and scrap reports can be generated on a shift and daily basis or the user can generate these reports for extended time periods by specifying a start and end date for the desired report Job history data is continuously summarized and available for management s review ProHelp EPM utilizes the Microsoft Windows 2000 operating system and the Microsoft SQL Server 2000 database Users can connect to the system from most Microsoft Windows operating systems This manual describes the basic functions in ProHelp EPM and is intended as a reference for all system users Copyright 1983 2004 1 4 810 0001 Rev C Mattec Corporation 1 2 System Components The following sections provide a brief overview of those components that comprise the ProHelp EPM system 1 2 1 Server Computer The main ProHelp EPM computer is referred to as the server host or monitoring node computer This is the only computer that is required to run the ProHelp EPM system This computer contains all of the configuration files data files and ProHelp EPM software The server computer runs Microsoft s Windows 2000 Server operating system and Microsoft s SQL Server 2000 database All MIUs connect to the server computer All data from MIUs is automatically recorded at the server and can be viewed from other computers in real time 1 2 2 Machine Interface Unit MIU The Machine Interface
39. for a specific job follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Downtime Edit The Downtime Edit Edit Facility will be displayed FE Edit Facilities for Release 6 1 0 Downtime E dit at File View Edit Application Window Help l x Machine Number o 1 000 Ton Injection y Machine Number 01 Job Number cap Lot 419 y ADS Part Number 2 i Tool Number 6 12 03 Shift 1 SCHED 6 12 03 Shift 1 o Ea A a MATL 6 12 03 Shift 1 TLPM 6 12 03 Shift 1 None 6 11 03 Shift 1 Job Status MATL 6 11 03 Shift 1 MACH 6 10 03 Shift 2 Bae QC 6 10 03 Shift 2 MACH 6 10 03 Shift 1 None 6 9 03 Shift 2 Denia None 629203 Shift 1 NOP 629 03 Shift 1 Downtime Reason SCHED 6 9 03 Shift 1 MATL 6 9 03 Shift 1 f None 6 6 03 Shift 2 Downtime None 6 6203 Shift 1 None 6 5203 Shift 2 Down Count None 6 5 03 Shift 1 None 6 4 03 Shift 1 Downtime Edit Downtime Edit Edit Facility Copyright 1983 2004 5 88 810 0001 Rev C Mattec Corporation e To reclassify an existing downtime entry from one downtime reason to another supported downtime reason locate the desired job shift and downtime reason using the selection facilities on the left hand side of the display Press the Reclassify button The Reclassify Down
40. help call These fields are green when the process parameter is within the user specified specification limits red if the process parameter exceeds the user specified upper specification limit and white if the process parameter falls below the user specified lower specification limit These fields are off green if the value of the process parameter can not be determined This is usually the result of setting up a new process parameter or some type of configuration error This field is purple if a PLC or AIU communication error exists otherwise it is cyan You can double click on this field to see additional information regarding the failure If you can not resolve this situation please contact the Mattec Customer Service Department immediately These fields are green if all observations for the last SPC SQC sample where within limits and red if one or more observations were out of limits These fields are cyan if there has been no SPC SQC sample taken These fields are yellow if the job has reached the End Of Job Warning and red if the job has reached the End of Job Alert otherwise these fields are cyan You can double click on these fields to see additional information regarding the end of job 3 13 810 0001 Rev C Field s Color Coding The End of Job Warning and End of Job Alert times are configured by the System Administrator Reference the System Administration Manual 810 0014 for additional information
41. number of users can login for Operator Efficiency and an unlimited number of users can login for Operator Tracking per machine When a user logs in for Operator Efficiency performance information is automatically collected by the system The system records the percent down percent scrap percent of machine cycles that are out of specification yield efficiency and more This information is available on the Real Time Display reference Section 3 13 and in the Operator Efficiency Report To generate the Operator Efficiency Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon e Click on the Planning menu click on the Operator menu and select Operator Efficiency Fill in the report data selection interface as appropriate Press ox The Operator Efficiency Report will be displayed Copyright O 1983 2004 4 51 810 0001 Rev C Mattec Corporation 2 System Reports for SNUFFY Operator Efficiency Report File Shift Job Planning Application Help Ha 308416820 Ki 4 1of2 gt y a Sel joz y C J Tota 24 100 24 of 24 Operator Efficiency Report attec Corporation breland Ohio 45140 lected Range from 04 10 03 to 04 30 03 ll Machines SH Erartmerd 4 14 03 11 38 32 AM 4 14 03 11 39 06 AM 4 17 03 8 53 14 AM 4 28 03 10 48 58 AM 4 28 03 10 49 09 AM 4 14 03 3 00 01 PM 4 14 03 3 00 01 PM 4 17 03 3 00 01 PM 4 23 03 3 00 01 PM 4 23 03 3 00 0
42. of observations that are grouped together when performing Moving Range calculations This value is only used if Moving Range is selected or 1f the number of observations per sample for the job is one 1 Display reference lines for mean Histogram This value causes ProStat to dynamically calculate the mean and display it on the chart Display curve showing normal distribution Gaussian Histogram The value causes a bell curve to be overlaid on the chart The bell curve represents a normal distribution Display number of observations in each cell Histogram When selected this value will cause the chart to display the number of observations for each cell on the chart Display horizontal grid lines Histogram Controls whether horizontal grid lines are displayed on the chart Display vertical grid lines Histogram Controls whether vertical grid lines are displayed on the chart 3 Dimensional Histogram Controls whether the chart is displayed in 2 D or 3 D Copyright 1983 2004 Mattec Corporation 7 163 810 0001 Rev C 7 13 Linear Regression Analysis Scatter Diagram Linear regression analysis allows users to investigate the relationships between any two related characteristics for which SPC SQC data has been collected When using linear regression analysis you must identify an independent characteristic and one or more dependent character
43. on time Reference Section 6 5 for additional information Copyright O 1983 2004 6 98 810 0001 Rev C Mattec Corporation Advanced Tip 1 Family Molding is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Mattec s Family Molding software works great in a variety of applications including the following Left Right and Front Rear Parts For example you may be making one front bumper and one rear bumper every machine cycle Although the parts are related you can make different quantities of each or have a need to track SPC scrap and other data individually With Family Molding each part will be its own son job with its own SPC history scrap parts lot size forecasted end date etc Color Changes for the Same Part For example you may plan to make 50 000 black pen casings 30 000 grey pen casings and 20 000 red pen casings All will be made with the same tool and on the same machine With Family Molding each color can be its own son job The jobs will be scheduled as a unit that is as a family but each son job will have its own lot size forecasted end date production history and process history The system will accurately forecast when each son job will end and when the next son job will start Multiple Releases of a Part For example your customer has ordered 200 000 parts but wants 50 000 parts delivered May 1 50 000 parts delivered June 1 etc Wit
44. s unique Gantt In Gantt Schedule see Section 6 5 Production and process history for each son job is maintained separately for easy retrieval Advanced Tip 2 Family Molding allows the user to create up to 1 000 son jobs per family Up to 100 of those son jobs can be running simultaneously on a single machine However many MIUs will only display data for 20 total son jobs per family and or 10 running son jobs Data will be collected properly for the remaining son jobs but the user must use the host based software to perform job changes or to view data Copyright O 1983 2004 6 100 810 0001 Rev C Mattec Corporation 6 2 Creating And Scheduling Bachelor Jobs A job descriptor represents a work order A bachelor job is often referred to simply as a job Most production and process information that is collected by the system is stored to the job descriptor To create and schedule a bachelor job follow these steps e Start the Main Menu and press the Launch Job Schedule icon Select the appropriate machine s and press ox The Job Schedule program will be displayed e Click on the Tools menu click on the New Job menu and select Single The Job Descriptor dialog will be displayed Job Descriptor E Job l Job Number Status PEND Forecasted Start Forecasted End Machine Number lt Non gt l T N A ONZA Part Number kNon gt l A ONZA ONZA Tool Number lt None gt E Desired Start Desired End Material ID
45. select the father job you can only select scheduled bachelor or family jobs in the Next Job Number picklist If you select a running son job in the Job Number picklist the action suspend or end will be performed on that specific son job Thus if you select a son job you can only select related pending son jobs in the Next Job Number picklist Advanced Tip 6 If a family job is running when you perform job control and you select a running son job in the Job Number picklist then you must select a pending son job in the Next Job Number picklist if a related son job is pending That is you can not select None Don t Start Another Job unless there are no pending son jobs for the family Advanced Tip 7 It s possible to make mistakes and to suspend a job when you intended to end it or to end a job when you intended to re run the job You can override a job s status in the Job Scheduler Reference Section 6 11 for additional information Copyright 1983 2004 6 124 810 0001 Rev C Mattec Corporation 6 11 Job Status Override It s possible to make mistakes and to suspend a job when you intended to end it or to end a job when you intended to re run the job and therefore intended to suspend it In such cases you will need to override the job s status To override a job s status follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Mach
46. start the Main Menu and press the Launch Real Time Display icon e Right click on the desired machine and select Remote Downtime The Remote Downtime dialog will be displayed Remote Downtime Selection Ea m Select Downtime Reason Machine Number INJ 01 Time In Status 0 02 New Downtime Reason MACH PROB Machine Probler y Remote Downtime Selection Dialog e Select the downtime reason in the New Downtime Reason picklist and press Apply The Real Time Display will contact the monitoring engine to request that the new downtime reason be applied to the MIU Copyright 1983 2004 3 30 810 0001 Rev C Mattec Corporation Advanced Tip 1 You can only select the downtime reason for an MIU via the Real Time Display if the MIU supports this functionality Contact the Mattec Customer Service Department to determine if your MIU supports this functionality Advanced Tip 2 The System Manager defines the system wide down codes creates the simple and advanced downtime maps specifies which down codes are force down reasons and assigns a Down Map to each MIU Reference the System Administration Manual 4810 0014 for additional information Advanced Tip 3 The downtime reasons that are displayed in the Remote Downtime Selection dialog are chosen from the Advanced Down Map or the Simple Down Map but not both The map that is used by the MIU is the map that the Remote Downtime Selection dialog us
47. that occurs automatically in ProHelp EPM when one shift ends and another shift starts 9 198 810 0001 Rev C Shift Exception Sigma 0 Sigma Estimate Sigma Individuals Significance Skewness Son Job SPC Specification Limit SQC Standard Cycle Time Copyright O 1983 2004 Mattec Corporation An exception to the standard shift schedule For example holidays are non working shift exceptions and overtime days are working shift exceptions The Greek letter used to designate a standard deviation The estimated standard deviation The actual standard deviation A measure of the significance between the Independent Characteristic and the Dependent Characteristic s when performing linear regression analysis A significance greater than 3 is often considered significant A measure of a given statistical distribution s Histogram Chart asymmetry A normal distribution that is symmetrical has a skewness of 0 A son job is often referred to as a component job Each son job represents one distinct part that will be created when a family job is run Most data that is collected by the system for a family job is stored to the son job not the father job Statistical Process Control The use of statistical techniques such as control charts to analyze a process or its outputs and to take appropriate actions to achieve and maintain a state of statistical control and to improve the process capabi
48. the Options dialog Advanced Tip 1 Downtime is automatically accumulated by the MIU The user can specify the current downtime reason at the MIU or via the Real Time Display If you make a mistake the System Manager can edit this data via Edit Facilities Reference Section 5 11 for additional information Advanced Tip 2 Any downtime reason that has accumulated downtime for the job will be displayed in the Downtime Pie Chart Advanced Tip 3 The Downtime Pie Chart is not available if you are analyzing data for multiple jobs e SPC By Part or SPC By Too Copyright 1983 2004 7 140 810 0001 Rev C Mattec Corporation 7 6 Overview Tab The Overview tab in ProStat displays basic information for the currently selected job s To display the Overview tab follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Overview tab The Overview tab will be displayed ProStat SPC SQC PE E3 lel 3 5 wem Overview Production Process Alarm x Bar R Chart x Bar s Chart Median Chart Histogram Job Data Machine Number INJ 01 1 000 Ton Injection Job Number CAP Lot 419 Part Number SBC 227277 Bottle Cap Bottle Cap Tool Number SBC 1115 Shampoo Bottle Cap Customer Mattec Status COMP r Date Range Jv All Dates Start Date
49. the entire facility This can increase the usability for all of these reports For example the Job Production Report can be selected for all currently running jobs and normally shows detailed production information for these jobs However when Individual Records are turned off this report shows production totals by department for these jobs Advanced Tip 4 Job reports show data for jobs that meet the criteria that is specified on the report interface For example you can often select to view data for all currently running jobs Shift reports typically allow you to select one or more machines and to specify a very precise date range that you wish to view For this reason shift reports may be easier to use if you want to view production totals for a department or for the entire facility Reference Section 4 1 for additional information Advanced Tip 5 Some job reports allow you to specify a date range For example when you specify Jobs Within Time Range you are prompted to enter a From date time and a To date time This may behave differently than expected Specifically the Jobs Within Time Range filter will select all jobs that likely ran during the specified time range However the data on the report is not limited to data that was collected during the specified time range Rather the data on the report is the job data that was collected for any job that likely ran during the specified time range J
50. to modify Press ox The Job Schedule program will be displayed Copyright O 1983 2004 6 95 810 0001 Rev C Mattec Corporation Ay Job Schedule olx File View Reports Tools Application Help HSA i ii Ea DLG a DLG b JF RB192 GREY _ B geyc 0 1 DLG i DLG k Moa DGkF34610583531 INJ 01 FEO O F RB192 Release 2 zi Ready Job Number NUM EDIT 4 Job Schedule Alternate Methods Jobs can also be created and scheduled via the Data Import Export program Reference the Data Exchange Manual 4810 0002 for additional information Advanced Tip 3 A large but finite number of jobs 15 000 can be scheduled at the same time By default your system is configured to permit the user to schedule up to 150 machines with up to 100 jobs per machine at one time If this is not sufficient for your needs contact the Mattec Customer Service Department for assistance reconfiguring your system The registry setting HKLM Software Mattec ProHelp JobSchedLimit defines the number of jobs that are permitted per machine thus it also controls the number of machines that can be scheduled at one time By default this value is set to 100 Copyright 1983 2004 6 96 810 0001 Rev C Mattec Corporation Each job that is scheduled is represented by a color coded bar on the display Family jobs have a single bar that represents the father job The user can display a variety of information on the job bar including
51. to save those control limits Copyright 1983 2004 7 170 810 0001 Rev C Mattec Corporation 7 15 SPC SQC Summary Report The SPC SQC Summary Report displays detailed information for each sample being analyzed Compatibility The SPC SQC Summary Report is only available for Automatic SPC Manual SPC or Variable SQC data It is not available for Attribute SQC data To display the SPC SQC Summary Report follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the SPC SQC Summary Report icon The SPC SQC Summary Report will be displayed File View ProStat SPC SQC Summary Machine Number NJ 01 Data Type Automatic X BarBar Job Number CAP Lot 419 Characteristic Cycle Time Part Number SBC 227277 Bottle Cap Start Date 05 13 2002 10 22 00 Tool Number SBC 1115 End Date 11 22 2002 14 36 00 2 3 4 5 1 6 fi 8 05 13 2002 05 17 2002 05 17 2002 06 04 2002 06 07 2002 06 07 2002 06 07 2002 06 07 2002 10 22 00 12 08 00 12 18 00 14 58 00 10 10 00 14 38 00 15 08 00 15 20 00 0 700 0 700 0 700 5 500 1 900 1 500 1 300 1 300 0 700 0 700 0 700 5 500 1 400 1 400 1 400 1 400 0 700 0 700 0 700 5 500 1 650 1 450 1 350 1 350 0 000 0 000 0 000 0 500 0 100 amm annm annn anen anen SPC SQC Summary Report Re
52. 1 Scrap and packed parts can be entered as parts or cases The number of parts per case is defined in the Part IDs Edit Facility Advanced Tip 2 The System Manager defines the system wide scrap codes creates the simple and advanced scrap maps and assigns a Scrap Map to each MIU Reference the System Administration Manual 810 0014 for additional information Advanced Tip 3 The scrap reasons that are displayed in the Scrap Entry dialog are chosen from the Advanced Scrap Map or the Simple Scrap Map but not both The map that is used by the MIU is the map that the Scrap Parts Entry dialog uses The Scrap Map is specified in the Machine Configuration program Copyright 1983 2004 3 29 810 0001 Rev C Mattec Corporation 3 9 Select Downtime Reasons Authorized users can use the Real Time Display to select a downtime reason for the MIU Selecting a downtime reason has the following effect e If the MIU is currently down all future downtime will be collected to the specified reason e Ifthe MIU is currently running the MIU will be forced down if the selected downtime reason is a force down downtime reason e Ifthe MIU is currently running the downtime selection will be ignored if the selected downtime reason is not a force down downtime reason Alternate Methods Users can select a downtime reason at the MIU To select a downtime reason for an MIU follow these steps e Start the Real Time Display To do this
53. 1 PM 1 Shift 4 17 03 8 53 09 AM 4 17 03 9 00 01 AM Dperator Efficiency Report loaded Operator Efficiency Report Advanced Tip 2 Operator Tracking is a standard feature that is included with the ProHelp EPM system Operator Efficiency is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 3 Operator Tracking and Operator Efficiency data is available for export to external time tracking systems via the Data Import Export program Reference the Data Exchange Manual 810 0002 for additional information Advanced Tip 4 Operators can be automatically logged out of the MIU at shift change if desired The System Manager establishes this setting via the System Configuration program Reference the System Administration Manual 810 0014 for additional information Copyright 1983 2004 4 52 Mattec Corporation 810 0001 Rev C 4 6 Audit Trail Reports Audit Trail reports exist to help users achieve FDA CFR 21 Part 11 Compliance with their ProHelp EPM software Selected areas of the system provide detailed logs of changes to existing data These logs are known as Audit Trails The Audit Trail reports display the information in these logs in an easy to read format To generate an Audit Trail Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon e Click on the Planning menu
54. 1 Rev C Data Type Description Attribute SQC Attribute SQC data is entered by the user either at an MIU a PC or both This data is limited to the system wide part defects 1 e Scrap Codes defined in System Configuration Attribute SQC data is loosely related to Manual SPC data and Variable SQC data Advanced Tip 1 ProStat is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Mattec offers a comprehensive 2 3 day seminar on ProStat Reference Section 1 4 for additional information Copyright O 1983 2004 Mattec Corporation 7 129 810 0001 Rev C 7 1 Enabling Data Collection SPC and SQC data can not be collected for a job until it has been enabled There are several ways this data collection may be enabled Data Type Enabling Method Automatic SPC Automatic SPC data collection is enabled in the System Configuration program and can be overridden on a machine by machine basis in the Machine Configuration program Automatic SPC sampling is always enabled for all process parameters for all machines Reference the System Administration Manual 4810 0014 for additional information Manual SPC Manual SPC Variable SQC and Attribute SQC data Variable SQC collection are enabled in a Sample Sheet A Sample Sheet Attribute SQC 1s associated with a job by being included in a Process Sheet Reference Section 5
55. 12345678901 234567890 Customer 112345 Next Job Next Job Number AIN Suspend Job End Job Refresh Job Control Program Alternate Methods You can start the Job Control program by right clicking on a machine in the Real Time Display and selecting Job Control or by right clicking on a machine in the Job Schedule and selecting Job Control In both cases the Job Control program will be started with the machine number already selected Copyright 1983 2004 6 123 810 0001 Rev C Mattec Corporation Advanced Tip 2 The jobs in the Next Job Number picklist include all jobs that have been scheduled for the selected machine using the Job Scheduler Advanced Tip 3 If no job is currently running on the machine when you start the Job Control program you can still select a job in the Next Job Number picklist then press the Start Job button to start that job Advanced Tip 4 When a job is suspended it can be rescheduled or left unscheduled This is determined by a setting in System Configuration Reference the System Administration Manual 810 0014 for additional information Advanced Tip 5 If a family job is running when you perform job control you will have the option of selecting the father job or any running son job in the Job Number picklist If you select the father job in the Job Number picklist the action suspend or end will be performed on all running son jobs Thus if you
56. 186 9 Glossary Of Tennis oisean io a 9 187 Copyright O 1983 2004 1 3 810 0001 Rev C Mattec Corporation 1 Introduction To ProHelp6 EPM The following sections provide a brief introduction to the ProHelp EPM Production and Process Monitoring System 1 1 Overview MATTEC Corporation s ProHelp EPM Production and Process Monitoring System is specifically designed for real time monitoring of all types of production equipment It is used extensively in the plastics injection molding extrusion blow molding blown film metal stamping die casting printing painting and assembly industries The basis behind the benefits from the ProHelp EPM system is the rationale that plant managers and operational people will take corrective actions to solve problems on production equipment when they are aware of such problems ProHelp EPM is the device to alert employees to problems immediately when the problems occur Therefore tremendous savings can occur in increased productivity and decreased scrap parts The ProHelp EPM system combines computer hardware computer software and Machine Interface Units MIUs into an efficient system to provide real time production monitoring production reports process alarms plant scheduling aids and SPC SQC process and part capability analysis Floor personnel can make use of the machine mounted terminals to signal different departments for help to view production results at the machine site and to enter
57. 27 html View Save Cancel Print _ Process Sheets Process Sheet Edit Facility Alternate Methods Process Sheets can also be created or modified via the Data Import Export program Reference the Data Exchange Manual 510 0002 for additional information Advanced Tip 1 A Machine ID Part ID Tool ID and Sample Sheet optional are associated with a job by being included in a Process Sheet A job must specify a Process Sheet when it is created either in the Job Schedule or the Data Import Export program Advanced Tip 2 You must have appropriate security permissions to view the Labor Cost field Contact the System Administrator for additional information Copyright 1983 2004 5 75 810 0001 Rev C Mattec Corporation The following table describes the fields that are available in the Process Sheet Edit Facility Field Description Machine Number The Machine Number Part Number and Tool Number Part Number uniquely identify the Process Sheet These settings can Tool Number not be modified once the Process Sheet has been saved Sample Sheet This field allows you to associate a Sample Sheet with the Process Sheet A Sample Sheet is used to enable Manual SPC Variable SQC and Attribute SQC sampling Reference Section 5 4 for additional information Last Update The date time of the last time this specific Process Sheet was modified by a user Percent Down This field allows you to specify th
58. 3 e Press the Production tab The Production tab will be displayed Jk ProStat SPC SQC Pie ES Sst O Le Overview Production Process Alarm x820 R Chart X Bar s Chart Median Chart Histogram Cpk Standard Parameter Deviation 204 7000 204 7000 1 73 oe NOTE The above data is based on the Job Engineering data that has been collected during the entire job run Calculated values e g CPK may differ from values that are calculated based on statistical samples OK ii ProStat Process Alarm Tab Copyright 1983 2004 7 144 810 0001 Rev C Mattec Corporation Alternate Methods Shift Engineering data can be viewed in the Shift Engineering Report in System Reports Job Engineering data can be viewed in the Job Engineering Report in System Reports Advanced Tip 1 The Job Engineering data on the Process Alarm tab is collected for all monitored process parameters on a cycle by cycle basis This data is always collected and is not associated with Automatic SPC or Manual SPC samples As such calculated values e g Cpk may differ from the values that are calculated based on statistical samples There is a degree of error in the Job Engineering data that is not present in SPC samples Advanced Tip 2 When analyzing data for multiple jobs i e SPC By Part or SPC By Tool the Process Alarm tab will show the combined process alarm data for all jobs being analyzed The s
59. 4 5 80 810 0001 Rev C Mattec Corporation 5 7 Tool Maintenance Log The Tool Maintenance Log in Edit Facilities allows you to create new Tool Preventive Maintenance History and view edit existing history records To enter preventive maintenance activity for a tool follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Tool Maintenance Log The select Tool Maintenance Log Edit Facility will be displayed E Edit Facilities for Release 6 1 0 Tool Maintenance Logs des File View Edit Application Window Help la x 4 8 8 2 Log Entries r Edit record Tools Time Logged 2 5 22 03 2 20 03 PM Maintenance Codes Tool Number M 1280 Injection Mold Maintenance Code DEPOS Deposit y Machine Number Jor 1 000 Ton Injection y mecormick 34535 Odom Adi 6 6 03 11 53 Run Time 136 hours M 1816 EJCTR 6 10 03 M 1211 SBC 1115 Employee ID Administrator Maintenance Description Deposit Removal Reason y Time Required minutes fiz o Save Cancel Frit Tool Maintenance Log Edit Facility e To edit an existing tool maintenance entry locate the desired entry using the selection facilities on the left hand side of the display Press the Edit button Modify the tool maintenance entry as appropriate Press Save to save your changes Co
60. 4 for additional information Advanced Tip 1 ProHelp Millennium allows the user to enable disable Automatic SPC data collection on a job by job basis This functionality does not exist in ProHelp EPM If you have the ProStat SPC SQC option Automatic SPC sampling is always enabled for all jobs Advanced Tip 2 ProHelp Millennium allows the user to individually enable disable process parameters for Automatic SPC sampling This functionality does not exist in ProHelp EPM Advanced Tip 3 ProHelp EPM allows the user to specify different subgroup sizes for Automatic SPC sampling and Manual SPC Variable SQC Attribute SQC sampling Most MIUs however do not support this functionality As such it is a good idea to use the same subgroup size throughout the system Copyright 1983 2004 7 130 810 0001 Rev C Mattec Corporation 7 2 Entering Data ProStat Sample Data Edit The ProStat Sample Data Edit program can be used to create modify Variable SQC and Attribute SQC samples It can be used to view modify Manual SPC samples To launch ProStat Sample Data Edit follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Press the Launch ProStat Sample Data Edit icon e Select the Job you wish to modify To do this select the Machine the job ran on then select the Job e Use the Previous and Next buttons to locate an existing SPC SQC sample To edi
61. 4M Duration 01 hours 27 minutes 21 seconds 7 qe af hij Ready Eind Next Cancel Tool Conflict Utility Alternate Methods You can launch the Tool Conflict locator by clicking on the Tool Conflicts icon on the toolbar To eliminate a tool conflict drag one of the jobs to a different machine or time slot that will eliminate the conflict This can be done while the Tool Conflict locator is still on the display Copyright 1983 2004 6 107 810 0001 Rev C Mattec Corporation Advanced Tip 1 The Tool Conflict Report allows you to see all tool conflicts at once and to print them To run this report click on the Reports menu and select Tool Conflict The Tool Conflict Report will be displayed Advanced Tip 2 It is possible to have a tool conflict between son jobs of a family job In this case only one job the father job will be highlighted when the Tool Conflict locator is run Copyright 1983 2004 6 108 810 0001 Rev C Mattec Corporation 6 5 Gantt In Gantt Schedule Mattec s unique Gantt In Gantt Job Schedule allows you to double click on a family job to see a Gantt chart for the individual son jobs in that family job You can then drag and drop the individual son jobs in order to schedule them in a manner that will allow each son job to finish on time To view the Gantt In Gantt Job Schedule for a family job follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Sc
62. 5 12 Production Easton Bd noia 5 92 5 13 Launching Other App ICAU ON dida 5 94 6 Job Schedule escoliosis ea it dada aislante Todas Toco 6 95 A A A TI 6 98 6 2 Creating And Scheduling Bachelor JODS ooooonnnncccnonccinoncccnoncnononccononcconnnccnnnnccnancnos 6 101 6 3 Creating And Scheduling Family JODS ooonncocnnncocnnncccnonccononcnononcnnnnnncononoconnnccnnnnnos 6 103 OAS Too Cons A A SS 6 107 6 5 Gantt In Gantt Schedule 6 109 66 Sehed le Repo oia 6 111 Ga Seneduled Jobs Li 6 112 A A E 6 114 6 9 Adva ced Seti GS a A a nS 6 116 0X Personal Preference set NOs can seuss utc sue A A EEN 6 119 6 10 JOD CONTO iain eee rey Ret eet el Sever a E REE S ett er enter Ener avery verte ent Parte 6 122 GLI Job SS TALUS ONES ad a SA ados 6 125 6 12 Launching Other ApplicatiODS ooooononnncconnncnnnnanonnnnnononaconnnnnnnnacononanonnna non naccn nacion nano 6 126 Te OSO PUSO E E E ata ie oia 7 127 dels Enabling Data Collection catia ait ed o NEO 7 130 7 2 Entering Data ProStat Sample Data Edit oooconnnnccnoncccnncccononcnnnnnacononacnnanacnnnaccnnnos 7 131 73 Selecting Data Por Analysis A aamdebaoeaes ees eaeeue devas EE Raas 7 133 7 3 1 Selecting Data Por Multiple Jobs ccc3 ce oik coat E 7 135 Dies IA Panel as o as 7 137 a Downtime Pie COn dins ii 7 139 TG OVERVIEW Lab a da da N RO ER 7 141 TL Prod c on Fab 053 A A ES 7 142 TS A e eter dau Laie Jalen talus Sauer ee am eoatlen taste 7 144 79 X Bar Chart and Range Cha
63. 6 000 NA 0 00 0 00 86 80 Recovery N A 0000 NA NA 0 00 0 00 0 00 Nozzle 008 117326 O01 6 46 5 965 65 125 00 579 80 Z Job Engineering Report Job reports are divided into the following categories Shift Report Category Description Production Reports in this category primarily show production related information for a machine job part or tool Downtime Reports in this category show job downtime and include the Job Downtime Report Scrap Reports in this category show scrap that has been entered for each job and include the Job Scrap Report Analysis Reports in this category show detailed information that may be of interest to managers or Process Engineers Cost Reports in this category show cost related information and include the Job Downtime Cost Report and the Job Scrap Cost Report Copyright 1983 2004 4 43 810 0001 Rev C Mattec Corporation Advanced Tip 2 The Job Overall Equipment Effectiveness Report is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Reference Section 4 3 for additional information regarding this report Advanced Tip 3 You must have appropriate security permissions to view the results of the cost related reports Reference the System Administration Manual 4810 0014 for additional information In many of the job reports if you disable the display of Individual Records you will see only totals for a Machine Department or
64. 6 07 200 n Ma olol 5555555505050 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 077087200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 07208200 CAP Lot A19 SBC 227277 SBC 1115 Cycle Time 07 08 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 072084200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 07 08 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 07 09 200 o 50050500500500050050000 SR SR MMH SS 2 2 2 2 2 2 2 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 07 08 2002 2 2 2 2 2 2 SPC SQC Summary Report Export Format Advanced Tip 1 The Export format of the SPC SQC Summary Report requires the Data Import Export option Data Import Export is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Copyright 1983 2004 7 172 810 0001 Rev C Mattec Corporation When in Report format the report can be saved in the following file formats e Microsoft Excel e Web Page When in Export format the export can be saved in the following file formats CSV comma delimited Unicode CSV comma delimited Text tab delimited Unicode Text tab delimited Microsoft Excel Web Page Copyright O 1983 2004 7 173 810 0001 Rev C Mattec Corporation 7 16 Process Exception Log The Process Exception Log will record any machine cycles that result in a violation of specification limits control limits and or part qualification limits for a
65. 8 108 01 52903 1 354211 SBC 221277 Bottle Cap 3 00 0 00 0 0 10 884 0 0 0 0 38 39 Dl 612103 1 354211 SBC 221277 Bottle Cap 15 29 0 00 0 0 924 0 0 0 0 38 2 01 6 2103 1 354221 SBC 221277 Bottle Cap 6 19 0 09 22 7 486 0 1 610 LRT 38 34 01 6303 1 354221 SBC 221277 Bottle Cap 0 00 8 00 100 0 0 0 0 NA NIA 0 01 6 4103 1 35422 1 SBC 221277 Bottle Cap 2 55 3 03 51 1 32 544 0 0 00 280 438 01 6 4 03 1 CAP Lot Al9 SBC 221277 Bottle Cap 3 21 0 00 0 0 12 924 0 0 oo 104 310 ol 615103 1 CAP Lot Al9 SBC 221277 Bottle Cap 7 52 0 07 14 31 295 147 900 l 02 107 121 01 6 6 03 1 CAP Lot Al9 SBC 221277 Bottle Cap 7 53 0 06 13 30 377 31 000 103 03 104 117 01 617103 1 CAP Lot Al9 SBC 221277 Bottle Cap 3 00 0 00 0 0 30 900 0 0 DO 104 119 Daily Production Report Shift reports are divided into the following categories Shift Report Category Description Production Reports in this category primarily show production related information for a machine job part or tool Downtime Reports in this category show machine downtime and include the Period Downtime Report and the Detailed Downtime Report Scrap Reports in this category show scrap that has been entered for each job and include the Period Scrap Report and the Detailed Scrap Report Analysis Reports in this category show detailed information that may be of interest to managers or Process Engineers Copyright O 1983 2004 4 40 810 0001 Rev C Mattec Corporation
66. 83 2004 7 133 810 0001 Rev C Mattec Corporation e To analyze all data that has been collected for the job press the A11 Dates checkbox To analyze only a subset of the data that has been collected uncheck the A11 Dates checkbox and enter the desired date time range for the data to be analyzed e Select the appropriate Data Type and Parameter to be analyzed The Parameter picklist will change depending on the Data Type that has been selected e Press ox The job data will be retrieved from the database and the ProStat program will be displayed You can now view any of the available charts or perform any data analysis as appropriate Alternate Methods You can start the ProStat program by right clicking on a machine in the Real Time Display and selecting ProStat The ProStat program will be started with the job number already selected You can start the ProStat program by clicking the ProStat icon in the ProStat Sample Data Edit program The ProStat program will be started with the job number already selected Advanced Tip 1 When analyzing data for a job you can press the Select Data icon at any time to select a different Data Type and or Parameter for analysis Copyright 1983 2004 7 134 810 0001 Rev C Mattec Corporation 7 3 1 Selecting Data For Multiple Jobs ProStat allows data to be analyzed for multiple jobs for Automatic SPC or Manual SPC data types This is sometimes refered to as SPC By Part or
67. 9 for additional information If son jobs have been created they are listed in the spreadsheet on the bottom of the Family tab of the Job Descriptor dialog The son jobs are listed in the order in which they will be run The system will accurately forecast each son job s start and end date You can double click on any son job in this spreadsheet to go to that son job s corresponding entry on the Component tab of the Job Descriptor dialog Copyright 1983 2004 6 104 810 0001 Rev C Mattec Corporation Advanced Tip 2 You can double click on a scheduled job in the Job Schedule to see the Job Descriptor dialog for thatjob This allows you to modify data for running or scheduled jobs Advanced Tip 3 A father job can optionally specify a Tool Number This allows for accurate preventive maintenance forecasting for both the father job s base mold and the insert mold for each son job All other data in the father s Tool ID is ignored including the active cavities Advanced Tip 4 You can not change the Active Components for a running family job This is usually only necessary if a problem has occurred with the father job s base mold In the event that the father job s base mold is temporarily unable to run the maximum number of insert molds son jobs you must Suspend the entire family job using Job Control modify the Active Components using the Job Schedule and re Start t
68. C sample Automatic SPC and Manual SPC or SQC sample Variable SQC or Attribute SQC can be seen on the Real Time Display The System Manager can add these fields to any custom Real Time Display These fields exist in the Basic Data category and are available via the Real Time Display Writer Reference the System Administration Manual 4810 0014 for additional information Advanced Tip 1 The system will only display Run alarms at the MIU or the status of the last sample on the Real Time Display for SPC SQC data that is collected by the MIU or that is input by the user at the MIU Samples that are entered by the user via the ProStat Sample Data Edit program are ignored for alarming purposes Advanced Tip 2 ProHelp Millennium allows the user to display SPC SQC Run Alarms Shifts and Trends on the Real Time Display This functionality does not exist in ProHelp EPM Copyright 1983 2004 7 176 810 0001 Rev C Mattec Corporation 7 18 Part Qualification The ProHelp EPM system is capable of qualifying 100 of parts during production based on the specification and control limits of all monitored process parameters When a part is produced during a cycle where any process parameter exceeds its limits upper or lower the MIU will ignite a digital contact that can be connected to a diverter or robot to place these parts away from good production Parts are qualified based upon two criteria e Specification limits that ar
69. Display Contact the System Administrator for additional information Advanced Tip 3 The Cost Real Time Display is resizable If the original display is too small to view all of the data simply drag the sides of the dialog box to make the window larger Copyright 1983 2004 3 36 810 0001 Rev C Mattec Corporation 3 15 Launching Other Applications The Real Time Display like the Main Menu can be used to launch most other applications in the system To launch an application using the Real Time Display follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon The Real Time Display will be displayed e Single click the icon on the toolbar that represents the application that you wish to start Advanced Tip 1 To determine which program will be launched when you press an icon on toolbar simply hover the mouse cursor over that icon A tool tip will be displayed In addition to the toolbar the Real Time Display provides special shortcuts to the Job Control and ProStat programs These shortcuts allow the programs to be started with the Machine Number Job Number and other relevant information already selected To launch the Job Control program or the ProStat program from the Real Time Display follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon The Real Time Displa
70. Export program Reference the Data Exchange Manual 810 0002 for additional information Advanced Tip 1 A Tool ID is associated with a job by being included in a Process Sheet The following table describes the fields that are available in the Tool ID Edit Facility Field Description Tool Number A unique identifier that identifies the tool Description A description for the tool This field is frequently displayed throughout the system to help you to identify a tool Group A descriptive field to identify a tool group The Mattec Customer Service Department can manually configure the names of each group This selection is ignored by the system Machine Type A descriptive field to identify a required machine type for the tool This field is ignored by the system Maker A descriptive field to identify the tool maker for the tool This field is ignored by the system Location A descriptive field to identify the present location of the tool This field is ignored by the system Last Update The date time of the last time this specific Tool ID was modified by a user Total Cavities The total number of cavities for the tool Copyright 1983 2004 Mattec Corporation 5 66 810 0001 Rev C Field Description Active Cavities The current number of cavities for the tool This value affects the number of parts that are produced with each machine cycle and cannot exceed the Total Caviti
71. Good Parts Cycle Efficiency A setting in the System Configuration program allows the System Manager to change the calculation to the following OEE Percent Uptime Percent Good Parts Yield Efficiency This latter calculation would actually double count the effect of scrap on the system Reference the System Administration Manual 4810 0014 for additional information Both calculations ignore the effect of downtime when a machine is idle that is when a job is not running Copyright 1983 2004 4 46 810 0001 Rev C Mattec Corporation 4 4 Preventive Maintenance Reports ProHelp EPM assists in forecasting and tracking machine and tool preventive maintenance The System Manager defines maintenance codes and how often the maintenance is performed ProHelp EPM automatically tracks machine and tool run time and cycles and accurately predicts when maintenance will be due Preventive Maintenance Reports are available to show when preventive maintenance is next due for a machine or tool to display maintenance history for a machine or tool and to display other useful information To generate a Preventive Maintenance Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon e To generate a Machine PM Report click on the Planning menu click on the Machine Maintenance menu and select the desired report Fill in the report data selection interface as a
72. M system will dynamically determine the specification and control limits that are sent to the MIU for process monitoring purposes The specification limits and control limits are determined by selecting the lowest upper limit and the highest lower limit for each process parameter for each running son job That is the tightest specification and control limits as determined by combining all of the running son job s Process Sheets together are used Thus when you end one son job and start running another related son job the specification and control limits that are in use may change slightly Copyright 1983 2004 5 61 810 0001 Rev C Mattec Corporation 5 2 Part ID A Part ID defines information for the part that will be created by a job including the material s that will be used the part weight and costs The Part ID Edit Facility is used to maintain and identify all available parts To launch the Part ID Edit Facility follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu and select Part ID The Part ID Edit Facility will be displayed ATN Facilities for Release 6 1 0 Part IDs day File View Edit Application Window Help le x 1 33 5138 JaAAZa2e Parts rm Edit record Current Gurren Parts Last Update 6 16 03 9 14 44 AM Part Number CAL164263M1 11 Part Weight fizeos g Description Rear Tail Ligt
73. O 1983 2004 Mattec Corporation A measure of a given statistical distribution s Histogram Chart asymmetry A normal distribution with a symmetrical bell curve has a Kurtosis of 0 This field is specified in a Process Sheet and allows you to specify the standard labor cost for the machine operators that are required per shift This field is specified in a Process Sheet and allows you to identify the number of machine operators that are required per shift This field is ignored by the system The date time that a record was last updated This field appears in many locations throughout the system See Lower Control Limit See Lower Control Limit See Channel The quantity of good parts to be produced for a job The lower bound of the statistical limits that are applied to measure the significance of the variation of a process parameter or part characteristic Control limits can be calculated from process data The lower bound of the engineering limit that defines the range of acceptable values for a monitored process parameter or part characteristic to produce a good part See Lower Specification Limit The number of times that the machine has cycled as accumulated by the MIU A Machine ID defines the physical characteristics of the MIU that will monitor a machine including the specific process parameters that will be collected A Machine ID 1s specified in a Process Sheet See MIU A descriptive identifier that u
74. ProHelp EPM Production amp Process Monitoring System User s Manual For ProHelp EPM Release 6 1 0 MANUAL 810 0001 Revision C March 17 2004 ATTENTION You can obtain service support by visiting Mattec s web site at http www mattec com by emailing the help desk at helpdesk mattec com or by telephone at 513 683 1802 This manual is intended for all users of the ProHelp EPM system TABLE OF CONTENTS 1 Introduction To ProHelpO EPM oia ed does aeei ta ide 1 4 LM OE SS Ai 1 4 12 A eaetvsqececsta A S aE AAEE 1 5 EA Server A o 1 5 1 2 2 Machine Interface Unit MIU ooooonnccncnnnonononannnnconconnnonononononcononnnno O R AIRRA 1 5 1 2 3 RocketPort Serial Communication Board And Buffer BOX ooooonnocccccoccccnonccnonnncnnenos 1 5 124 A A O ee hse E adalat RGR 1 6 1 3 Shut Down Procedure saciar eed ia asiaa 1 6 A Additional Traine secs A IAS 1 7 2 Main MA camaieh E E 2 9 iin RS Abe A sa cad ceo A E E adades cade eacewveaeuasteneeathe 3 10 A ON 3 12 3 2 Filterins Data iii tdi 3 15 3 9 a A O O 3 19 Os Serap Pareto Ch da Mats 3 21 33 Downtme Pie Chau e ts 3 23 30 Process Excepto Log rana 3 25 O A Center AAA sea E REE aA u ite E NER 3 27 3 8 ibe Scrap And Packed Pai dase sensaeeaes 3 28 3 9 Select Downtime AAA E 3 30 3 10 Change Active Cavities osoric eee eie n E A aSa REEE A I a 3 32 3 11 Cancel Acknowledge Help Calls a aci n 3 33 3 12 Additional F nctronality srie a a a ae mea oad 3
75. Range Chart Copyright 1983 2004 7 146 810 0001 Rev C Mattec Corporation Advanced Tip 1 If the number of observations per sample for the job equals one 1 the Chart of Individuals and Moving Range chart will be automatically selected instead of the X Bar Range Charts You can force the Chart of Individuals and Moving Range Chart to be displayed by selecting the Moving Range option on the R MRx Chart tab on the Options dialog Reference Section 7 9 1 for additional information You can double click on any point in either the X Bar or Range Charts to see additional data for that sample including the observations that comprised the sample the date time that the sample was taken and the X Bar Range Standard Deviation and Median for the sample Advanced Tip 2 The X Bar Range Charts are available when performing analysis for multiple jobs i e SPC By Part or SPC By Tool Data for the jobs are arranged in chronological order by job starting with the job that ran first You can double click on any point in either chart to see which job is associated with the sample A number of options are available to control the behavior of the charts To modify the behavior of the X Bar Range Charts follow these steps e Press the Options button The Options dialog will be displayed e Press the X Bar Chart tab or the R MRx Chart tab Copyright O 1983 2004 7 147 810 0001 Rev C Mattec Corporation ProStat Options
76. Time Display Advanced Tip 1 Operator Efficiency logging is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 You must have appropriate security permissions to view the Operator Efficiency Real Time Display Contact the System Administrator for additional information Advanced Tip 3 The Operator Efficiency Real Time Display is resizable If the original display is too small to view all of the data simply drag the sides of the dialog box to make the window larger Copyright 1983 2004 3 35 810 0001 Rev C Mattec Corporation 3 14 Cost Display The Cost Display shows scrap and downtime costs for all machines in the plant in real time A default Cost Display shipped with your system and the System Manager can easily create custom displays using the Real Time Display Writer To start the Cost Display follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Press the Cost Display icon on the toolbar The Cost Real Time Display will be displayed Cost Real Time Display x Cost Scrap 3 Refresh Options Cost Real Time Display Advanced Tip 1 Cost Cost Manager is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 You must have appropriate security permissions to view the Cost Real Time
77. Time and Machine Cycles when the maintenance was performed Fill in the fields on the display as appropriate Press Save to save your changes Alternate Methods Users can log preventive maintenance activity as it occurs at the MIU When this is done the system will automatically calculate the amount of time that it took to perform the maintenance activity Advanced Tip 1 Preventive Maintenance is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 The System Manager defines Preventive Maintenance Reasons Codes Up to 100 Machine PM Codes can be created Each PM Code specifies when it is due in terms of run hours or machine cycles or both Advanced Tip 3 The ProHelp EPM system will not forecast that preventive maintenance is due for a specific machine for a specific PM Code unless maintenance history has been entered for that machine for that specific code at least one time Thus although the PM Codes are defined system wide they do not necessarily apply to all machines You can include notes with each preventive maintenance activity that is performed To include detailed notes about the maintenance activity press the Notes button Modify the Maintenance Notes as appropriate Press OK to temporarily save your changes You will be returned to the Machine Maintenance Log Edit Facility Press Save to save your changes Copyright 1983 200
78. U is capable of displaying the entire Sample Sheet Setup Sheet for the currently running job s and for all scheduled jobs Copyright 1983 2004 5 73 810 0001 Rev C Mattec Corporation 5 5 Process Sheet A Process Sheet defines the machine specific process limits e g specification limits and control limits that will be used when a job is run on a specific machine The Process Sheet Edit Facility 1s used to maintain and identify all available Process Sheets A bachelor job or son job is comprised of a Process Sheet which in turn is comprised of a Machine ID a Part ID a Tool ID and a Sample Sheet optional When a job is moved from one machine to another machine via the Job Schedule program it will continue to produce the same part with the same tool but it will necessarily use a different process sheet This allows your Process Engineer s to define different standards e g specification and control limits for jobs depending on which machines the job will run on If a particular machine does not have a Process Sheet defined that would permit that job to run on the machine an error is displayed and the person is prevented from moving the job to that machine This allows your Process Engineer s to define rules that prevent jobs from being scheduled on machines that aren t capable of running the job To launch the Process Sheet Edit Facility follow these steps e Start the Main Menu and press the Launch Edit Facilities ic
79. a consistency Advanced Tip 4 When you edit time related data you are only given an opportunity to edit the standard fields e g total time downtime and down count A best guess algorithm is used to make appropriate changes to the weighted fields e g weighted total time weighted downtime and weighted down count These weighted fields are used to calculate the totals line in reports Copyright 1983 2004 5 93 810 0001 Rev C Mattec Corporation 5 13 Launching Other Applications The Edit Facilities program like the Main Menu can be used to launch most other applications in the system To launch an application using Edit Facilities follow these steps e Start Edit Facilities To do this start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Single click the icon on the toolbar that represents the application that you wish to start Advanced Tip 1 To determine which program will be launched when you press an icon on toolbar simply hover the mouse cursor over that icon A tool tip will be displayed Copyright O 1983 2004 5 94 810 0001 Rev C Mattec Corporation 6 Job Schedule ProHelp EPM allows users to create and schedule jobs several years in advance for 4 096 machines Changes in actual cycle times downtime scrap etc can extend the amount of time it will take for a job to run and are reflected in real time
80. aintenance History This report lists all preventive maintenance history 1 e preventive maintenance that has been performed for all selected machines and all selected PM Codes for the given timeframe Machine Odometer This reports lists the cumulative machine cycles and cumulative run hours for all selected machines The following table describes the available Tool Preventive Maintenance reports Tool PM Report Description Tool PM Due This reports forecasts when preventive maintenance will be due for all selected tools and all selected PM Codes for the given timeframe Tool Maintenance History This report lists all preventive maintenance history 1 e preventive maintenance that has been performed for all selected tools and all selected PM Codes for the given timeframe Tool Odometer This reports lists the cumulative machine cycles and cumulative run hours for all selected tools Advanced Tip 2 Preventive Maintenance history for a specific PM Code can be entered from an MIU or via Edit Facilities Reference Section 5 6 or Section 5 7 for additional information Advanced Tip 3 The System Manager defines Preventive Maintenance Reasons Codes Up to 100 Machine PM Codes and 100 Tool PM Codes can be created Each PM Code specifies when it is due in terms of run hours or machine cycles or both Copyright 1983 2004 Mattec Corporation 4 48 810 0001 Rev C
81. al SPC sampling in the Machine Configuration program If a job s Process Sheet has a Sample Sheet then Manual SPC sampling is enabled Specification and control limits for the Manual SPC process parameters are stored in the Process Sheet Advanced Tip 7 Variable SQC characteristics are defined on the Specification and Control tabs in the Sample Sheet You must manually define these characteristics by pressing the Add Variable button If a job s Process Sheet has a Sample Sheet then Variable SQC sampling will have been enabled if you have added one or more Variable characteristics to the Specification or Control tabs Specification and control limits for the Variable SQC characteristics are stored in the Sample Sheet Advanced Tip 8 Attribute SQC sampling uses the system wide scrap reasons as defect reasons for Attribute SQC purposes If ajob s Process Sheet has a Sample Sheet then Attribute SQC sampling is enabled The ten 10 scrap defect reasons that are configured in the Simple Scrap Map are used to enable Attribute SQC data entry at an MIU The System Manager creates the Simple Scrap Map and the Advanced Scrap Map and assigns these maps to an MIU via the Machine Configuration program Reference the System Administration Manual 4810 0014 for additional information There is no place in the ProHelp EPM software to enter specification or control limits for Attribut
82. alue must be set between and 9 for data entry for Variable SQC data and Attribute SQC data to be performed at an MIU If this field is greater than 9 it is treated as if it were 9 for Manual SPC sampling Copyright 1983 2004 Mattec Corporation 5 70 810 0001 Rev C Field Description Parts Per Cycle This field is used to define the number of parts that will be inspected for Variable SQC or Attribute SQC for each machine cycle that is associated with a sample Valid values are 1 to 320 However this value must be set to 1 for data entry for Variable SQC data and Attribute SQC data to be performed at an MIU The Parts Per Cycle field is ignored for Manual SPC samples Sample Size The Sample Sheet calculates this field It is the Number of Cycles times the Parts Per Cycle This field represents the number of parts inspected that is required for many Attribute SQC calculations Comment 1 Descriptive fields used for adding notes about the Sample Comment 2 Sheet Web Setup Document The web address URL of a setup sheet that is associated with this Sample Sheet This web based setup sheet can be viewed using the Document Control Center or by pressing the View Document button Specification The fields on this tab represent the Variable SQC Characteristics that are available for data entry Specification limits lower nominal and upper are specified on this page Control Con
83. ameter Parm 6 0 000 0 000 0 000 0 000 0 000 Parm 7 0 000 0 000 0 000 0 000 0 000 Parm 8 0 000 0 000 0 000 0 000 0 000 Parm 9 0 000 0 000 0 000 0 000 Parm 10 0 000 0 000 0 000 0 000 Parm 11 0 000 0 000 0 000 0 000 Save Cancel Calculate Control Limits Results Display Y ou can modify any of the calculated control limits directly in the spreadsheet that is displayed To save the new limits press the Save button Any parameter with a red checkmark next to the parameter name will be saved To close the program and exit without saving press the Cancel button Advanced Tip 1 If you save the calculated control limits the new limits will replace the user specified control limits in the Process Sheet Automatic SPC Manual SPC or Sample Sheet Variable SQC as appropriate Advanced Tip 2 If you save the calculated control limits for a job that is currently running the MIU will be updated with the new limits automatically and in real time Copyright O 1983 2004 7 169 810 0001 Rev C Mattec Corporation The following table briefly describes the calculation methods that are available Calculation Method Description Table Of Constants Control limits are calculated using X BarBar and R Bar values and the standard SPC Table of Constants Sigma Individuals Control limits are calculated using the actual standard deviation Sigma Individuals and the user specified Sigma Multiplier The user speci
84. and Capability Analysis Copyright O 1983 2004 7 161 Mattec Corporation 810 0001 Rev C Advanced Tip 1 If the number of observations per sample for the job equals one 1 the Histogram Chart automatically adjusts its calculations as appropriate The Histogram Chart will use Moving Range Calculations to calculate a value for R Bar which is used to calculate Sigma Estimated In this case the Observations Per Range field from the Options dialog is used to determine the number of observations per sample Advanced Tip 2 The Histogram Chart is available when performing analysis for multiple jobs 1 e SPC By Part or SPC By Tool Data for the jobs are combined together to perform this analysis The specification limits and control limits are determined by selecting the lowest upper limit and the highest upper limit for each process parameter That is the tightest specification and control limits as determined by combining all of the jobs together are used A number of options are available to control the behavior of the chart To modify the behavior of the Histogram Chart follow these steps e Press the Options button The Options dialog will be displayed e Press the Histogram Chart tab ProStat Options x Production X Bar Chart R MAx Chart s Chart Median Chart Histogram Attribute Number of Cells 5 M Calculate number of cells Sigma Multiplier 3 Reference Lines Spe
85. aphical representation of the average number of non conformities defects in an Attribute SQC sample See Upper Control Limit The upper bound of the statistical limits that are applied to measure the significance of the variation of a process parameter or part characteristic Control limits can be calculated from process data The upper bound of the engineering limit that defines the range of acceptable values for a monitored process parameter or part characteristic to produce a good part See Upper Specification Limit The use of statistical techniques to analyze the variable characteristics e g height weight of a manufactured part A measure of the spread or dispersion of an SPC SQC sample distribution An optional feature that allows reports to be run through a supported web browser An optional feature that allows documents on a web server or other computer to be linked to Process Sheets Part ID Tool IDs and other standards in the ProHelp EPM system These documents may be viewed via the Document Control Center 9 201 810 0001 Rev C X Bar X Bar Chart X BarBar X LCL X LSL X UCL X USL Yield Efficiency Copyright O 1983 2004 Mattec Corporation The average of the observations in a sample X Bar Observation Observation 2 Observation N N A graphical representation of the average of the observations in an SPC or SQC sample The average of the averages the average of the
86. automatically recorded by the system Copyright O 1983 2004 3 26 810 0001 Rev C Mattec Corporation 3 7 Document Control Center The Document Control Center allows you to easily browse the web based setup sheets that have been configured for ajob You can easily switch between running jobs or scheduled jobs To view the Document Control Center for a running job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired job and select Document Control Center The Document Control Center will be displayed EF Document Control Center x Job Data Machine Number JinJ 01 1 000 Ton Injection y Job Number J01 v Part Number SBC 227300 Bottle Cap Bottle Cap Style Tool Number SBC 3 Bottle Cap Style A Customer Mattec Job Status Status Running Jobs y m Setup Sheets Process Sheet Part ID Tool ID Machine http machine 82 net View QC Sample http intranet qape1 htm View Close i Document Control Center Advanced Tip 1 Web based Setup Sheets is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Copyright 1983 2004 3 27 810 0001 Rev C Mattec Corporation 3 8 Enter Scrap And Packed Parts Authorized users can use the Real Time Display to enter scrap parts or cases and packed par
87. automatically selected instead of the X Bar Range Charts Advanced Tip 2 You can force the Chart of Individuals and Moving Range Chart to be displayed by selecting the Moving Range option on the R MRx Chart tab on the Options dialog Copyright 1983 2004 7 151 810 0001 Rev C Mattec Corporation ProStat SPC SQC a ES YES _i S 6 hi Ml m Overview Production Process Alarm X MAx Chart x8a1 s Chart Median Chart Histogram Chart of Individuals and Moving Range for Cycle Time Automatic Machine INJ 01 Job CAP LotA19 Part SBC 227277 Bottle Cap Tool SBC 1115 7 00 USC 550 ee ee a a kk ss 6 00 5 00 AAA OP ARAS ARAS AAA R AS 4 00 3 004 OK Refresh F Chart of Individuals and Moving Range Chart Advanced Tip 3 Notice that the first several points on the Moving Range chart do not exist The first point that is graphed on the Moving Range chart is the n point where n equals Observations Per Range from the Options dialog The Chart of Individuals behaves in a manner similar to the X Bar Chart The Moving Range Chart behaves in a manner similar to the Range Chart Reference Section 7 9 for additional information Advanced Tip 4 The X Bar Range Charts are available when performing analysis for multiple jobs i e SPC By Part or SPC By Tool Data for the jobs are arranged in chronological order by job starting with t
88. bed in this section To set personal preference settings for the Job Schedule follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Click on the Tools menu and select Properties The Properties dialog will be displayed Properties f 70 f 1s d Properties Dialog e Modify the settings as desired and press ox to save your changes Advanced Tip 1 Advanced settings that all users should have set the same way are described in Section 6 9 Copyright 1983 2004 6 119 810 0001 Rev C Mattec Corporation Advanced Tip 2 If you have modified any Job Schedule properties you can restore the properties for a single tab by right clicking on the tab and selecting Restore Defaults This will only restore the values for the currently selected tab Advanced Tip 3 You can restore the default settings for all Job Schedule properties by clicking on the Tools menu and selecting Restore Defaults This should be done with care because this will also restore the Advanced Settings that have been modified The following table describes many of the personal preference settings that are available for modification Properties Tab Description Jobs Fields on this tab modify the text that is displayed in a job bar and the formatting fo
89. calculations A Sample Sheet is used to enable Manual SPC Variable SQC and Attribute SQC for ajob A Sample Sheet is specified in a Process Sheet A descriptive reason that is entered by the machine operator to specify the scrap reason for a part A subset of the system wide Scrap Codes that are available for use for a particular machine The System Manager specifies a Scrap Map in the machine configuration program Parts that are associated with a job that are not good and that can not be reworked into good parts A value that minimizes the impact of the actual scrap percent when calculating a job s forecasted end date The main ProHelp EPM computer that contains the configuration files data files and ProHelp EPM software All MIUs are wired into this computer An estimate of the amount of time that is required to setup a tool before the job will be ready to produce parts This value is specified in the Tool ID The Job Schedule uses this value to adjust forecasted start end times for non running jobs A shift defines the normal day to day working schedule for one or more machines Most data in ProHelp EPM is collected for a machine or job in units that correspond to shifts A Shift indicates that the last n consecutive SPC or SQC samples where n equals the Number of Samples Per Run from System Configuration were above the upper control limit or below the lower control limit The transition
90. can be done to eliminate these errors in the future Advanced Tip 6 When you edit downtime data changes are applied equally to the related job tables dbo JobProd and dbo JobDown and the related shift tables dbo ShiftProd and dbo ShiftDown This helps to maintain data consistency Copyright 1983 2004 5 90 810 0001 Rev C Mattec Corporation Advanced Tip 7 When you edit downtime data you are only given an opportunity to edit the standard downtime related fields including downtime and down count A best guess algorithm is used to make appropriate changes to the weighted downtime related fields including weighted downtime and weighted down count These weighted fields are used to calculate the totals line in reports Copyright 1983 2004 5 91 810 0001 Rev C Mattec Corporation 5 12 Production History Edit The Production History Edit program in Edit Facilities allows you edit production related data that was collected by the MIU Editing production history is a non standard operation and should be avoided unless absolutely necessary To directly edit production history for a specific job follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Production History Edit The Production History Edit Edit Facility will be displayed AT Facilities for Rel
91. cheduled jobs Copyright 1983 2004 5 68 810 0001 Rev C Mattec Corporation 5 4 Sample Sheet A Sample Sheet is used to enable Manual SPC Variable SQC and Attribute SQC data entry for ajob The Sample Sheet Edit Facility is used to maintain and identify all available Sample Sheets To launch the Sample Sheet Edit Facility follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Prostate spc soc menu and select Sample Sheet The Sample Sheet Edit Facility will be displayed FZ Edit Facilities for Release 6 1 0 Sample Sheets a File View Edit Application Window Help lej x 16B Sala 2 8 Sample Sheets Edit record Current 2 Cunsrk Sample Shezi Last Updated 12 23 03 11 38 35 AM AlllGanple Sheets Sample Sheet ID Plug seal PAE Edit Description rounded flange ney Basic Specification Control Delete Period E0 Cycles Setup Sheet Minutes Number of Cycles 5 Parts per Cycle 1 Sample Size 5 Parts Comment 1 tight tolerance dim Comment 2 hold true to dim B Web Setup Document View Save Cancel Print Add Variable Delete Var Sample Sheets Sample Sheet Edit Facility e To edit an existing Sample Sheet locate the desired Sample Sheet using the selection facilities on the left hand side of the display
92. cification Limits y Moving Range if sample size equals one moving range is selected by default Observations Per Range 2 FT Display reference line for mean Tl Display horizontal grid lines I Display curve showing normal distribution Gaussian F Display vertical grid lines Tl Display number of observations in each cell T 3 Dimensional Cancel Histogram Chart Options Copyright 1983 2004 7 162 810 0001 Rev C Mattec Corporation The following table describes the options that affect the Histogram Chart Option Options Tab Description Number of Cells Calculate Number of Cells Histogram This value controls the number of cells e classes for the chart This value may range from 1 to 30 Check the Calculate number of cells field to instruct the software to automatically calculate the number of cells Sigma Multiplier Histogram This value is used to draw reference lines on the Histogram chart The user specified Sigma Multiplier is a value so a Sigma Multiplier of 3 equals 6 Sigma Reference Lines Histogram This value controls the reference lines that are displayed on the chart Moving Range Histogram This value forces ProStat to use special Moving Range calculations for the Histogram Chart even if the number of observation per sample is greater than one 1 Observations Per Range Histogram This value specifies the number
93. created and scheduled via the Data Import Export program Reference the Data Exchange Manual 4810 0002 for additional information Advanced Tip 1 Family Molding is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department The following table describes the fields that are available on the Family tab of the Job Descriptor dialog These fields apply to the father job descriptor Field Description Job Number An identifier that identifies the father job Machine Number The Machine Number that the family job is expected to run on The family job can be dragged to another machine via the Job Schedule provided that a Process Sheet exists for the Part Number and Tool Number on that new machine for all son jobs Tool Number The Tool Number for the father job This field is optional This field allows for accurate preventive maintenance forecasting for the father job s base mold Active Components The number of son jobs that will be run simultaneously when the family job is started ProHelp EPM calculates additional fields on the Family tab of the Job Descriptor dialog For example the system will accurately forecast when the entire family job will start and when the last son job will end When the family job is created the job is added to the machine schedule as configured in the Insert Jobs By setting on the Properties dialog Reference Section 6
94. dary 0 Lower boundary 0 Approximate number of points visible on chart 50 J Calculate and display control limits from sample data FT Display median for each sample F Display individual observations for each sample FT Display value of each observation Tl Display point markers Tl Display horizontal grid lines Tl Display vertical grid lines J 3 Dimensional Median Chart Options The following table describes the options that affect the Median Chart Copyright 1983 2004 Mattec Corporation Option Options Tab Description Upper Boundary Median Chart This value controls the maximum value that is displayed on the Y Axis If both Upper Boundary and Lower Boundary are 0 the chart will automatically chose appropriate values for scaling Lower Boundary Median Chart This value controls the minimum value that is displayed on the Y Axis Number of points visible on chart Median Chart This value controls the approximate number of points that will be displayed on the chart Additional points can be viewed by scrolling the chart to the left or the right Calculate and display control limits Median Chart This value causes ProStat to dynamically from sample data calculate median control limits and display them on the chart Display median for each sample Median Chart When selected this value will cause the chart to display the median value for each sample above the sam
95. de manually in unusual circumstances Audit Trails Changes to existing Manual SPC Variable SQC or Attribute SQC samples will automatically receive an Audit Trail provided that you have purchased the Audit Trail option from Mattec This Audit Trail can be viewed by pressing the Audit Trail button in the ProStat Sample Data Edit program This data is also available in System Reports Reference Section 4 6 for additional information Audit Trails is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Copyright 1983 2004 7 132 810 0001 Rev C Mattec Corporation 7 3 Selecting Data For Analysis You must select the data to be analyzed before you can access any of the functions of ProStat Typically data is selected for one specific job Advanced Tip 1 ProStat can be used to analyze data for multiple jobs by selecting a Part and or Tool Reference Section 7 3 1 for additional information To select data for a specific job for use by ProStat follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed e Press the Select Data icon The Select Data dialog will be displayed Select Data Automatic SPC Cycle Time Machine Cycle Time Select Data Dialog e Select the desired Job Number in the Job Number picklist If you need assistance locating a specific job press the Find button Copyright O 19
96. des a brief overview of the four SPC SQC data types Data Type Description Automatic SPC Automatic SPC data is automatically collected by the MIU at random intervals This data is limited to the machine process parameters e g Cycle Time Injection Pressure that are being monitored by the MIU Manual SPC Manual SPC data is collected by the MIU whenever instructed by the user This data is limited to the machine process parameters e g Cycle Time Injection Pressure that are being monitored by the MIU The parts that are associated with a Manual SPC sample are usually gathered by the machine operator or quality control personnel to be used for Variable SQC and or Attribute SQC data entry Manual SPC data is closely related to Variable SQC data For example the user can perform Linear Regression Analysis between a Manual SPC process parameter and a Variable SQC characteristic Reference Section 7 13 for additional information Variable SQC Variable SQC data is entered by the user either at an MIU a PC or both This data is limited to user specified part characteristics e g Height Weight Variable SQC data is closely related to Manual SPC data For example the user can perform Linear Regression Analysis between a Variable SQC characteristic and a Manual SPC process parameter Reference Section 7 13 for additional information Copyright O 1983 2004 Mattec Corporation 7 128 810 000
97. e Click on the shift menu and select the desired report The report data selection interface will be displayed 9 s s s 2 2 2 LIVE LIVE Demo M Stamping Injection Injection M Blow Moldi Typical Shift Report Interface e Fill in the report data selection interface as appropriate Press ox The selected report will be displayed Copyright 1983 2004 4 39 810 0001 Rev C Mattec Corporation Advanced Tip 1 Options in the Select Shift dialog will be enabled or disabled depending on the machines that have been selected For example you can only specify Current Shift 1f all machines that have been selected share the same shift configuration 8 System Reports Release 6 1 0 Daily Production Report File Shift Job Planning Application Help HSS 23814890 KI 4 157 gt alel pox z TB Totatt657 100 1657 of 1857 a Daily Production Report Mattec Corporation Loveland Ohio 45140 Selected Range from Shift 3 1 28 03 11 00 00 PM to Shift 2 3 4 04 4 56 33 PM present All Machines Run Down Percent Good Packed Scrap Percent Cycle Yield Mach Date SH Job Number Part Number Time Time Down Parts Parts Parts Scrap Eff Eff Department Injection Injection Moling 01 5103 1 354211 SBC 221277 Bottle Cap 1 53 0 17 13 4 3 132 0 0 0 0 44 53 01 512103 1 354211 SBC 221277 Bottle Cap 2 46 0 02 11 2 984 0 D 0 0 38 36 01 5 28 03 1 354211 SBC 221277 Bottle Cap 721 0 39 3 2 10 649 D 23 0 2 3
98. e Machine Numbers and Tool IDs that have a Process Sheet defined for that Part ID The job can be dragged to another machine via the Job Schedule provided that a Process Sheet exists for the Part Number and Tool Number on that new machine Customer The customer name Comment 1 Descriptive fields used for adding notes about the job Comment 2 Lot Size The quantity of good parts to be produced for the job Desired Start The date time that you desire the job to be started or Desired End ended You can only enter one of these dates Reference Section 6 9 for additional information ProHelp EPM calculates additional fields on the Job Descriptor dialog For example the system will accurately forecast when a scheduled job will end Other fields on the Job Descriptor dialog are read from Edit Facilities For example the Material ID and Color ID are read from the appropriate Part ID in Edit Facilities When the bachelor job is created the job is added to the machine schedule as configured in the Insert Jobs By setting on the Properties dialog Reference Section 6 9 for additional information Advanced Tip 1 You can double click on a scheduled job in the Job Schedule to see the Job Descriptor dialog for that job This allows you to modify data for running or scheduled jobs Copyright 1983 2004 Mattec Corporation 6 102 810 0001 Rev C 6 3 Creating And Scheduling Family Jobs A job descriptor
99. e SQC defects However the ProStat software is capable of dynamically calculating control limits for Attribute SQC data and displaying these control limits on the appropriate charts Reference Section 7 19 1 for additional information Copyright 1983 2004 5 72 810 0001 Rev C Mattec Corporation Advanced Tip 9 It is possible to create a configuration for Variable SQC data entry or Attribute SQC data entry that would prohibit the data entry from being performed at an MIU In this case all data entry must be performed at a computer terminal For example Parts Per Cycle must be equal to 1 in order to perform Variable SQC data entry and Attribute SQC data entry at an MIU If Parts Per Cycle is greater than 1 this data entry must be performed at a computer terminal Advanced Tip 10 ProHelp EPM allows the user to specify different subgroup sizes for Automatic SPC sampling and Manual SPC Variable SQC Attribute SQC sampling Most MIUs however do not support this functionality As such it is a good idea to use the same subgroup size throughout the system To modify the standard Sample Sheet Sheet press the Setup Sheet button Modify the Setup Sheet as appropriate Press OK to temporarily save your changes You will be returned to the Sample Sheet Edit Facility Press Save to save your changes Advanced Tip 11 Many MIUs are capable of viewing all or part of the standard Sample Sheet Setup Sheet For example the TSMI
100. e Scrap Pareto Chart is available in the ProStat program This allows you to view the chart for jobs that have been ended The Scrap Pareto Chart updates automatically and in real time The refresh rate is specified on the Options dialog If the refresh rate is 0 the display will not refresh automatically and will only be refreshed when the user presses the Refresh button It is safe to press the Refresh button even when automatic refreshes are enabled Scrap Reasons are always displayed in order of scrap parts that have been entered with the Scrap Reasons with the most quantity displayed on the left hand side of the display You can scroll to the left or right to see additional data on the chart You can display the chart in 2 Dimensions or 3 Dimensions These settings are specified on the Options dialog Advanced Tip 1 Scrap can be entered by authorized users at the MIU on the Real Time Display or via Edit Facilities Advanced Tip 2 The scrap reasons that are displayed in the Scrap Pareto Chart include all scrap reasons that are configured in the Scrap Map for this machine including reasons from the Advanced Scrap Map and the Simple Scrap Map The Scrap Map is specified in the Machine Configuration program Advanced Tip 3 If you have entered scrap for a scrap reason that is not defined in the Scrap Map that scrap reason will be displayed in the Scrap Pareto Chart Copyright 1983 2004 3 22 810 0001 Rev C Mattec Corpora
101. e expected percent down for the machine The Job Schedule uses the standard value for non running jobs when calculating forecasted end dates The historical value is for display purposed only Percent Scrap This field allows you to specify the expected percent scrap for the part The Job Schedule uses the standard value for non running jobs when calculating forecasted end dates The historical value is for display purposed only Cycle Time This field allows you to specify the expected cycle time for the machine The Job Schedule uses the standard value for non running jobs when calculating forecasted end dates The historical value is for display purposed only Non Production Limit The non production limit is used by the MIU to determine that the machine is down and is not cycling After a machine cycle the MIU expects to another machine cycle to occur within a certain period of time If the next machine cycle does not occur before the non production limit is reached the machine is determined to be down Cavity PSI Transfer This field allows you to specify a value for use with the Cavity Pressure Transfer feature in the MIU When the monitored cavity pressure reaches this value the MIU will ignite a digital contact This digital contact can be connected to the machine to cause the machine to transfer from injection pressure to hold pressure The System Manager defines the analog
102. e scheduled Copyright 1983 2004 6 112 810 0001 Rev C Mattec Corporation for one specific machine or for all machines You can limit the amount of data that is displayed by selecting a specific machine number in the Machine Number picklist To remove a job from the schedule and place it in the Unscheduled Jobs list simply highlight the job s and press the Unschedule button You can highlight multiple jobs by holding down the CTRL key while you use the mouse to click on each job To permanently delete a job and remove it entirely from the database simply highlight the job s and press the Delete button You can highlight multiple jobs by holding down the CTRL key while you use the mouse to click on each job You should delete jobs with caution this action can not be undone after the schedule has been saved Son jobs appear in the Schedule Jobs list but father jobs do not If you highlight a son job in the Scheduled Jobs list all related son jobs will be highlighted automatically To locate a specific job in the Scheduled Jobs list press the Find button You will be permitted to search only on those fields that are displayed in the Scheduled Jobs list To print the Scheduled Jobs list press the Print button Advanced Tip 1 It can be hard to double click on a job in the graphical Job Schedule if that job has a very small lot size The Scheduled Jobs list can be used to accomplish this Copyright O 1983 2004 6 113 810 0001 Re
103. e specified in the Process Sheet e Control Limits X UCL and X LCL that are specified in the Process Sheet Each cycle of the machine will be monitored against both types of limits for 100 part qualification Part qualification is an automatic way to monitor bad parts based on specification and control limits The user should be cautious in specifying these limits Use only those parameters that you know from experience and careful studies always produce a bad part when their limits are exceeded Indiscriminate use of this feature could produce a large quantity of quarantined parts that are acceptable or could allow bad parts to go undetected Advanced Tip 1 ProHelp Millennium allows the user to automatically scrap parts that do not pass part qualification criteria This functionality does not exist in ProHelp EPM Advanced Tip 2 ProHelp Millennium allows the user to individually enable disable process parameters for part qualification for specific jobs This functionality does not exist in ProHelp EPM Advanced Tip 3 ProHelp Millennium allows the user to individually enable disable upper limit checking and lower limit checking for each process parameter for each machine This functionality does not exist in ProHelp EPM Copyright 1983 2004 7 177 810 0001 Rev C Mattec Corporation 7 19 Attribute SQC Attribute SQC data analysis is performed to analyze non conformities defects of parts Data entry can be perfo
104. eal if you would like to view all data for a job without regard to time ranges To generate a Job Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon e Click on the Job menu and select the desired report The report data selection interface will be displayed 9 5 Loeb ana UTE Gis ES Gute Seneaulea Jas RLS 5 al a Taschen slasher 1G gt Y njection Injection Blow Moldi at Typical Job Report Interface e Fill in the report data selection interface as appropriate Press ox The selected report will be displayed Copyright O 1983 2004 4 42 810 0001 Rev C Mattec Corporation x System Reports Release 6 1 0 Job Engineering Report File Shift Job Planning Application Help Ha 3AE e KI 4 1 of 33 gt gt i n alel 100 1 Total 78 100 76 of 76 Job Engineering Report Mattec Corporation Loveland Ohio 45140 Cunent Jobs All Machines Mach 01 1 000 Ton Injection Start Time 6 4103 Job Number CAP Lot Al9 End Time Cuner Part Number SBC 221277 Bottle Cap Bottle Cap Tool Number SBC 1115 Shampoo Bottle Cap E ering A is Parameter Standard Cycles Miniraura Maximum Name Units CPK Deviation CP K 00S oos Value Value Cycle Tm 107 0655 127 016 2 307 25 030 90 00 Hold Time 9 92 0007 000 NA 0 00 0 00 0 50 Fill Tra 10 45 0010 000 NA 0 00 0 00 0 60 Inj Time 0 16 042
105. ease 6 1 0 Production Edit La File View Edit Application Window Help pa laj xj EEES Machine Number 01 1 000 Ton Injection tots Job Number CAP Lot 419 Job Number Part Number 580 2212 Tool Number Customer Valeo Job Status Date Total Parts pozz Machine Cycles 242000 ase Dany p Total Time pao Down Time j2 Pun Tine 202 da po Labor Time jo Save Cancel Print _ Production Edit Ready Z Production History Edit Edit Facility e To directly an existing production history entry locate the desired job and shift using the selection facilities on the left hand side of the display Press the Edit button Make your changes as appropriate and press Save Copyright 1983 2004 5 92 810 0001 Rev C Mattec Corporation Advanced Tip 1 If you need to edit production history data you should investigate why What caused the incorrect recording of data in the first place What can be done to eliminate these errors in the future Advanced Tip 2 If you need to modify downtime and or down count it is better to make these changes using the Downtime Edit Edit Facility Reference Section 5 11 for additional information Advanced Tip 3 When you edit production history data changes are applied equally to the related job tables dbo JobProd and the related shift tables dbo ShiftProd This helps to maintain dat
106. ed Tip 2 MIU Security and ProStat SPC SQC are optional features You may purchase either of these features at any time by contacting the Mattec Sales Department Copyright 1983 2004 4 54 810 0001 Rev C Mattec Corporation 4 7 Log Reports Log Reports can help with troubleshooting production and process problems and can even be useful to users who are trying to achieve FDA CFR 21 Part 11 Compliance with their ProHelp EPM software To generate a Log Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon e Click on the Planning menu click on the Logs menu and select the desired report Fill in the report data selection interface as appropriate Press ok The selected report will be displayed Biles fie System Reports ITCHY Scrap Log Report File Shift Job Planning Application Help 1of1 rd el foo JAM Toaz 100 Scrap Log Report Mattec Corporation Loveland Ohio All Machines Scrap Date Parts Code Description Operator ID 11 11 03 11 24 36 AM 5 BUBB Bubbles brian 11 11 03 11 38 41 AM 2 BUBB Bubbles brian 11 11 03 2 23 27 PM 4 BUBB Bubbles brian 11 11 03 2 27 39 PM 1 ASTAT Anti Stat Test brian 11 11 03 2 27 50 PM 100 ASTAT Anti Stat Test brian 11 11 03 3 32 08 PM 10 BUBB Bubbles brian 11 11 03 3 32 18 PM 1 BUBB Bubbles brian Scrap Log Report Advanced Tip 1 Most logs in ProHelp EPM are always enabled and in fact can no
107. ed and manufactured by MATTEC that converts the RS 485 signal from a channel of MIUs to an RS 232 signal and conditions the signal A graphical representation of the total number of non conformities defects in an Attribute SQC sample Calculated Production is an obsolete term See Good Parts or Total Parts See Active Cavities or Total Cavities 9 187 810 0001 Rev C Cavity PSI Transfer Cell Width Channel Chi Squared Coefficient Variable Color ID Component Job Control Limit Copyright O 1983 2004 Mattec Corporation This field is specified in a Process Sheet and allows you to specify a value for use with the Cavity Pressure Transfer feature in the MIU When the monitored cavity pressure reaches this value the MIU will ignite a digital contact This digital contact can be connected to the machine to cause the machine to transfer from injection pressure to hold pressure Cavity Pressure Transfer is an optional feature Cell width is associated with Histogram charts The widths of the bars on the chart represent class intervals whose areas are proportional to the corresponding frequencies A collection of up to 16 MIUs that are daisy chained together and are physically wired into the server computer for communication purposes Each channel corresponds to one physical COMM port on the server computer often on a RocketPort board and one port on the buffer box A measure of the variance in a give
108. eep ProHelp EPM synchronized with the monitored machines ProHelp EPM must be directed to start collecting data for a job and to end collecting data when the job is done It is very important that the commands to start and end be given at the same time job changes are taking place on the actual machine Users can perform these commands directly at the Machine Interface Units MIUs or at a computer that is connected to the system A job can have one of four 4 basic states including PENDING A pending job is a new job that has never been run before This job may have been created via the Job Scheduler or it may have been imported into the system via the Data Import Export application RUNNING A running job is the job that is currently running on a machine and automatically collecting data via the MIU If the current job is a bachelor job there can be only one running job on the machine If the current job is a family job there can be up to 100 son jobs that are running simultaneously on the machine and up to 1000 son jobs that are waiting to be run on the machine SUSPENDED A suspended job is a job that has previously been run and was temporarily suspended to allow a different job to run Suspended jobs are expected to be re run completion A completed job will not be re run Advanced Tip 1 Unlike earlier ProHelp systems suspended jobs can only be re run on the same machine that t
109. ends the next son job will start Advanced Tip 4 If any son job in a family job is colored red the father job s bar is colored red Copyright 1983 2004 6 110 810 0001 Rev C Mattec Corporation 6 6 Schedule Reports Several reports are available from within the Job Schedule including Schedule Summary Report List of Unscheduled Jobs Report Performance Against Schedule Report Tool Conflict Report These reports are accessed from inside the Job Schedule There is no need to exit the application to view and print these reports To view a schedule related report follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Click on the Reports menu and select the desired report The report will be displayed y Job Schedule File View Reports Tools Application Help HSA Ii Machine JOB 78N4 J04 Schedule Summary Report Hours ToGo Status 342 730 9520 RUN Schedule Summary Report e To print the report click on the File menu and select Print e To close the report and return to the Job Schedule click on the File menu and select Close Copyright 1983 2004 6 111 810 0001 Rev C Mattec Corporation 6 7 Scheduled Jobs List The Scheduled Jobs list is a convenient way to view all of the jobs that are scheduled for one specific machine or for all mac
110. erally considered capable Cpk equals the lesser of the following two equations USL Mean 3 Standard Deviation Mean LSL 3 Standard Deviation Cr is a measure of process capability or the repeatability of a process and is the inverse of Cp Cr 1 Cp The customer for a job The ratio of the expected cycle time to the average cycle time as accumulated by the MIU CE Standard Cycle Time Average Cycle Time A value that minimizes the impact of fast or slow average cycle times when calculating a job s forecasted end date The number of machine cycles that are out of specification as accumulated by the MIU 9 189 810 0001 Rev C Data Import Export Defect Desired End Desired Start Distribution Document Control Center Down Code Down Map Down Occurrences Downtime DTR Data Export Expected Cycle Time Copyright O 1983 2004 Mattec Corporation An optional feature that is designed to facilitate the sharing of data between ProHelp EPM and external ERP applications Reference the Data Exchange Manual 4810 0002 for additional information A part attribute that is associated with Attribute SQC The user specified desired end date for a job The user specified desired start date for a job A method of describing the output of a collection of statistical data An application that allows the user to view web based setup sheets for Process Sheets Part IDs Tool IDs and o
111. es The Down Map is specified in the Machine Configuration program Copyright 1983 2004 3 31 810 0001 Rev C Mattec Corporation 3 10 Change Active Cavities Authorized users can use the Real Time Display to change the active number of cavities for a tool Alternate Methods Users can change the number of active cavities at the MIU Users can change the number of active cavities via the Tool ID Edit Facility Reference Section 5 3 for additional information To change the active number of cavities for a running tool job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired machine and select Change Active Cavities The Change Active Cavities dialog will be displayed Change Active Cavities Ea Job Data Machine Number INJ 01 Job Number ot 2 Cavities Standard Cavities lt Active Cavities ww ees Change Active Cavities Dialog e Enter the new number of cavities in the Active Cavities field and press Apply The change will take effect immediately Copyright 1983 2004 3 32 810 0001 Rev C Mattec Corporation 3 11 Cancel Acknowledge Help Calls Authorized users can use the Real Time Display to cancel acknowledge a help call Alternate Methods Users can cancel help calls at the MIU To cancel acknowledge a help call for an MIU follow these steps e Start the
112. es in the Tool This number should be modified any time a cavity is plugged Runner Weight The amount of excess material that is consumed during a machine cycle and that does not go into the resulting part Setup Time An estimate of the amount of time that is required to setup this tool before the job will be ready to produce parts The Job Schedule uses this value to adjust forecasted start end times for non running jobs Comment 1 Descriptive fields used for adding notes about the tool Comment 2 Web Setup Document The web address URL of a setup sheet that is associated with this Tool ID This web based setup sheet can be viewed using the Document Control Center or by pressing the View Document button Tool Machine Compatibility Values These fields allow you to specify requirements to determine the compatibility between tools and machines These requirements are not enforced by the ProHelp EPM software Similar compatibility requirements can be specified in the Machine Configuration program Reference the System Administration Manual 810 0014 for additional information Advanced Tip 2 Web based Setup Sheets is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 3 The Active Cavities in the Tool ID affects the number of parts that are produced with each machine cycle and cannot exceed the Total Cavities in the Tool T
113. etermine how frequently the Real Time Display should page down to see more machines Multiple Display Refresh The Real Time Display allows several displays to be open at one time For example when you double click on a machine number the Machine Status display is opened When Multiple Display Refresh is enabled all of the open displays will update automatically This will consume additional system resources and is not recommended When Multiple Display Refresh is disabled only the top screen that is displayed will be refreshed automatically provided that automatic refresh is enabled for that display Department This field allows you to filter the Real Time Display to view all machines that are assigned to a specific department Set this field to All Departments to disable department filtering Down Reason This field allows you to filter the Real Time Display to view any machines that are down for any downtime reason or any machines that are down for one specific downtime reason Set this field to All Machines to disable down reason Copyright 1983 2004 Mattec Corporation 3 16 810 0001 Rev C Field Description filtering Help Call Reason This field allows you to filter the Real Time Display to view any machines that are calling for help for any help call reason or any machines that are calling for help for one specific help call reason Set th
114. fied Sigma Multiplier is a value so a Sigma Multiplier of 3 equals 6 Sigma Sigma Estimated Control limits are calculated using an estimate of the standard deviation Sigma Estimated and the user specified Sigma Multiplier The user specified Sigma Multiplier is a value so a Sigma Multiplier of 3 equals 6 Sigma Advanced Tip 3 Several charts allow the user to overlay calculated control limits on the chart These control limits are calculated on the fly for display purposes only and can not be saved to the Process Sheet or Sample Sheet If you wish to calculate control limits and save those limits to the Process Sheet or Sample Sheet you must use the Calculate Control Limits function that is described in this section Advanced Tip 4 The Standard Deviation Chart and Median Chart allow the user to overlay calculated control limits on the chart There is no corresponding location for the user to specify standard deviation or median control limits Thus it is not possible to calculate standard deviation or median control limits and to save those control limits Advanced Tip 5 The Attribute SQC charts p Chart np Chart c Chart and u Chart allow the user to overlay calculated control limits on the charts There is no corresponding location for the user to specify Attribute SQC control limits Thus for Attribute SQC data it is not possible to calculate control limits and
115. ght 1983 2004 3 19 810 0001 Rev C Mattec Corporation Alternate Methods You can start the Last 500 Chart for a process parameter by double clicking on a machine number or job number to display the Machine Status display Press the Process Alarm tab and the value for the last machine cycle for all monitored process parameters will be displayed Double click on any process parameter to display the Last 500 Chart You can start the Last 500 Chart by double clicking on any process parameter e g Actual Speed is available on the Standard Real Time Display on the display Specification limits and control limits 1f specified in the Process Sheet are displayed on the chart and make it easy to determine if the machine is running within limits The Last 500 Chart updates automatically and in real time The refresh rate is specified on the Options dialog If the refresh rate is 0 the display will not refresh automatically and will only be refreshed when the user presses the Refresh button It is safe to press the Refresh button even when automatic refreshes are enabled You can press the Zoom button to magnify the points on the chart and press the Zoom button a second time to return to the original display When the charted is zoomed you can scroll to the left or the right to see additional data on the chart The number of points that are displayed when the chart is zoomed is specified on the Options dialog You can control whet
116. h Family Molding each delivery can be considered its own son job As such each son job will have its own lot size and desired end date The jobs will be scheduled as one unit that is as a family but each son job will have its own lot size and forecasted end date If desired you can even give each son job the same Job Number and still track the son jobs individually Unrelated Parts made with the Same Base Mold For example you have 10 different insert molds parts that can be plugged into the same base mold in different combinations Each part s mold can have a different number of cavities and you have the need to track Preventive Maintenance for the base mold and or the individual molds that can be inserted into the base mold Copyright O 1983 2004 6 99 810 0001 Rev C Mattec Corporation As an example today you might be making 3 key chains and 5 luggage tags with each machine cycle now but this evening you will be making 3 key chains and 2 plastic toys with each machine cycle With Family Molding this type of application is easily accomplished Each part insert mold will be its own unique son job You can control the number of son jobs that will be running simultaneously up to 100 per machine and the total number of son jobs in the family up to 1 000 per family ProHelp EPM will individually forecast when each son job will start end and you can easily rearrange the order in which son jobs will run using Mattec
117. h job You should delete jobs with caution this action can not be undone after the schedule has been saved The system will prevent you from deleting a job that has been suspended and thus has job data that has been collected Father jobs appear in the Unscheduled Jobs list but son jobs do not If you schedule a father job via the Unscheduled Jobs list all related son jobs that are available will be scheduled too To locate a specific job in the Unscheduled Jobs list press the Find button You will be permitted to search only on those fields that are displayed in the Unscheduled Jobs list To print the Unscheduled Jobs list press the Print button Advanced Tip 3 Only pending or suspended jobs that are not currently scheduled will be displayed in the Unscheduled Jobs list Jobs that have been completed will not be displayed Advanced Tip 4 If you want to re schedule a job that has been completed you must first override the job s status and set the job to suspended The job will then be placed in the Unscheduled Jobs list and can be re scheduled Reference Section 6 11 for additional information Copyright 1983 2004 6 115 810 0001 Rev C Mattec Corporation 6 9 Advanced Settings The Job Schedule is highly configurable There are some settings that all users in your facility should have set the same way Other settings are based on personal preference All advanced settings that most user
118. he Mattec Customer Service Department if you need assistance Copyright 1983 2004 2 9 810 0001 Rev C Mattec Corporation 3 Real Time Display The Real Time Display shows you the status of all machines at a glance including machines that are running out of specification limits machines that are down and operators who have called for help Data on the display is updated automatically and in real time Several displays shipped with your system and the System Manager can easily create custom displays using the Real Time Display Writer To launch the Real Time Display follow these steps e Start the Main Menu and press the Launch Real Time Display icon The Real Time Display will be displayed EL Real Time Display Al E File View Application Help Kes SOAK R ES Machine non rar Hours Standard Actual Yield a ACT ction a_i Molding All Machines Updated 05 21 2003 9 29 Standard Real Time Display More than 200 fields are available for display including the following Job Standards Part Standards Tool Standards Current Process Parameter Values Shift Production History Job Production History Next Job Data Copyright 1983 2004 3 10 810 0001 Rev C Mattec Corporation Double click on a specific machine job to see detailed shift and job production information detailed process parameter information the Material ID Color ID and Material Lot s in use access setup sheets and see detailed informatio
119. he family job using Job Control The following table describes the fields that are available on the Components tab of the Job Descriptor dialog These fields apply to individual son job descriptors Component Tab Field Description Job Number An identifier that identifies the son job Machine Number The Machine Number Part Number and Tool Number Part Number determine the Process Sheet that will be used by the son Tool Number job The Machine Number is initially specified in the father job on the Family tab of the Job Descriptor dialog and is modified any time the family job is dragged to another machine When you make a selection in any of these picklists the remaining picklists will be adjusted as appropriate For example when you specify a Machine Number for the father job the Part Number and Tool Number picklists will automatically adjust to only include Part IDs and Tool IDs that have a Process Sheet defined for that Machine Number The family job can be dragged to another machine via the Job Schedule provided that a Process Sheet exists for the Copyright O 1983 2004 6 105 810 0001 Rev C Mattec Corporation Component Tab Field Description Part Number and Tool Number on that new machine for all son jobs Customer The customer name Comment 1 Descriptive fields used for adding notes about this son job Comment 2 Lot Size The quantity of good parts to be produced for
120. he job that ran first You can double click on any point in either chart to see which job is associated with the sample Copyright O 1983 2004 7 152 810 0001 Rev C Mattec Corporation 7 10 X Bar Chart and Standard Deviation Chart S An X Bar Chart displays the average of the observations in a sample A Standard Deviation Chart S Chart displays the standard deviation of the observations in each sample Compatibility The X Bar Standard Deviation Charts are available for Automatic SPC Manual SPC or Variable SQC Data They are not available for Attribute SQC data To display the X Bar Standard Deviation Charts follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the X Bar S Chart tab The X Bar Standard Deviation Charts will be displayed ProStat SPC SQC Sy x Ae alle al Overview Production Process Alarm X Bar R Chart X Bar s Chart Median Chart Histogram X Bar and Standard Deviation for Cycle Time Automatic Machine INJ 01 Job CAP Lot419 Part SBC 227277 Bottle Cap Tool SBC 1115 Standard Deviation D 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 E Refresh Options X Bar Chart and Standard Deviation Chart Copyright 1983 2004 7 153 810 0001 Rev C Mattec Corporation Advanced Tip 1 If the number of observat
121. hedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Double click on a family job Press the Schedule tab 4 Job Schedule Jal x File View Reports Tools Application Help pr Job Descriptor x DLG a Family Components Schedule DLG b DLG 1 DLG j DLG k INJ 01 Gantt In Gantt Schedule For Family Jobs All son jobs will be displayed in the Gantt In Gantt Job Schedule with their appropriate color coding You can drag and drop the individual son jobs in order to re arrange their order within the family job Copyright O 1983 2004 6 109 810 0001 Rev C Mattec Corporation Alternate Methods The order that son jobs will be run can be adjusted on the Family tab by moving the son jobs up or down Advanced Tip 1 Family Molding is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 The field Active Components on the Family tab controls the number of son jobs that are scheduled to run simultaneously This field typically corresponds to the number of insert molds that can be inserted into the father job s base mold Advanced Tip 3 Regardless of the Schedule Method that is being used Gaps No Gaps or Smart Gaps the son jobs in a family job are scheduled using the No Gaps method This is due to the nature of a family job where it is expected that when one son job
122. her new machine cycles data points are added to the left side of the chart or the right side of the chart You can display the chart in 2 Dimensions or 3 Dimensions These settings are specified on the Options dialog Advanced Tip 1 The calculated values on the bottom of the Last 500 Chart e g Cpk Cp k are calculated from the last 500 machine cycles and are not based on statistical sampling nor the Shift Engineering nor Job Engineering data Copyright O 1983 2004 3 20 810 0001 Rev C Mattec Corporation 3 4 Scrap Pareto Chart The Scrap Pareto Chart displays the scrap that has been entered for the job It quickly identifies the most significant causes of scrap parts and helps you to focus your attention on resolving those problems To generate a Scrap Pareto Chart for a running job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired job and select Scrap Pareto Chart The Scrap Pareto Chart will be displayed Job Scrap Pareto INJ 01 500 Ton Injection JF MAY02 BUMPER FB 8901 Front Bumper Job Scrap Pareto JF MAY02 BUMPER A AAA AAA SS _ AENA Job Scrap Pareto Chart Copyright O 1983 2004 3 21 810 0001 Rev C Mattec Corporation Alternate Methods You can start the Scrap Pareto Chart by double clicking on the Scrap Parts or Percent Scrap fields on the Real Time Display Th
123. hey initially ran on This is necessary to preserve the integrity of the data that has been collected by the system If you need to suspend a job and restart that job on a different machine you should end the original job create a copy of that job with a modified lot size and schedule the copied job to run on a different machine The copied job can have the same Job Number as the original job Copyright O 1983 2004 6 122 810 0001 Rev C Mattec Corporation To perform Job Control for a specific machine follow these steps e Start the Job Control program To do this start the Main Menu and press the Launch Job Control icon e Select the Machine that you wish to modify e Ifa job is currently running you must select the Job in the Job Number picklist This job will either be ended or suspended e If you wish to start running another job you should select the appropriate job in the Next Job Number picklist If you do not wish to start running another job select None Don t Start Another Job in the Next Job Number picklist e To end the job in the Job Number picklist and start the job in the Next Job Number picklist press the End Job button To suspend the job in the Job Number picklist and start the job in the Next Job Number picklist press the Suspend Job button Job Control x Current Job Machine Number fin 01 Injection 01 y Job Number uo y Part Number 12345 12345 Tool Number 112345FGHIJKLMNOPOZ
124. hines To view the Scheduled Jobs list follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Click on the Tools menu and select scheduled Jobs The Scheduled Jobs list will be displayed Scheduled Unscheduled Machine Number All y Job Number Forecasted End Status 2 AS ES A ieee et oon DO RE CAP Lot 419 958 035 50 000 50 000 50 000 CAP Lot 420 700 000 BLACK 187 500 000 CAP Lot 487 5 500 1 500 000 06 04 2003 11 39 03 15 2004 13 38 03 15 2004 13 38 03 15 2004 13 38 03 22 2004 13 46 03 31 2004 20 44 04 07 2004 12 34 04 08 2004 08 04 03 15 2004 13 42 03 22 2004 13 45 03 22 2004 13 45 03 22 2004 13 45 03 31 2004 20 44 04 07 2004 12 34 04 08 2004 08 04 05 02 2004 19 03 7 366 608 13 000 000 132 000 132 000 05 20 2003 16 03 03 26 2004 07 23 05 05 2004 10 10 05 05 2004 22 54 05 06 2004 11 38 03 26 2004 07 23 05 05 2004 10 10 05 05 2004 22 54 05 06 2004 11 38 05 09 2004 23 50 Schedule Jobs List Alternate Methods You can launch the Scheduled Jobs list by pressing the Scheduled Jobs icon on the toolbar You can launch the Scheduled Jobs list for a specific machine by right clicking on the machine number and selecting Scheduled Jobs The Scheduled Jobs list will display detailed information about all of the jobs that ar
125. his number should be modified any time a cavity is plugged This number is typically modified via the MIU or the Real Time Display but can be modified using the Tool ID Edit Facility Copyright 1983 2004 Mattec Corporation 5 67 810 0001 Rev C Advanced Tip 4 The Setup Time in the Tool ID is used by the Job Schedule to adjust when scheduled jobs are expected to start end It s important to keep this value up to date Advanced Tip 5 Father jobs can optionally specify a base tool This is used for Preventive Maintenance calculations only All other fields in the Tool ID for father jobs are for reference purposes only Advanced Tip 6 The Tool Odometer can be adjusted in the Tool IDs Edit Facility The Odometer is used by the Tool PM Due Report to determine when preventive maintenance will next be due for a tool The Tool Odometer is updated automatically and in real time by the ProHelp EPM system Manual changes to the Tool Odometer should be made with care To modify the standard Tool Setup Sheet press the Setup Sheet button Modify the Setup Sheet as appropriate Press OK to temporarily save your changes You will be returned to the Tool ID Edit Facility Press Save to save your changes Advanced Tip 7 Many MIUs are capable of viewing all or part of the standard Tool Setup Sheet For example the TSMIU is capable of displaying the entire Tool Setup Sheet for the currently running job s and for all s
126. iency Yield Efficiency or OEE A Tool ID defines information for the tool that will be used to create a part including the number of cavities that the tool has A Tool ID is specified in a Process Sheet An identifier that uniquely identifies a Tool ID The accumulated run time and machine cycles for a tool The Tool Odometer is used in Preventive Maintenance calculations to determine when a PM Action is next due A Tool Preventive Maintenance Code The maintenance operator enters this code at the MIU when preventive maintenance is performed on a running tool The total number of cavities in a Tool ID The total number of parts for a job as accumulated by the MIU Total Part Good Parts Scrap Parts 9 200 810 0001 Rev C Total Parts To Go Trend u Chart UCL Upper Control Limit Upper Specification Limit USL Variable SQC Variance Web Reports Web Setup Sheets Copyright 1983 2004 Mattec Corporation The total number of parts that need to be produced for a job This value differs from Good Parts To Go in that it takes into account the actual percent scrap for the job if the job is running or the standard percent scrap if the job is scheduled ProHelp EPM calculates this value in real time A Trend indicates that the last n consecutive SPC or SQC samples where n equals the Number of Samples Per Run from System Configuration were all increasing or all decreasing A gr
127. ine s that you wish to modify Press ox The Job Schedule program will be displayed e Click the Tools menu and select Status Override The Status Override screen will be displayed e Locate the job to be modified Press the Suspend button to suspend a job that has been mistakenly ended Press the End button to end a job that has been mistakenly suspended Status Override Al ES Machine Number i y Status COMP Job Number 1234567890 Y Actual Start Actual End Part Number 6c 7895 2003 01709 2003 01 27 Tool Number acs zz 17 13 OK Suspend End Status Override Screen Advanced Tip 1 The Status Override function in the Job Scheduler is used to correct mistakes The Job Control program Section 6 10 should be used for normal starting and stopping of jobs Advanced Tip 2 When you use the Status Override function to suspend a job that was mistakenly ended the job is placed in the Unscheduled Jobs list for the appropriate machine You must then manually reschedule the job before you can re run the job Copyright 1983 2004 6 125 810 0001 Rev C Mattec Corporation 6 12 Launching Other Applications The Job Schedule like the Main Menu can be used to launch most other applications in the system To launch an application using the Job Schedule program follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that y
128. ing mode the Refresh Rate is used to determine how frequently the Real Time Display should page down to see more machines Reference Section 3 2 for additional information High Contrast This mode causes the Real Time Display to translate colored fields to shades of black white and gray to facilitate use by the visually disabled Touchscreen Mode This mode causes the Real Time Display to translate many fields into a larger size that may be appropriate for use in a touchscreen environment Toolbar Shows or hides the Real Time Display s toolbar Status Shows or hides the Status bar at the bottom of the display Copyright 1983 2004 Mattec Corporation 3 34 810 0001 Rev C 3 13 Operator Efficiency Display The Operator Efficiency Display shows login and performance information for all users throughout the plant who have logged in at the MIU for Operator Efficiency A default Operator Efficiency Display shipped with your system and the System Manager can easily create custom displays using the Real Time Display Writer To start the Operator Efficiency Display follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Press the Operator Efficiency Display icon on the toolbar The Operator Efficiency Real Time Display Will be displayed Operator Efficiency Real Time Display x DO Operator Efficiency Real
129. inistrator 6 16 01 Packed Quant ty Administrator 6 16 Employee ID brian 01 Packed Quantity Administrator 6 16 HEA E ER M A Mew MM Scrap Entry 306 6 16 Scrap Reason cE y crap Entry Admit nistrator 6 16 1 Scrap Entry Administrator 6 164 01 Scrap Entry 356 6 16 crap Entry 356 6 16 F shed 2146 6 12 5 Scrap Quantity f 00 uantity L Audit Time Cc E da dl Save Cancel Prt c zan wee ID Short Shot Description Scrap And Pack Scrap and Packed Parts Edit Facility e To edit an existing scrap or packed parts entry locate the desired entry using the selection facilities on the left hand side of the display Press the Edit button Modify the scrap or packed parts entry as appropriate Press Save to save your changes Copyright 1983 2004 5 83 810 0001 Rev C Mattec Corporation e To create a new scrap or packed parts entry press the New button Select an existing Machine Number and Job Number Select the appropriate Date and shift Select the appropriate Transaction Type Scrap Entry Of Packed Quantity Fill in the fields on the display as appropriate Press Save to save your changes Alternate Methods Users can enter scrap parts or cases and packed parts or cases for the current shift at the MIU Users can enter scrap parts or cases and packed parts or cases for the current shift via the Real Time Display Reference Section 3 8 for additional infor
130. ion Board in the server computer The RS 232 signal from the Buffer Box is connected to one of the channels on the RocketPort board The RocketPort board contains multiple communication ports and is a smart device that improves the communication process 1 2 4 Client Computers Although the server computer is a fully functioning client system most users will want to connect to the system from their own computer To do so they will need to have an approved Microsoft operating system loaded on their computer The System Manager will load the ProHelp EPM Client software on that computer and configure it to connect to the server computer The user will be given permissions to access or modify data as appropriate These users with then be able to view data for the entire facility in real time 1 3 Shut Down Procedure ProHelp EPM is intended to run 24 hours per day every day When it does become necessary to reboot the system use this procedure It will bring the system to an orderly shut down e Announce to all users that you will be taking the system down Have all users exit the ProHelp EPM software Ensure that no ProHelp EPM job changes are under way Ensure that a shift change is not in progress Login to the server computer as an authorized user Using the mouse click on the Microsoft Windows Start Menu and select Shut Down The Shut Down Windows dialog box will be displayed e Select Shut Down the computer and p
131. ions per sample for the job equals one 1 the X Bar Standard Deviation Charts will not be displayed However if you have forced ProStat to display a Chart of Individuals and Moving Range chart by selecting Moving Range on the R MRx tab of the Options dialog then the standard X Bar Standard Deviation Charts will be displayed You can double click on any point in either the X Bar or Standard Deviation Charts to see additional data for that sample including the observations that comprised the sample the date time that the sample was taken and the X Bar Range Standard Deviation and Median for the sample Advanced Tip 2 The X Bar Standard Deviation Charts are available when performing analysis for multiple jobs i e SPC By Part or SPC By Tool Data for the jobs are arranged in chronological order by job starting with the job that ran first You can double click on any point in either chart to see which job is associated with the sample A number of options are available to control the behavior of the charts To modify the behavior of the X Bar Standard Deviation Charts follow these steps e Press the Options button The Options dialog will be displayed e Press the x Bar Chart tab or the s Chart tab Copyright 1983 2004 7 154 810 0001 Rev C Mattec Corporation ProStat Options E Production X Bar Chart R MRx Chart s Chart Median Chart Histogram Attribute Upper boundary 0 Lower
132. is field to All Machines to disable help call reason filtering Machines Nearing End Of Job This field allows you to filter the Real Time Display to view any machines that are nearing the end of job Uncheck this field to disable end of job filtering Machines That Are Out Of This field allows you to filter the Real Time Display to Specification view any machines that have one or more process parameters that are out of specification Uncheck this field to disable out of specification filtering Machines That Are Not This field allows you to filter the Real Time Display to Communicating view any machines that are not communicating with the server computer These machines are colored purple on the Real Time Display Uncheck this field to disable not communicating filtering This filter condition exists primarily for use by the Mattec Customer Service Department Machine Group Filters 1 4 These fields allow you to filter the Real Time Display to view any machines that meet the specified criteria The System Administrator assigns the Machine Group filters to machines via the Machine Configuration program The Mattec Customer Service Department can manually configure the names of each filter and the values in each group Copyright 1983 2004 Mattec Corporation 3 17 810 0001 Rev C Advanced Tip 2 Filter conditions are cumulative You can specify one or more filter conditions on the Real
133. istic s to be from the same machine cycle to be statistically valid By their very nature Automatic SPC samples are initiated without user interaction and without the user s knowledge Thus it would not be reasonably possible to enter Variable SQC data and know with any certainty that it could be correlated with Automatic SPC data In fact the entire reason for Manual SPC sampling to exist is to permit correlation between the machine s process parameters and the part s variable characteristics The machine operator instructs the MIU to sample the machine s process parameters so the corresponding parts that are produced can be collected and used for Variable SQC and or Attribute SQC data entry Copyright 1983 2004 7 167 810 0001 Rev C Mattec Corporation 7 14 Calculating Control Limits ProHelp EPM allows users to directly enter control limits for process parameters Automatic SPC and Manual SPC and part characteristics Variable SQC You can optionally calculate these control limits via the ProStat program The following table describes the location of control limits for the four SPC SQC data types Data Type Control Limits Automatic SPC Control Limits for process parameters are specified in the Manual SPC Process Sheet These limits are used for Automatic SPC Manual SPC and for real time monitoring by the MIU Variable SQC Control Limits for part characteristics are specified in the Sample Sheet Attribute
134. istics These characteristics are then subjected to a precise and complicated analysis process that determines to what degree changes in the independent characteristic affect changes in the dependent characteristic s Compatibility Linear regression analysis is available for Automatic SPC Manual SPC or Variable SQC Data It is not available for Attribute SQC data Additionally you can perform linear regression analysis between the following data types Automatic SPC versus Automatic SPC Manual SPC versus Manual SPC Variable SOC versus Variable SQC Manual SPC versus Variable SQC and vice versa To perform linear regression analysis follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Linear Regression Analysis icon Linear Regression Select x Independent Data Type MAIEN I nN Characteristic Height y Dependent Data Type Manual SPC y Charactieristic an Parameters y Cancel Linear Regression Analysis Data Selection Copyright 1983 2004 7 164 810 0001 Rev C Mattec Corporation e Specify the Independent Characteristic to be analyzed e Select the Dependent Characteristic s to be analyzed You may select one Dependent Characteristic or select A11 Parameters The list of Dependent Characteristics that can be chosen will be adjusted
135. ker Display point markers X Bar Chart Displays a large marker for each point on the chart This makes it easier to double click on a sample but makes the chart harder to read if you have specified a large number of points visible on chart Display horizontal grid lines X Bar Chart Controls whether horizontal grid lines are displayed on the chart Display vertical grid lines X Bar Chart Controls whether vertical grid lines are displayed on the chart 3 Dimensional X Bar Chart Controls whether the chart is displayed in 2 D or 3 D Copyright O 1983 2004 Mattec Corporation 7 149 810 0001 Rev C Option Options Tab Description Upper Boundary R MRx Chart This value controls the maximum value that is displayed on the Y Axis If both Upper Boundary and Lower Boundary are 0 the chart will automatically chose appropriate values Lower Boundary R MRx Chart This value controls the minimum value that is displayed on the Y Axis Moving Range R MRx Chart This value forces ProStat to use special calculations for the X Bar and Range Charts even if the number of observation per sample 1s greater than one 1 When selected a Chart of Individuals will be displayed in place of the X Bar chart and a Moving Range Chart will be displayed in place of the Range Chart Observations Per Range R MRx Chart This value specifies
136. l Cavities fi Description Injection Component Active Cavities fi en Group ToallDs Group 1 1 y Runner Weight 0 000711 g Edit Machine Type Setup Time 60 mins Copy Maker Mattec Mold Comment 1 New Location 8 15 491 Comment 2 Delete Web Setup Document _ View Document Setup Sheet r Tool Machine Compatibility meag Minimum Required Compatibility Values Required Compatibility Options Machine Tonnage 1000 Ton V Tonnage Hot Runner Control 11 Avail Y Hot Runner Control 21 200 Water Chiller 1 Avail IM Water Chiller ps T 400 a Test Fixture 1 Avail FT Test Fixture ST 500 Metal Shot Size 10 OZ T Shot Size E A En Screw Diameter 0 MM I Screw Diameter Unused 0 J Unused Unused 0 M Unused Save Cancel Print Tool IDs Ready Z Tool ID Edit Facility Copyright 1983 2004 5 65 810 0001 Rev C Mattec Corporation e To edit an existing Tool ID locate the desired Tool ID using the selection facilities on the left hand side of the display Press the Edit button Modify the Tool ID as appropriate Press Save to save your changes e To create a new Tool ID press the New button Specify a unique Tool Number and fill in the fields on the display as appropriate Press Save to save your changes Alternate Methods You can click on the Edit Tool IDs icon on the toolbar to launch the Tool ID Edit Facility Tool IDs can also be created or modified via the Data Import
137. lication This program is very limited in its functionality and may be removed in future releases of software Alternate Methods Users can enter material lot changes as they occur at the MIU This is the preferred method for entering material lots Advanced Tip 1 The Material Lot Edit program does not allow you to create new material lot entries Advanced Tip 2 The Material Lot Edit program in Edit Facilities works directly on existing material lot entries in the dbo IdTrack database table Material lot entries in this database table are not displayed anywhere in the ProHelp EPM software The Material Lot Edit program does not modify material lot entries in the dbo OperLog database table Material lot entries in this table are the material lots that are displayed on the Material Lot Report in ProStat on the Production tab and elsewhere in the system Copyright 1983 2004 5 87 810 0001 Rev C Mattec Corporation 5 11 Downtime Edit The Downtime Edit program in Edit Facilities allows you to reclassify downtime from one downtime reason to another or to edit the amount of downtime that was collected by the MIU Reclassifying downtime via the Reclassify button is a normal operation that can be safely performed at any time Editing downtime via the Edit button is a non standard operation and should be avoided unless absolutely necessary To reclassify downtime from one downtime reason to another downtime reason
138. lity u Charts are only available for Attribute SQC data They are not available for Automatic SPC Manual SPC or Variable SQC data To display the u Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 Select Attribute Soc in the Data Type field e Press the u Chart tab The u Chart will be displayed Ak ProStat SPC SQC Attribute SQC u Chart Copyright 1983 2004 7 184 810 0001 Rev C Mattec Corporation 7 20 Launching Other Applications ProStat can be used to launch the Data Import Export program or the ProStat Sample Data Edit program To launch ProStat Sample Data Edit follow these steps e Start the Main Menu and press the Launch ProState icon The ProState program will be displayed Press the Launch ProStat Sample Data Edit icon To launch the Data Import Export program follow these steps e Start the Main Menu and press the Launch ProState icon The Prostate program will be displayed Press the Launch Data Import Export icon Advanced Tip 1 To determine which program will be launched when you press an icon on toolbar simply hover the mouse cursor over that icon A tool tip will be displayed Copyright O 1983 2004 7 185 810 0001 Rev C Mattec Corporation 8 Miscellaneous Applications The following sections describe miscellaneous applicatio
139. lity An engineering limit that defines the range of acceptable values for a monitored process parameter or part characteristic to produce a good part See Lower Specification Limit and Upper Specification Limit Statistical Quality Control The use of statistical techniques to analyze the variable and attribute characteristics of a manufactured part The expected cycle time for a job The Job Schedule uses this value for non running jobs when calculating forecasted end dates This value is also used to determine Cycle Efficiency 9 199 810 0001 Rev C Standard Deviation Standard Percent Down Standard Percent Scrap Status Subgroup Size System Administrator Theoretical Production Tool ID Tool Number Tool Odometer Tool PM Code Total Cavities Total Parts Copyright 1983 2004 Mattec Corporation A measure of the variability of a statistical sample The expected percent down for the machine The Job Schedule uses this value for non running jobs when calculating forecasted end dates The expected percent scrap for a job The Job Schedule uses this value for non running jobs when calculating forecasted end dates See Job Status or Machine Status The number of observations per sample for an Automatic SPC sample or a Manual Variable Attribute SQC sample A person who is appointed to be the expert on the ProHelp EPM system Theoretical Production is an obsolete term See Cycle Effic
140. mation Audit Trail Changes to existing scrap entries or packed parts entries automatically receive an Audit Trail This Audit Trail can be viewed in the Scrap Log Report in System Reports This Audit Trail is created even if you have not purchased the Audit Trail optional feature from Mattec Advanced Tip 1 Scrap and packed parts can be entered as parts only Advanced Tip 2 The scrap reasons that are displayed in the Scrap Entry dialog are not chosen from the Advanced Scrap Map or the Simple Scrap Map Rather the scrap reasons that are displayed are the system wide scrap reasons that were created by the System Manager Copyright O 1983 2004 5 84 810 0001 Rev C Mattec Corporation 5 9 Job Setup Notes The Job Setup Notes Edit Facility is useful for creating notes regarding the setup for a specific job Unlike other setup sheets the Job Setup Notes are probably more useful to record what was done rather than to instruct the user how to setup the job To create or modify a setup note for a specific job follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Job Setup Notes The Job Setup Notes Edit Facility will be displayed F E dit Facilities for Release 6 1 0 Job Setups ds File View Edit Application Window Help 0 0 Jobs wth Setup Notes r Br
141. mize system performance common software troubleshooting techniques file transfers and techniques for overall system implementation and control Who should attend ProHelp EPM system administrators managers Those who have the responsibility to ensure that ProHelp EPM is being used to its full potential ProStat SPC SQC 2 Days This course is designed specifically to teach users how to implement ProStat ProHelp EPM s SPC SQC option and begin to collect and monitor data for statistical analysis Topics covered include manual and automatic process parameter data collection part variable data input and attribute data entry This class does not teach basic statistics nor basic ProHelp EPM It is recommended for users who have a working knowledge of SPC SQC theory and ProHelp EPM Who should attend SPC SQC coordinators quality control personnel and users who are responsible for implementing the SPC SQC program in your company Copyright 1983 2004 1 7 810 0001 Rev C Mattec Corporation Maintenance Calibration and Troubleshooting 2 Days This course is designed to teach the maintenance technician how to locate hardware problems throughout the system This class begins with a basic system overview followed by a basic how to use ProHelp EPM Topics such as proper installation and troubleshooting techniques on the various system components along with analog setup and calibration will be covered Component level
142. n for the next job to be run Machine Status Ea Machine Number EASTO 750 Ton Engle Last Update 06 16 2003 14 31 11 Job Number 32616 56 VAL240128737 JH Forecasted End Date 04 03 2004 07 23 57 Part Number WAL24012873 7 Pipe Cap Tool Number WAL24012873 7 Injection Mold Customer Valeo Overview Process Alarm Material Setup Sheets Next Job Production Machine Status Shit deb Too Status Running Total Parts 105412 5663820 7366608 J cs z Time In Status 4 01 Good Parts 105398 5650594 7349406 Help Call Serap Pante A E Help Start Time Packed Parts 0 2200000 10800000 Machine Cycles 26353 1415955 ae E is Cycles Out Of Spec ha MES Cycle Efficiency 387 98 9 Run Time 7 30 418 48 549 42 Yield Efficiency MSA 980 Down Time 0 01 6 58 Cavities Po 4 Std 4 Actual Desmer U a Last Cycle Time 1 0200 Refresh Options Select Down Machine Status Display Copyright 1983 2004 3 11 810 0001 Rev C Mattec Corporation 3 1 Color Coding Fields on the Real Time Display are color coded to draw your attention to those items that need immediate attention The following is a general overview of the color coding on the Real Time Display being monitored Green is good usually associated with a newly configured machine Red typically indicates that a monitored process parameter ha
143. n statistical distribution Histogram Chart in relation to normal A measure of the ratio of the Standard Deviation Sigma and the Mean for a frequency distribution Histogram Chart CV Standard Deviation Mean The Color ID or other material that is used to make the part See Son Job Statistical limits that are applied to measure the significance of the variation of a process parameter or part characteristic Control limits can be calculated from process data See Lower Control Limit and Upper Control Limit 9 188 810 0001 Rev C Correlation Coefficient Cost Manager Cp Cpk Cr Customer Cycle Efficiency Cycle Time Predictor Limit Cycles Out Of Spec Copyright O 1983 2004 Mattec Corporation Pearson product moment The correlation coefficient is associated with Linear Regression Analysis and numerically measures to what degree changes in the independent characteristic affect changes in the dependent characteristic s An optional feature that allows authorized users to view scrap and downtime costs for jobs in real time Cp is a measure of process capability or the repeatability of a process that relates the variation of the process to the specification limits Cp USL LSL 6 Standard Deviation Cpk is a measure of process capability or the repeatability of a process that relates the variation of the process to the specification limits and the mean A Cpk greater than 1 is gen
144. nal feature You may purchase this feature at any time by contacting the Mattec Sales Department Audit Trails Changes to existing Process Sheets will automatically receive an Audit Trail provided that you have purchased the Audit Trail option from Mattec This Audit Trail can be viewed by pressing the Audit Trail button in the Process Sheet Edit Facility This data is also available in System Reports Reference Section 4 6 for additional information Audit Trails is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Copyright O 1983 2004 Mattec Corporation 5 77 810 0001 Rev C To modify the standard Process Sheet Sheet press the Setup Sheet button Modify the Setup Sheet as appropriate Press OK to temporarily save your changes You will be returned to the Process Sheet Edit Facility Press Save to save your changes Advanced Tip 5 Many MIUs are capable of viewing all or part of the standard Process Sheet Setup Sheet For example the TSMIU is capable of displaying the entire Process Sheet Setup Sheet for the currently running job s and for all scheduled jobs A job s specification limits and control limits are specified in the Process Sheet These values are used by the MIU for real time process monitoring These specification limits and control limits are also used for Automatic SPC and Manual SPC purposes If you make changes to the Process Sheet for a run
145. ng the Unscheduled Jobs icon on the toolbar You can launch the Unscheduled Jobs list for a specific machine by right clicking on the machine number and selecting Unscheduled Jobs The Unscheduled Jobs list will display detailed information about all of the jobs that exist but Copyright O 1983 2004 6 114 810 0001 Rev C Mattec Corporation that are not scheduled These jobs can be displayed for one specific machine or for all machines You can limit the amount of data that is displayed by selecting a specific machine number in the Machine Number picklist Advanced Tip 1 Jobs in the Unscheduled Jobs list are not scheduled but they do have a Machine Number that is associated with the Job A job must have a Machine Number Part Number and Tool Number assigned to it in order for the job to be created Thus all jobs including jobs that are not scheduled have a Machine Number To schedule a job from the Unscheduled Jobs list simply highlight the job s and press the Schedule button You can highlight multiple jobs by holding down the CTRL key while you use the mouse to click on each job Advanced Tip 2 A suspended job can only be re scheduled and re run on the same machine that the job initially ran on To permanently delete a job and remove it entirely from the database simply highlight the job s and press the Delete button You can highlight multiple jobs by holding down the CTRL key while you use the mouse to click on eac
146. ning job these changes are updated automatically at the MIU when you press Save ProStat can calculate appropriate control limits based on actual Automatic SPC or Manual SPC sample data that has been collected Reference Section 7 14 for additional information Advanced Tip 6 Family jobs are comprised of one or more son jobs Each son job has its own Process Sheet that includes user specified specification and control limits When two or more son jobs are running on the same machine the ProHelp EPM system will dynamically determine the specification and control limits that are sent to the MIU for process monitoring purposes The specification limits and control limits are determined by selecting the lowest upper limit and the highest lower limit for each process parameter for each running son job That is the tightest specification and control limits as determined by combining all of the running son job s Process Sheets together are used Thus when you end one son job and start running another related son job the specification and control limits that are in use may change slightly Copyright 1983 2004 5 78 810 0001 Rev C Mattec Corporation 5 6 Machine Maintenance Log The Machine Maintenance Log in Edit Facilities allows you to create new Machine Preventive Maintenance History and view edit existing history records To enter preventive maintenance activity for a machine follow these steps e Start the Main Men
147. niquely identifies a Machine ID 9 193 810 0001 Rev C Machine Odometer Machine Operator Machine PM Code Machine Status Manual SPC Material ID Maximum Simultaneous Sons Median MIU MIU Operator Security Mold Monitoring Node Copyright O 1983 2004 Mattec Corporation The accumulated run time and machine cycles for a machine The Machine Odometer is used in Preventive Maintenance calculations to determine when a PM Action is next due An employee who is responsible for operating a machine The machine operator can play an important role in the ProHelp EPM system by being responsible for entering scrap selecting downtime reasons and performing job changes A Machine Preventive Maintenance Code The maintenance operator enters this code at the MIU when preventive maintenance is performed on a machine The current status of a monitored machine The use of statistical techniques to analyze machine process parameters that are collected automatically by the MIU when initiated by the user Manual SPC is closely related to Variable SQC and Attribute SQC and allows for linear regression analysis between machine process parameters and part variable characteristics The primary material that is used to make the part See Active Components A value in a statistical sample or a collection of samples above and below which there is an equal number of values or which is the average of the two middle values if
148. ns that are part of the ProHelp EPM system 8 1 Shift Time Utility The Shift Time Utility is used to convert a time_t value to a readable date time string and to assist the user in determining where the present week would fall within a multi week shift configuration Details of the Shift Time Utility are available in the System Administration Manual 4810 0014 8 2 System Configuration The System Configuration program is to configure ProHelp EPM in an appropriate manner for your facility Caution It is a good idea to contact the MATTEC Customer Service Department for assistance when you need to modify an area of system configuration with which you are unfamiliar Settings in the System Configuration application control the behavior of your ProHelp EPM system and deleting some settings can cause a permanent loss of data Details of the System Configuration program are available in the System Administration Manual 810 0014 8 3 System Names Edit The System Names Edit program is used to configure the software when you are performing an installation on a client PC Details of the System Names Edit program are available in the System Administration Manual 810 0014 8 4 Data Import Export ProHelp EPM is very powerful in its ability to share data with external systems such as ERP or accounting systems The Data Import Export program and the DTR Data Export program have been created to simplify this process for you De
149. ntt chart for the individual son jobs in that family job You can then drag and drop the individual son jobs in order to schedule them in a manner that will allow each son job to finish on time Reference Section 6 5 for additional information Copyright 1983 2004 Mattec Corporation 6 106 810 0001 Rev C 6 4 Tool Conflicts Tool Conflicts can be automatically highlighted and resolved interactively from within the Job Schedule Users can easily see which tools conflict and the length of the conflict To view all tool conflicts follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Click on the Tools menu and select Tool Conflicts All tool conflicts will be displayed individually e To view the next tool conflict press the Find Next button Ey Job Schedule olx File View Reports Tools Application Help CESE Machine o d1 314151 Sle i i DAA NANA IIMB I iGO ANA ANn Sand mi WUU U2 03 Game Co 148 721 04 04 PESA Di cas DLcar 1234s DLG b JF RB192 GHJF RB192 RED Tool Conflict ofocirosiisfocieoffofocira co DLG j DBi MS ockeJockr34610 Joc oc ocke Jock INJ 01 JF RB 192 Release 2 Tool Number 12345 Machines 02 DLG a Jobs JOB 78N4 DLGaB Start Date 5 20 2003 4 21 17 AM End Date 5 24 2003 5 48 33
150. nual SPC samples via the ProStat Sample Data Edit Program Reference Section 7 2 for additional information Enter or modify Machine Maintenance History via the Machine Maintenance Log Edit Facility Enter or modify Tool Maintenance History via the Tool Maintenance Log Edit Facility Enter or modify scrap parts or packed parts via the Scrap and Packed Parts Edit Facility Create notes regarding the setup for a specific job via the Job Setup Notes Edit Facility Reclassify downtime that was recorded by the MIU from one downtime reason to another downtime reason or directly modify the amount of downtime that was recorded by the MIU via the Downtime Edit Log Edit Facility Directly modify the total parts machine cycles or time that was recorded by the MIU via the Production History Edit Facility To launch Edit Facilities follow these steps Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed Copyright O 1983 2004 5 58 810 0001 Rev C Mattec Corporation E Edit Facilities for Release 6 1 0 File View Edit ate Help Edit Facilities Copyright 1983 2004 5 59 810 0001 Rev C Mattec Corporation 5 1 Job Descriptor A job descriptor represents a work order Most production and process information that is collected by the system is stored to the job descriptor A bachelor job or son job is comprised of a Process Sheet which in turn is comprised of a Machine ID a Pa
151. ny color to Copyright 1983 2004 Mattec Corporation 6 120 810 0001 Rev C Properties Tab Description display a palette of supported colors You can select a new color by clicking the desired color from the color palette then press OK Fonts Fields on this tab modify the fonts for miscellaneous text fields on the Job Schedule display You can click on any displayed font on this tab to display a font selector dialog You can select a new font and point size then press OK Print Fields on this tab modify the behavior of the Job Schedule when you press the Print button When Print Screen is specified only that portion of the Job Schedule that is visible when you press the Print button will be printed When Print Chart is specified the entire Job Schedule including those portions that can not be currently seen will be printed when you press the Print button General Fields on this tab modify miscellaneous behavior of the job Schedule You can click on any Color field on the Properties dialog to display a palette of supported colors You can select a new color by clicking the desired color then press OK Copyright O 1983 2004 Mattec Corporation Color HEI Basic colors EEE Mm Custom colors ge eee fg eee eee eg Define Custom Colors gt gt Cancel Color Palette 6 121 810 0001 Rev C 6 10 Job Control Job Control is used to k
152. ny monitored process parameter WARNING The Process Exception Log has the potential to grow very rapidly and should only be turned on 1f the data collected will be used The Process Exception Log is intended to be a short term debugging tool and should not be used in place of statistical analysis of data To view the Process Exception Log for a job follow these steps e Start Prostate To do this start the Main Menu and press the Launch ProStat Display icon Select the appropriate job as described in Section 7 3 e Press the Process Exception Log icon The Process Exception Log will be displayed Process Exception Log Xx Parameter Cycle Time Machine Cycle Time v Start Date 10 31 03 9 02 00 AM MV All Dates Maximum exceptions to display 1000 End Date pomo E ey gt E ert i Refresh Process Exception Log Copyright 1983 2004 7 174 810 0001 Rev C Mattec Corporation Alternate Methods A Process Exception Log Report is available in System Reports This report can be used to view process exceptions for any job The Process Exception Log is available in the Real Time Display program This allows you to easily view this data for running jobs Advanced Tip 1 Process Exception Logging is enabled in the Machine Configuration program When enabled all exceptions to any process parameter are automatically recorded by the system Reference the System Administra
153. obs that were suspended during the specified time range may also be included in these reports even if the jobs did not actually run during the specified time range Shift reports are ideal if you would like to view data for a very precise time range Reference Section 4 1 for additional information Copyright 1983 2004 4 44 810 0001 Rev C Mattec Corporation 4 3 Overall Equipment Effectiveness OEE Reports OEE is a simple way of measuring and improving the utilization of the machines in your plant It differs from the Cycle Efficiency and Yield Efficiency calculations that are common in ProHelp EPM OEE is commonly used in Total Productive Maintenance TPM programs Ideally your factory would operate 100 of the time at 100 capacity and with 100 good parts In reality however this rarely occurs OEE provides a measure of the difference between the ideal and what is actually happening on your shop floor OEE data is collected in Real Time by the ProHelp EPM system This data can be seen in the Shift OEE Report and the Job OEE Report This provides you with the information that you need to improve the asset utilization in your plant To generate an OEE Report follow these steps e Start system Reports To do this start the Main Menu and press the Launch System Reports icon e To generate the Shift OEE Report click on the Shift menu click on the Analysis menu and select Shift Overall Equipment Effectiveness Fill in the
154. on The Edit Facilities program will be displayed e Click on the Edit menu and select Process Sheet The Process Sheet Edit Facility will be displayed e To edit an existing Process Sheet locate the desired Process Sheet using the selection facilities on the left hand side of the display Press the Edit button Modify the Process Sheet as appropriate Press Save to save your changes e To create a new Process Sheet press the New button Select an existing Machine Number Part Number and Tool Number The combination that is selected must be unique Fill in the fields on the display as appropriate Press Save to save your changes Copyright O 1983 2004 5 74 810 0001 Rev C Mattec Corporation FZ Edit Facilities for Release 6 1 0 Process Sheets iy File View Edit Application Window Help 181x Process Sheet Last Update 3 1 04 10 27 28 AM Machine Part Number Tool Number Sample Sheet n gt sec 221277 Bote Cap z secans y Puoseal 1 000 Ton Inje Bottle Cap Shampoo Bottle Cap rounded flange Basic Specification Control Delete Standard Historical See alee Percent Down q 9 5 Labor Hour Factor 1 25 x Audit Trail Percent Scrap 6 6 8 Labor Cost hr 18 50 Tool Number Part Number Cycle Time 11 5 12 1 Non Production Limit 23 Cavity PSI Transfer 0 Comment 1 Light Green Comment 2 Shampoo Bottle Cap Web Setup Document frttp matnet SBC221 2
155. on the chart This makes it easier to double click on a sample but makes the chart harder to read if you have specified a large number of points visible on chart Display horizontal grid lines s Chart Controls whether horizontal grid lines are displayed on the chart Copyright O 1983 2004 Mattec Corporation 7 155 810 0001 Rev C Option Options Tab Description Display vertical grid lines s Chart Controls whether vertical grid lines are displayed on the chart 3 Dimensional s Chart Controls whether the chart is displayed in 2 D or 3 D Advanced Tip 3 There is no place in the ProHelp EPM software to enter standard control limits for standard deviation However the ProStat software is capable of calculating these control limits dynamically and displaying them on the s Chart Copyright O 1983 2004 Mattec Corporation 7 156 810 0001 Rev C 7 11 Median Chart A Median Chart displays the median of the observations in each sample Compatibility The Median Chart is available for Automatic SPC Manual SPC or Variable SQC Data It is not available for Attribute SQC data To display the Median Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Median Chart tab The Median Chart will be displayed Ak ProStat9 SPC SQC
156. onding frequencies The historical cycle time for a job This value is for display purposes only The historical percent down for the machine This value is for display purposes only The historical percent scrap for a job This value is for display purposes only See Server Computer The number of hours to go in order to produce the parts that are needed for a job ProHelp EPM calculates this value in real time A job descriptor represents a work order Most production and process information that is collected by the system is stored to the job descriptor A job change is performed to keep ProHelp EPM synchronized with the monitored machines ProHelp EPM must be directed to start collecting data for a job and to end collecting data when the job is done Job changes are performed via the Job Control program See Job An identifier that identifies a job ProHelp EPM allows the user to specify duplicate Job Numbers but each job is treated as a unique unit The current disposition for a job including PENDING RUNNING SUSPENDED and COMPLETE k is an index of process centering that is associated with measuring process capability Cpk Cp 1 k 9 192 810 0001 Rev C Kurtosis Labor Cost Labor Hour Factor Last Update LCL LCL Loop Lot Size Lower Control Limit Lower Specification Limit LSL Machine Cycles Machine ID Machine Interface Unit Machine Number Copyright
157. or 3 D Copyright O 1983 2004 Mattec Corporation 7 150 810 0001 Rev C 7 9 1 Chart of Individuals X and Moving Range Chart MRx A Chart of Individuals X Chart is a special case of an X Bar Chart where the number of observations per sample equals one 1 A Moving Range Chart MRx Chart is a special case of a Range Chart where the number of observations per sample equals one 1 Compatibility The Chart of Individuals and Moving Range Chart are available for Automatic SPC Manual SPC or Variable SQC Data They are not available for Attribute SQC data If the number of observations per sample for the job equals 1 the Chart of Individuals and Moving Range Chart are automatically selected instead of the X Bar Range Charts To force a Chart of Individuals and Moving Range Chart to be displayed in place of the X Bar Range Charts follow these steps e Start the Main Menu and press the Launch ProState icon The ProState program will be displayed Select the appropriate job as described in Section 7 3 e Press the Options button The Options dialog will be displayed e Press the R MRx Chart tab e Place a checkmark in the Moving Range checkbox e Enter a value in the Number of Observations field e Press ox The Chart of Individuals and Moving Range Chart will be displayed Advanced Tip 1 If the number of observations per sample for the job equals one 1 the Chart of Individuals and Moving Range chart will be
158. oration 3 6 Process Exception Log The Process Exception Log will record any machine cycles that result in a violation of specification limits control limits and or part qualification limits for any monitored process parameter WARNING The Process Exception Log has the potential to grow very rapidly and should only be turned on 1f the data collected will be used The Process Exception Log is intended to be a short term debugging tool and should not be used in place of statistical analysis of data To view the Process Exception Log for a running job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired job and select Process Exception Log The Process Exception Log Will be displayed Process Exception Log x Machine Number MAA Job Number J01 12345 y Parameter Cycle Time Machine Cycle Time as Dptions Process Exception Log Copyright 1983 2004 3 25 810 0001 Rev C Mattec Corporation Alternate Methods A Process Exception Log Report is available in System Reports This report can be used to view process exceptions for any job The Process Exception Log can be viewed in ProStat This allows you to view process exceptions for any job Advanced Tip 1 Process Exception Logging is enabled in the Machine Configuration program When enabled all exceptions to any process parameter are
159. otal Productive Maintenance TPM programs Mattec s standard OEE calculation is OEE Percent Uptime Percent Good Parts Cycle Efficiency A setting in the System Configuration program allows the calculation to be changed to the following OEE Percent Uptime Percent Good Parts Yield Efficiency OEE is an optional feature in ProHelp EPM A form of operator login in which performance information is automatically collected by the system Operator Efficiency is an optional feature A form of operator login similar to a time clock See OEE A graphical representation of the proportion of non conforming items defects in an Attribute SQC sample 9 195 810 0001 Rev C Packed Parts Part ID Part Number Parts To Go Pearson Product Moment Correlation Coefficient Percent Down Percent Out Of Spec Percent Scrap PM Code Preventive Maintenance Process Parameter Process Sheet Production Efficiency Copyright O 1983 2004 Mattec Corporation The number of parts that have been packed into boxes prepared for shipment etc This value is entered by the machine operator and can be used in a variety of manners A setting in System Configuration allows Packed Parts to be used in place of Scrap Parts in Parts to Go calculations A Part ID defines information for the part that will be created including the material s that will be used the part weight and costs A Part ID is specified in a P
160. ou wish to modify Press ox The Job Schedule program will be displayed e Single click the icon on the toolbar that represents the application that you wish to start Advanced Tip 1 To determine which program will be launched when you press an icon on the toolbar simply hover the mouse cursor over that icon A tool tip will be displayed In addition to the toolbar the Job Schedule provides special shortcuts to the Document Control Center and the Job Control programs These shortcuts allow the programs to be started with the Machine Number and other relevant information already selected To launch the Document Control Center or the Job Control program from the Job Schedule program follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ox The Job Schedule program will be displayed e To start the Document Control Center program right click on a machine and select Document Control Center The Document Control Center program will be started with the machine number already selected e To start the Job Control program right click on a machine and select Job Control The Job Control program will be started with the machine number already selected Copyright 1983 2004 6 126 810 0001 Rev C Mattec Corporation 7 ProStat SPC SQC ProStat is ProHelp EPM s real time Statistical Process Control Stati
161. owse record Current Jobs ee Machine Number Machine Number Job Number All Machines Status dit E Start Time Stop Time New zee GAYE Bancel Setups Sheet Job Setups Job Setup Notes Edit Facility e To edit an existing Job Setup Note locate the desired job using the selection facilities on the left hand side of the display Press the Edit button Press the Setup Sheet button The existing Job Setup Note will be displayed Copyright 1983 2004 5 85 810 0001 Rev C Mattec Corporation e Tocreate a new Job Setup Note press the New button Select the Machine Number that the job ran on or that the job is scheduled on Select the Job Number Press the Setup Sheet button A blank Job Setup Note will be displayed Job Setup New Job Setup x Print Cancel Creating a New Job Setup Note e Modify the Job Setup Note as appropriate Press OK to temporarily save your changes You will be returned to the Job Setup Notes Edit Facility Press Save to save your changes Advanced Tip 1 Setup sheets are also available in the following Machine ID Tool ID Part ID Process Sheet Sample Sheet These setup sheets may be more appropriate than the Job Setup Notes if you wish to create instructions for how to setup a job Copyright 1983 2004 5 86 810 0001 Rev C Mattec Corporation 5 10 Material Lot Edit The Material Lot Edit program in Edit Facilities is a legacy app
162. pecification limits and control limits are determined by selecting the lowest upper limit and the highest lower limit for each process parameter That is the tightest specification and control limits as determined by combining all of the jobs together are used Copyright O 1983 2004 7 145 810 0001 Rev C Mattec Corporation 7 9 X Bar Chart and Range Chart R An X Bar chart displays the average of the observations in a sample A Range Chart R Chart displays the range of the observations in each sample Compatibility The X Bar Range Charts are available for Automatic SPC Manual SPC or Variable SQC Data They are not available for Attribute SQC data If the number of observations per sample for the job equals 1 the Chart of Individuals and Moving Range Chart are automatically selected instead of the X Bar Range Charts To display the X Bar Range Charts follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the X Bar R Chart tab The X Bar Range Charts will be displayed Ak ProStat SPC SQC A E JAEN mema X Bar and Range for Cycle Time Automatic Overview Production Process Alarm X Bar R Chart Bars Chart Median Chart Histogram Machine INJ 01 Job CAP Lot A19 Part SBC 227277 Bottle Cap Tool SBC 1115 OK Options X Bar Chart and
163. ple marker Display individual observations for Median Chart When selected this value will cause the chart each sample to display all of the observations for each sample in addition to the calculated median 7 159 810 0001 Rev C Option Options Tab Description Display value of each observation Median Chart When selected this value will cause the chart to display the Median value for each observation above the observation s marker This value requires you to enable the display individual observations for each sample option Display point markers Median Chart Displays a large marker for each point on the chart This makes it easier to double click on a sample but makes the chart harder to read if you have specified a large number of points visible on chart Display horizontal grid lines Median Chart Controls whether horizontal grid lines are displayed on the chart Display vertical grid lines Median Chart Controls whether vertical grid lines are displayed on the chart 3 Dimensional Median Chart Controls whether the chart is displayed in 2 D or 3 D Advanced Tip 3 There is no place in the ProHelp EPM software to enter standard control limits for medians However the ProStat software is capable of calculating these control limits dynamically and displaying them on the Median Chart Copyright 1983 2004 Mattec Corporation 7 160
164. port Format You can print the report by clicking on the File menu and selecting Print You can save the report to disk by clicking on the File menu and selecting Save As Copyright 1983 2004 7 171 810 0001 Rev C Mattec Corporation The SPC SQC Summary Report is available in two formats Report and Export These formats are described below Report Format Description Report This format presents all samples and related data including the observations that comprised the samples in an easy to read display Export This format presents all samples and related data in an ASCII text format that would be appropriate for use with exporting this data out of the ProHelp EPM system to an external system This feature requires the Data Import Export option To change the format of the SPC SQC Summary Report follow these steps e Click on the view menu and select Report to display the Report format e Click on the view menu and select Export to display the Export format SPC SQC Summary olx File View CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 05 13 2002 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 05 17 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 05 17 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 06 04 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 06 07 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 06 07 200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 067077200 CAP Lot 419 SBC 227277 SBC 1115 Cycle Time 0
165. ppropriate Press ox The selected report will be displayed e To generate a Tool PM Report click on the Planning menu click on the Tool Maintenance menu and select the desired report Fill in the report data selection interface as appropriate Press ox The selected report will be displayed ry System Reports ITCHY PM Due Report File Shift Job Planning Application Help HS 2410320 fa 101 yy S foe JH Toas 100 olx Machine PM Due Report Mattec Corporation Loveland Ohio All Machines All Codes Maintenance Required by 3111 04 PM Mach Code Date Last Performed Due Date Description Department Injection Injection Molding DLG i COOL 12 2102 4 09 52 PM PAST DUE PAST DUE PAST DUE Cooling System Cl DLG i EJECT 12 2 02 4 09 48 PM N A PAST DUE PAST DUE Ejector Inspection RM 75 OTHER 2 26 04 9 00 17 AM 104 00 N A 3 10 04 Shift 2 Explain New PM Due Report loaded Ui Machine PM Due Report Copyright 1983 2004 4 47 810 0001 Rev C Mattec Corporation Advanced Tip 1 Preventive Maintenance is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department The following table describes the available Machine Preventive Maintenance reports Machine PM Report Description Machine PM Due This reports forecasts when preventive maintenance will be due for all selected machines and all selected PM Codes for the given timeframe Machine M
166. pyright 1983 2004 5 81 810 0001 Rev C Mattec Corporation e To create a new tool maintenance entry press the New button Select an existing Tool Number and Maintenance Code If the tool was running in a machine at the time that the maintenance was performed select the Machine Number Select the appropriate Run Time and Cycles when the maintenance was performed Fill in the fields on the display as appropriate Press Save to save your changes Alternate Methods Users can log preventive maintenance activity as it occurs at the MIU When this is done the system will automatically calculate the amount of time that it took to perform the maintenance activity Advanced Tip 1 Preventive Maintenance is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 The System Manager defines Preventive Maintenance Reasons Codes Up to 100 Tool PM Codes can be created Each PM Code specifies when it is due in terms of run hours or machine cycles or both Advanced Tip 3 The ProHelp EPM system will not forecast that preventive maintenance is due for a specific tool for a specific PM Code unless maintenance history has been entered for that tool for that specific code at least one time Thus although the PM Codes are defined system wide they do not necessarily apply to all machines You can include notes with each preventive maintenance activity that is perfo
167. pyright 1983 2004 7 136 810 0001 Rev C Mattec Corporation 7 4 Scrap Pareto Chart The Scrap Pareto Chart displays the scrap that has been entered for the job It quickly identifies the most significant causes of scrap parts and helps you to focus your attention on resolving those problems To generate a Scrap Pareto Chart for a job follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 e Press the Scrap Pareto Chart icon The Scrap Pareto Chart will be displayed Job Scrap Pareto Job Scrap Pareto CAP Lot A19 x HU i AY 4 A A Job Scrap Pareto Chart Alternate Methods The Scrap Pareto Chart is available in the Real Time Display program This allows you to easily view the chart for running jobs Copyright O 1983 2004 7 137 810 0001 Rev C Mattec Corporation The Scrap Pareto Chart will not refresh automatically and will only be refreshed when the user presses the Refresh button Itis safe to press the Refresh button at any time Scrap Reasons are always displayed in order of scrap parts that have been entered with the Scrap Reasons with the most quantity displayed on the left hand side of the display You can scroll to the left or right to see additional data on the chart You can display the chart in 2 Dimensions or 3 Dimensions These settings are specified on the Options dialog
168. r that text Rules Fields on this tab modify advanced settings that should probably be standardized throughout your facility Changes to this tab should be made with care Reference Section 6 9 for additional information Schedule Fields on this tab modify the formatting for miscellaneous areas on the Job Schedule display Machines Fields on this tab modify the formatting for miscellaneous areas on the Job Schedule display General Fields on this tab modify miscellaneous settings on the Job Schedule Timescale display related to dates and times The End Date field on this tab temporarily limits the last date that will be displayed in the Job Schedule This field will be reset the next time the Job Schedule is started Major Minor Fields on this tab allow you to zoom the Job Schedule display This Timescale may be necessary for example if you have a lot of short run jobs and are more interested in viewing just a day s worth of jobs instead of several months worth of jobs Copy Fields on this tab modify the behavior of the Job Schedule when you copy an existing job For example the Job Schedule can always prompt you to enter a new job number or it can dynamically create a job number for you Date Time Fields on this tab modify the vertical reference lines that are shown on the Job Schedule display Colors Fields on this tab modify the color settings for the majority of the fields on the Job Schedule display You can click on a
169. rails is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department The following table describes the available Audit Trail reports Audit Trail Report Description Login Failure This Audit Trail report shows MIU login failures Operator Tracking Operator Efficiency Machine PM and Tool PM for MIUs that support this functionality This requires the MIU Security option Manual SPC Audit Trail This Audit Trail report shows modifications to Manual SPC samples These modifications can be made using the ProStat Sample Data Edit program Variable SQC Audit Trail This Audit Trail report shows modifications to Variable SQC samples These modifications can be made using the ProStat Sample Data Edit program Attribute SQC Audit Trail This Audit Trail report shows modifications to Attribute SQC samples These modifications can be made using the ProStat Sample Data Edit program Process Sheet Basic Audit This Audit Trail report shows modifications to fields on Trail the Basic tab of the Process Sheet in Edit Facilities Process Sheet Specification This Audit Trail report shows modifications to fields on Limit Audit Trail the Specification tab of the Process Sheet in Edit Facilities Process Sheet Control Limits This Audit Trail report shows modifications to fields on Audit Trail the Control tab of the Process Sheet in Edit Facilities Advanc
170. report data selection interface as appropriate Press ox The Shift OEE Report will be displayed e To generate the Job OEE Report click on the Job menu click on the Analysis menu and select Job Overall Equipment Effectiveness Fill in the report data selection interface as appropriate Press ox The Job OEE Report will be displayed Copyright 1983 2004 4 45 810 0001 Rev C Mattec Corporation 18 System Reports Plant 1 Overall Equipment Effectiveness Report File Shift Job Planning Application Help HSS JRA PT 4 1 of 16 gt gt i lel esz y L a Total 440 100 4400f440 Overall Equipment Effectiveness Report battec Corporation oveland Ohio elected Range from Shit 3 1 19 03 11 00 00 PM to Shit 1 5 23 03 10 05 05 AM presert Bingle Machine DLG i 5 23 03 10 05 05 AM Em Date SH Time Deparimeni InjecboxX Injection DepboooxX DL G i 1 20 03 4 20 DL G i 1 2103 21 32 DLG i 1 22 03 6 02 DL G i 1 23 03 3 80 DLG i 1 2403 0 05 DLG i 1 24 03 5 64 4 Overall Equipment Effectiveness Report loaded Shift OEE Report Advanced Tip 1 Overall Equipment Effectiveness is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department Advanced Tip 2 Mattec s OFE calculation uses industry standard calculations to measure machine downtime machine cycle time 1 e speed and scrap parts Specifically OEE Percent Uptime Percent
171. represents a work order A family job is comprised of a father job and one or more son jobs and is used to monitor production and process information for distinctly different jobs parts that are running on the same machine at the same time Most production and process information that is collected by the system is stored to the son job descriptor s To create and schedule a family job father job and sons jobs follow these steps e Start the Main Menu and press the Launch Job Schedule icon Select the appropriate machine s and press ox The Job Schedule program will be displayed e Click on the Tools menu click on the New Job menu and select Family The Job Descriptor dialog will be displayed Job Descriptor E3 Family Components Job Number l Active Components 1 A Forecasted Start Forecasted End Machine Number lt none gt f NA N A Tool Number cNone gt A O NA N A _ Job Number ForecastedEnd Status cme J n Job Descriptor Dialog Family Job Fill in the Family tab of the Job Descriptor page as appropriate e Fill in the Component tab of the Job Descriptor page for each son job as appropriate e Press ox The new family job father job and son jobs will be created and added to the machine schedule Copyright 1983 2004 6 103 810 0001 Rev C Mattec Corporation Alternate Methods You can click on the New Family Job icon on the toolbar to create a new family job Jobs can also be
172. ress Yes Copyright 1983 2004 1 6 810 0001 Rev C Mattec Corporation 1 4 Additional Training Mattec offers several comprehensive seminars for customers who wish to sharpen their ProHelp EPM system skills These seminars are held in a hands on classroom environment at Mattec s headquarters in Cincinnati Ohio A Mattec trainer can also conduct any of these seminars in your plant using your system For details and current pricing information contact the Mattec Customer Service Department Classes include the following ProHelp EPM Basic User 2 Days This course is designed for the beginner intermediate user who never had any training or who needs to brush up on basic ProHelp EPM functionality Topics will include an overview of all ProHelp EPM software screens and various Machine Interface Units MIUs This class will not get into the specifics of ProStat ProHelp EPM s SPC SQC option or System Administration functions Who should attend New employees current employees who are assigned new ProHelp EPM responsibilities or anyone who wants a basic understanding of the ProHelp EPM system ProHelp EPM System Administration 2 3 Days This course is designed for users who wish to gain a deeper understanding of the ProHelp EPM Production and Process Monitoring system Topics will include a detailed overview of the ProHelp EPM system hardware and software and how they make the system tick how to maxi
173. riate Copyright 1983 2004 3 12 810 0001 Rev C Mattec Corporation The following table lists many of the fields that can be displayed on the Real Time Display and the color coding that is applied to those fields Field s Color Coding Father Job Number Job Number Machine Number Part Number Status Internal MachNo Internal JobSeq Internal FatherJobSeq Down Description Down Description with Elapsed Time Internal DownNo Help HP Help Description Help Start Time Internal HelpNo Process Parameters PLC AIU Indicator Attribute SQC Flag Automatic SPC Flag Manual SPC Flag Variable SQC Flag Hours To Go Total Parts To Go Copyright 1983 2004 Mattec Corporation These fields are green when all process parameters are within the user specified specification limits These fields are red when one or more process parameters are out of specification These fields are yellow when the machine is down These fields are cyan when no job is running and the machine is idle These fields are purple if the MIU is not communicating with the server computer If you can not resolve this situation please contact the Mattec Customer Service Department immediately These fields are yellow if the machine is down otherwise they are cyan These fields are red when a help call is active otherwise they are cyan You can double click on these fields to see additional information regarding the help call and to acknowledge cancel the
174. rmation for the part that will be produced including the material s that will be used the part weight costs etc Part IDs are created via Edit Facilities 4 A Process Sheet must be created A Process Sheet defines the machine specific process limits e g specification limits and control limits that will be used Process Sheets are created via Edit Facilities 5 A Job must be created and scheduled This can be done via the Job Schedule or via the Data Import Export program Reference Section 6 2 for additional information 6 The job must be started and ended This can be done at the MIU or via the host based Job Control program Reference Section 6 10 for additional information Job history data is available in real time while the job is running and after the job is ended Copyright 1983 2004 5 60 810 0001 Rev C Mattec Corporation The System Administrator determines the amount of time that the job history data will be kept on line in the system Advanced Tip 1 Job standards including the user specified specification and control limits are specified in a Process Sheet not in the job descriptor Other standards are specified in the appropriate Part ID Tool ID or Machine ID Advanced Tip 2 Family jobs are comprised of one or more son jobs Each son job has its own Process Sheet that includes user specified specification and control limits When two or more son jobs are running on the same machine the ProHelp EP
175. rmed To include detailed notes about the maintenance activity press the Notes button Modify the Maintenance Notes as appropriate Press OK to temporarily save your changes You will be returned to the Tool Maintenance Log Edit Facility Press Save to save your changes Copyright 1983 2004 5 82 810 0001 Rev C Mattec Corporation 5 8 Enter Scrap And Packed Parts The Scrap and Packed Parts Log in Edit Facilities allows you to enter new scrap or packed parts for any job and to view edit existing scrap or packed parts entries To enter scrap or packed parts for a job follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Scrap and Packed Parts The Scrap and Packed Parts Edit Facility will be displayed E Edit Facilities for Release 6 1 0 Scrap And Packed Parts Ma File View Edit Application Window Help telo JeW r Edit record 01 Machine Number or 1 000 Ton Injection y Job Number cap Lot 419 y Date 6 16 03 gt Shift fi y Machine Number 1 000 Ton Injection Transaction Type All Transactions From 13 1 03 To 3 8 04 Date Henge Transaction Time 11 19 03 11 31 56 AM Scrap Entry trator 1171 01 Packed Quantity Administrator 6 16 Transaction Type Scrap Entry 01 Packed Quant ty Adm
176. rmed via the ProStat Sample Data Edit program or from supported MIUs Advanced Tip 1 An Attribute defect does not necessarily mean that the part is scrap Thus scrap entry and Attribute SQC data entry are separate functions in ProHelp EPM Advanced Tip 2 ProHelp Millennium allows the user to configure Attribute names for each job ProHelp EPM uses the system wide scrap reasons as the Attribute names Advanced Tip 3 Some Attribute Charts p Chart and u Chart need to know the number of parts inspected for each sample in order to perform calculations ProHelp Millennium allows the user to enter this number and to record it with each sample ProHelp EPM does not have this functionality The Sample Size from the Sample Sheet is used by ProStat to represent the number of parts inspected If Attribute SQC data entry is performed from an MIU the user is prompted to enter the number of parts inspected This data is discarded and is not recorded Advanced Tip 4 ProHelp Millennium allows the user to specify U type or P type data entry U attributes measure the number of non conformities per sample P attributes measure the proportion of non conformities in a sample ProHelp EPM s Attribute SQC feature is slightly different than ProHelp Millennium s feature and permits the user to perform both U and P type data analysis on the same job Advanced Tip 5
177. rocess Sheet An identifier that uniquely identifies a Part ID See Total Parts To Go See Correlation Coefficient See Historical Percent Down and Standard Percent Down The percent of machine cycles that are outside of the user specified specification limits The ratio of scrap parts to total parts for a job See Historical Percent Scrap and Standard Percent Scrap See Machine PM Code or Tool PM Code An optional feature that assists in forecasting and tracking machine and tool preventive maintenance A machine value that is automatically monitored by an MIU Process Parameters may include digital inputs analog inputs and PLC inputs A Process Sheet defines the machine specific process limits e g specification limits and control limits that will be used when a job is run on a specific machine Production Efficiency is an obsolete term See Cycle Efficiency 9 196 810 0001 Rev C ProStat R Chart Range Chart R Bar Real Time Display Reduction Method R LCL RocketPort Board R UCL Run Run Time Copyright 1983 2004 Mattec Corporation ProHelp EPM s real time Statistical Process Control Statistical Quality Control program ProStat is designed to assist the user in implementing a program of process control and quality control for all monitored machines See Range Chart A graphical representation of the range of the observations in an SPC or SQC sample Range Ab
178. rt R oci scseasicvciscasscscteaseecarmaversccesbiecesanvcoaatetabenseve sisas 7 146 7 9 1 Chart of Individuals X and Moving Range Chart MRxX ooooooccccoccccnoncnonanccnonncnnn 7 151 7 10 X Bar Chart and Standard Deviation Chart S ccccccccccccccsesesssseceeececeseeserseceeeeess 7 153 TIE Media Chart Sco O 7 157 7 12 Histogram Chart Capability Analysis oooococnnccccnoncccnoncconnncnononnccnnnccnnanocononccnnnnccnnnos 7 161 7 13 Linear Regression Analysis Scatter Diagram oooonocccnoncccnnoccnonancononccnonnncnnnnccnnnnnnnnnos 7 164 TAA Cn Control A ae 7 168 JA PES UE Summary REO di A dd 7 171 TAG Process Exception LOS visitan lira tas 7 174 TA R ealeTime SPC SOC A latins iii AS dE AS bbw AA Cees dins 7 176 TUS Par Oualification aida idea coi 7 177 TIO Abe SOU N er neser O oe PEE Cee PE 7 178 7 19 1 Attribute SOC Chart Op ons rss ra iio 7 179 PAG 2 pr ica ves aad ost ea 7 181 A snag E E E Aisa Ra I 7 182 Copyright 1983 2004 1 2 810 0001 Rev C Mattec Corporation IDA 6 EM EET adas 7 183 TASS M Charten Sh essay Vacate te tneceac ales be nac cats arte by naa ata e Val hs Uren 7 184 7 20 Launching Other Appl cavonscisnc 2st oan stampa ten Gaaitenicdid aan siete ete 7 185 8 Miscellaneous Applications no 8 186 SL Shift Mme Si a e bade aea A a a iS 8 186 8 25 System COn suratin 63 Ta e O T E E es E 8 186 83 temas lt A tone E N a a i S eas 8 186 S Data Import POM voi tias a goats fas Case sass EEEa iSS 8
179. rt ID a Tool ID and a Sample Sheet optional When a job is moved from one machine to another machine via the Job Schedule program it will continue to produce the same part with the same tool but it will necessarily use a different process sheet This allows your Process Engineer s to define different standards e g specification and control limits for jobs depending on which machines the job will run on If a particular machine does not have a Process Sheet defined that would permit that job to run on the machine an error is displayed and the person is prevented from moving the job to that machine This allows your Process Engineer s to define rules that prevent jobs from being scheduled on machines that aren t capable of running the job For ProHelp EPM to monitor production and process information for a specific job several things must occur 1 A Machine ID must exist The System Administrator creates Machine IDs with the assistance of the Mattec Customer Service Department when your system is installed and configured A Machine ID defines the physical characteristics of the MIU that will monitor a machine including the specific process parameters that will be collected 2 A Tool ID must be created A Tool ID defines information for the tool that will be used to create a part including the number of cavities that the tool has Tool IDs are created via Edit Facilities 3 A Part ID must be created A Part ID defines info
180. s exceeded the user specified upper specification limit WHITE White typically indicates that a monitored process parameter has fallen below the user specified lower specification limit YELLOW Yellow typically indicates that the machine is not cycling and is down CYAN Lt Blue A machine number shown in cyan indicates that the machine is idle and no job is currently running on the machine Other fields are shown in cyan to indicate that there is no color coding for this field PURPLE Purple typically indicates that the MIU is not communicating with the Server computer If you can not resolve this situation please contact the Mattec Customer Service Department immediately Machine operators and Shop Foremen should concentrate on keeping all machines in the green Advanced Tip 1 You can double click on many of the fields on the Real Time Display to see additional information about that field This information will generally explain why the field is color coded For example you can double click on a process parameter to see the last 500 chart for that specific parameter You can overlay the user specified specification limits and or control limits on the chart If the process parameter was within the user specified specification limits then the field will be colored green on the Real Time Display If the process parameter was out of specification then the field will be colored red or white on the Real Time Display as approp
181. s will have in common are described in this section To set advanced settings for the Job Schedule follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Click on the Tools menu and select Properties The Properties dialog will be displayed Properties Smart Gaps MS nm Properties Dialog e Press the Rules tab Modify the settings on this tab as desired and press ok to save your changes Copyright O 1983 2004 6 116 810 0001 Rev C Mattec Corporation The following table describes the Schedule Method selections that are available on the Rules tab of the Properties dialog Schedule Method Properties Tab Description Gaps Rules Jobs are scheduled strictly according to the desired date Idle time gaps is allowed between jobs Smart Gaps Rules Jobs are scheduled loosely according to the Default desired date Idle time gaps is allowed between jobs but the Job schedule will prevent a job from being late if idle time is available anywhere preceding the job The late job will push forward jobs that are scheduled before it until no gaps are left or until the job will finish on time No Gaps Rules The next job is started immediately after the previous job Idle time gaps is not permitted between jobs
182. scheduled during that time the new job is inserted immediately before the scheduled job First Available Gap Rules Newly created jobs are inserted into the Job Schedule in the first gap that is large enough to fit the job the Slack Tolerance If no gap is available the job is inserted at the end of the machine schedule Before After Prompt Rules After creating a new job the user is prompted to select the location in the Job Schedule where the job will be inserted The user can choose to insert the job before or after any other job in the Job Schedule Note You can not schedule a job before a job that is currently running Remain Unscheduled Rules Newly created jobs are placed in the Unscheduled Jobs list Advanced Tip 1 Some settings that impact the Job Schedule are configured in System Configuration For example the Scrap Predictor Limit minimizes the impact of the actual scrap percent when calculating a job s forecasted end date The Cycle Time Predictor Limit minimizes the impact of fast or slow average cycle times when calculating a job s forecasted end date Reference the System Administration Manual 810 0014 for additional information Copyright 1983 2004 Mattec Corporation 6 118 810 0001 Rev C 6 9 1 Personal Preference Settings Many settings that affect the Job Schedule can be set based purely on personal preference Those settings are descri
183. se events and this information is available in the Operator Login Report To generate the Operator Login Report follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon e Click on the Planning menu click on the Operator menu and select Operator Login Fill in the report data selection interface as appropriate Press ox The Operator Login Report will be displayed re System Reports for SNUFFY Operator Login Report File Shift Job Planning Application Help Ha 26154270 Ki 4 1of1 ym n Sel joz C J Tota 24 100 24 of 24 Operator Login Report Mattec Corporation Loveland Ohio 45140 Selected Range from 04 10 03 to 04 30 03 All Machines Mach SH Operator ID Logout Time Total Time Depariment Inject Injection Molding 126 123 4114 03 11 38 32 AM 4 14 03 3 00 01 PM 126 456 4114 03 11 39 06 AM 4114 03 3 00 01 PM 126 321 4117 03 8 53 14 AM 4 17 03 3 00 01 PM 126 123 4128 03 10 48 53 AM 4 23 03 3 00 01 PM 126 456 4 28 03 10 49 09 AM 4 28 03 3 00 01 PM Dperator Login Report loaded Operator Login Report Copyright O 1983 2004 4 50 810 0001 Rev C Mattec Corporation Advanced Tip 2 The Operator Login report includes information for all machine operators whether they logged in for Operator Tracking or Operator Efficiency The Operator Efficiency Report includes information only for machine operators who logged in for Operator Efficiency An unlimited
184. solute Value Biggest Obs Smallest Obs The expected Range increases both with sample size and with the standard deviation The average of the Range values An application that shows you the status of all machines at a glance including machines that are running out of specification limits machines that are down and operators who have called for help Data on the display is updated automatically and in real time A technique for reducing raw digital or analog inputs into a monitored process parameter value The Lower Control Limit for Range See Lower Control Limit A smart serial I O board that is often installed in the server computer to improve the MIU communication process and to expand the number of COMM ports that are available for communications The Upper Control Limit for Range See Upper Control Limit A Run indicates that a Trend or a Shift has occurred in SPC or SQC sampling The amount of time for a job when the machine was running and was not down Run Time is automatically accumulated by the MIU 9 197 810 0001 Rev C Runner Weight Sample Sheet Scrap Code Scrap Map Scrap Parts Scrap Predictor Limit Server Computer Setup Time Shift Shift SPC Terminology Shift Change Copyright O 1983 2004 Mattec Corporation The weight of excess material that is consumed during a machine cycle but does not go into the resulting part This value is used in material usage
185. st have appropriate security permissions to view the Part Cost and Material Cost fields Contact the System Administrator for additional information Advanced Tip 4 The Material ID Color ID Part Weight and Percent Regrind fields are used throughout the ProHelp EPM system These fields can be viewed on numerous displays To modify the standard Part Setup Sheet press the Setup Sheet button Modify the Setup Sheet as appropriate Press OK to temporarily save your changes You will be returned to the Part ID Edit Facility Press Save to save your changes Advanced Tip 5 Most MIUs are not capable of viewing the standard Part Setup Sheet Copyright 1983 2004 5 64 810 0001 Rev C Mattec Corporation 5 3 Tool ID A Tool ID defines information for the tool that will be used to create a part including the number of cavities that the tool has The Tool ID Edit Facility is used to maintain and identify all available tools To launch the Tool ID Edit Facility follow these steps e Start the Main Menu and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu and select Tool ID The Tool ID Edit Facility will be displayed FZ Edit Facilities for Release 6 1 0 Tool IDs i File View Edit Application Window Help 12 x all 26448 218 Edit record Current Last Update 5 13 9 44 25 AM Tool Number ma 068 Tota
186. stical Quality Control program It is designed to assist the user in implementing a program of process control and quality control for all monitored machines ProStat allows the user to collect process data and quality data for specified jobs throughout the entire job run ProStat is the tool that is then used to analyze this data by applying statistical methods To launch ProStat follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Jk ProStat SPC SQC ie ES Overview Production Process Alarm x Bar R Chart XBar s Chatt Median Chart Histogram Job Data Machine Number Job Number Part Number Tool Number Customer Status Date Range M Apaes Start Date End Date SPC SOC Data Type Data Type Parameter OK Refresh Options ProStat SPC SQC Copyright 1983 2004 7 127 810 0001 Rev C Mattec Corporation Alternate Methods You can start the ProStat program by right clicking on a machine in the Real Time Display and selecting ProStat SPC SQC The ProStat program will be started with the job number already selected You can start the ProStat program by clicking the ProStat icon in the ProStat Sample Data Edit program The ProStat program will be started with the job number already selected The following table provi
187. t an existing sample press the Edit button To create a new SPC SQC sample press the New button tl ProStat Sample Data Edit for ProHelp EPM File Edit View Application Help mo or A GA rye Winn ES Machine Select a machine y Edit Part Number Job Number F WEY Tool Number Sample E Jai Sample Sheet SEVIGUS ext Sancel Inspector J Edit Mill Weasorenents G Epitharactenstic crass Aud lf rail Status M Weming FGuriPSpeciicaton By Gbservaton Down Part 1 Part 2 Part 3 Part 4 Manual SPC Variable SQC Attribute SOC Ready a en A YY ProStat Sample Data Edit Copyright 1983 2004 7 131 810 0001 Rev C Mattec Corporation Alternate Methods The ProStat Sample Data Edit program can be launched from Edit Facilities To launch ProStat Sample Data Edit from within Edit Facilities click on the Edit menu click on the ProStat SPC SQC menu and select Enter Data Manual SPC samples are initiated at an MIU and the data is automatically collected by the MIU After initiating a Manual SPC sample Variable SQC and Attribute SQC samples can be entered at most MIUs Advanced Tip 1 The ProStat Sample Data Edit program allows the user to modify Manual SPC samples However this data is automatically collected by the MIU when initiated by the user at the MIU and thus changes should only be ma
188. t be disabled For example the Help Call Log the Scrap Entry Log the Downtime Log and the Material Lot Entry Log are always enabled Copyright O 1983 2004 4 55 810 0001 Rev C Mattec Corporation The following table describes the available Log reports Log Report Description Help Call Log This report shows detailed information about every call for help from an MIU Downtime Log This report shows detailed information about every downtime occurrence that was monitored by an MIU Scrap Log This report shows detailed information about every scrap entry that was made anywhere in the system Material Lot This report shows detailed information about all material lot changes related to a job Detailed Operator Log This reports shows detailed information about numerous logs related to a job or a machine Process Exception Log This report shows detailed information about all process exceptions that were recorded by an MIU This log is disabled by default WARNING The Process Exception Log has the potential to grow very rapidly and should only be turned on 1f the data collected will be used The Process Exception Log is intended to be a short term debugging tool and should not be used in place of statistical analysis of data Advanced Tip 2 Process Exception Logging is enabled in the Machine Configuration program When enabled all exceptions to any process parameter are automatically recorded by the sys
189. tails of the Data Import Export program and the DTR Data Export program are available in the Data Exchange Manual 4810 0002 Copyright 1983 2004 8 186 810 0001 Rev C Mattec Corporation 9 Glossary Of Terms Active Cavities Active Components Actual End Actual Start Attribute SQC Audit Trails Automatic SPC Bachelor Job Buffer Box c Chart Calculated Production Cavities Copyright O 1983 2004 Mattec Corporation The number of cavities in a Tool ID that are currently being used to make parts This number affects the number of parts that are produced with each machine cycle and cannot exceed the Total Cavities in the Tool The number of son jobs that will be run simultaneously in a family job The actual end date time for a job The actual start date time for a job The use of statistical techniques to analyze the non conformities i e attributes or defects of a part Audit Trails exist to help users achieve FDA CFR 21 Part 11 Compliance with their ProHelp EPM software by providing logs of changes to existing data in selected areas of the system Audit Trails is an optional feature The use of statistical techniques to analyze machine process parameters that are collected automatically by the MIU A bachelor job is often referred to simply as a job A bachelor job is any job that produces one distinct part and that is not related to any other job A small device that has been design
190. tem Reference the System Administration Manual 4810 0014 for additional information Copyright O 1983 2004 4 56 810 0001 Rev C Mattec Corporation 4 8 Launching Other Applications The System Reports program like the Main Menu can be used to launch most other applications in the system To launch an application using System Reports follow these steps e Start System Reports To do this start the Main Menu and press the Launch System Reports icon The System Reports program will be displayed e Single click the icon on the toolbar that represents the application that you wish to start Advanced Tip 1 To determine which program will be launched when you press an icon on toolbar simply hover the mouse cursor over that icon A tool tip will be displayed Copyright O 1983 2004 4 57 810 0001 Rev C Mattec Corporation 5 Edit Facilities Edit Facilities is a program that allows you to maintain various standards that are needed for ProHelp EPM including the following Create and maintain Tool IDs using the Tool ID Edit Facility Create and maintain Part IDs using the Part ID Edit Facility Create and maintain Sample Sheets using the Sample Sheet Edit Facility Create and maintain Process Sheets using the Process Sheet Edit Facility Additionally Edit Facilities can be used to enter or modify data including the following Enter or modify Variable SQC and Attribute SQC samples and view or modify Ma
191. the number of observations that are grouped together when creating a Chart of Individuals and a Moving Range Chart This value is only used if Moving Range is selected or if the number of observations per sample for the job is one 1 Display user defined control limits R MRx Chart This value controls whether the user entered control limits will be displayed on the chart Control limits for Automatic SPC and Manual SPC are entered in the Process Sheet Control limits for Variable SQC are entered in the Sample Sheet Calculate and display control limits from data R MRx Chart This value causes ProStat to dynamically calculate Range control limits and display them on the chart Display range for each sample R MRx Chart When selected this value will cause the chart to display the Range value for each sample above the sample marker Display point markers R MRx Chart Displays a large marker for each point on the chart This makes it easier to double click on a sample but makes the chart harder to read if you have specified a large number of points visible on chart Display horizontal grid lines R MRx Chart Controls whether horizontal grid lines are displayed on the chart Display vertical grid lines R MRx Chart Controls whether vertical grid lines are displayed on the chart 3 Dimensional R MRx Chart Controls whether the chart is displayed in 2 D
192. ther standards in the ProHelp EPM system A descriptive reason that is selected by the machine operator at the MIU to specify the reason for machine downtime A subset of the system wide Down Codes that are available for use for a particular machine The System Manager specifies a Down Map in the machine configuration program The number of times a machine job went down Time when the machine is not cycling or has been forced down e g for machine setup Downtime is automatically accumulated by the MIU but the Machine Operator must select a valid Down Code for this data to be recorded properly An optional feature that is implemented in the Data Import Export program for the purpose of exporting ProHelp EPM data into DTR s The Manufacturing Manager software See Standard Cycle Time 9 190 810 0001 Rev C Expected Parts Expected Percent Down Expected Percent Scrap Expected Production Family Molding Father Job Forecasted End Forecasted Start Good Parts Good Parts To Go Help Code Help Map Copyright O 1983 2004 Mattec Corporation The expected number of parts to be produced based on standards in the Process Sheet This value is commonly expressed as a component of Yield Efficiency EP Total Time Standard Percent Up 100 Total Cavities Standard Percent Good 100 Standard Cycle Time See Yield Efficiency See Standard Percent Down See Standard Percent Scrap
193. there is no middle number Machine Interface Unit An industrial strength data collection device that has been designed and manufactured by MATTEC that is used to collect production and process information from the manufacturing machine and transmits that data in real time to the server computer An optional feature that adds User ID and password validation to all MIU functions See Tool ID See Server Computer 9 194 810 0001 Rev C Nominal Non Production Limit Normal Distribution np Chart OEE Operator Efficiency Operator Tracking Overall Equipment Effectiveness p Chart Copyright O 1983 2004 Mattec Corporation The target value for a monitored process parameter that is specified in a Process Sheet The non production limit is used by the MIU to determine that the machine is down and is not cycling After a machine cycle the MIU expects to another machine cycle to occur within a certain period of time If the next machine cycle does not occur before the non production limit is reached the machine is determined to be down The non production limit is specified in the Process Sheet A symmetrical bell shaped frequency distribution Histogram Chart A graphical representation of the number of non conforming items defects in an Attribute SQC sample Overall Equipment Effectiveness OEE is a simple way of measuring and improving the utilization of machines in your plant OEE is commonly used in T
194. this son job Desired Start The date time that you desire the job to be started or Desired End ended You can only enter one of these dates Reference Section 6 9 for additional information The following table describes the function of some of the buttons that are available on the Component tab of the Job Descriptor dialog Component Tab Button Description Add New This button allows you to add a new son job to the family job You must then fill in all of the fields on the display as appropriate Add Copy This button allows you to add a copy of the son job that is currently displayed The son job s name will be modified as configured in the Copy setting on the Properties dialog Reference Section 6 9 1 for additional information Delete This button allows you to delete the son job that is currently displayed Adopt This button allows you to adopt an existing bachelor job into the family job The bachelor job then becomes a son job Orphan This button orphans the son job that is currently displayed The son job will be removed from the family job and becomes a bachelor job Advanced Tip 4 If you double click on a scheduled family job in the Job Schedule you will notice that the Job Descriptor dialog has three 3 tabs labeled Family Component and Schedule The Schedule tab is the Gantt In Gantt Job Schedule and allows you to see a Ga
195. time CAP Lot 419 Other 10 2 80 WATER 6 47 PMMLD 24 99 MACHPROB 65 75 Refresh Options Print Job Downtime Pie Chart Copyright O 1983 2004 7 139 810 0001 Rev C Mattec Corporation Alternate Methods The Downtime Pie Chart is available in the Real Time Display program This allows you to easily view the chart for running jobs The Downtime Pie Chart will not refresh automatically and will only be refreshed when the user presses the Refresh button Itis safe to press the Refresh button at any time You can optionally display run time along with downtime You may want to disable the display of run time if the percentage of downtime is very low and thus the display would show mostly run time This is specified on the Options dialog You control the number of slices that will be displayed in the pie When more downtime reasons exist than there are slices to the pie the smallest downtime reasons are accumulated and displayed in the last slice of the pie The number of downtime reasons that were accumulated into that last slice of the pie is displayed in parenthesis By controlling the number of slices in the pie you can minimize the visual impact of having a lot of downtime reasons that have very little downtime accumulated This is specified on the Options dialog You can display the chart as a doughnut chart and display the chart in 2 Dimensions or 3 Dimensions These settings are specified on
196. time dialog will be displayed Reclassify Downtime x Detail Machine Number Job Number CAP Lot A19 Down Code Po Downtime Reason WATER waterLeak y Downtime faro Down Count fi Help Use this display to move down time down counts or both from one downtime reason to another You are not required to move all of the time count and may move only a subset if desired Cancel Reclassify Downtime Dialog e Select the new Downtime Reason from the picklist All downtime reasons that exist in the Down Map for this machine will be displayed You can reclassify all of the downtime and all down counts downtime occurrences that are associated with the original downtime reason or only a subset of the downtime and or down counts Make your changes as appropriate Press Save Advanced Tip 1 Reclassifying downtime via the Reclassify button is a normal operation that can be safely performed at any time Editing downtime via the Edit button is a non standard operation and should be avoided unless absolutely necessary Editing downtime can cause inconsistent data throughout the system and may negatively affect reports Copyright 1983 2004 5 89 810 0001 Rev C Mattec Corporation Advanced Tip 2 The downtime reasons that are displayed in the Reclassify Downtime dialog are chosen from the Advanced Down Map or the Simple Down Map but not both The map that is used by the MIU
197. tion 3 5 Downtime Pie Chart The Downtime Pie Chart displays the downtime that has been accumulated for the job It quickly identifies the most significant causes of machine downtime and helps you to focus your attention on resolving those problems To generate a Downtime Pie Chart for a running job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired job and select Downtime Pie Chart The Downtime Pie Chart will be displayed Job Downtime Chart x Machine Number inJ 01 1 000 Ton Injection y Job Number fio 12345 y Job Downtime J01 Other 10 2 17 MACHPROB 41 33 Run Time 56 50 Refresh Options Print Job Downtime Pie Chart Copyright O 1983 2004 3 23 810 0001 Rev C Mattec Corporation Alternate Methods You can start the Downtime Pie Chart by double clicking on downtime related fields on the Real Time display including the Downtime Weighted Downtime Down Occurrences Weighted Down Occurrences and Percent Down fields The Downtime Pie Chart is available in the ProStat program This allows you to view the chart for jobs that have been ended The Downtime Pie Chart updates automatically and in real time The refresh rate is specified on the Options dialog If the refresh rate is O the display will not refresh automatically and will only be refreshed when the user presses the
198. tion Manual 4810 0014 for additional information Copyright O 1983 2004 7 175 810 0001 Rev C Mattec Corporation 7 17 Real Time SPC SQC Alarms ProHelp EPM is a very powerful tool that is capable of alerting you to process parameter problems and part quality problems before these problems occur This allows you to take steps to adjust the machine before you start making scrap parts Definitions Run A Run indicates that a Trend or a Shift has occurred in SPC or SQC sampling Shift A Shift indicates that the last n consecutive SPC or SQC samples where n equals the Number of Samples Per Run from System Configuration were above the upper control limit or below the lower control limit A Shift may indicate that a fundamental change has occurred to the machine Trend A Trend indicates that the last n consecutive SPC or SQC samples where n equals the Number of Samples Per Run from System Configuration were all increasing or all decreasing A Trend may indicate that the machine will soon be exceeding the job s specification limits and may be about to start producing bad parts When a Run Shift or Trend is detected by the MIU an alarm condition is displayed on the MIU s SPC SQC Results screen This can be used to alert the machine operator or quality control personnel that a change needs to be made to the machine before scrap parts are produced The status of the last SP
199. to show only those characteristics that are valid with the selected Independent Characteristic e Press ox If you have selected only one Dependent Characteristic the Scatter Diagram will be displayed If you have selected multiple Dependent Characteristics i e All Parameters a spreadsheet will be displayed listing relevant information for each Dependent Characteristic Double click on any row in the spreadsheet to see the Scatter Diagram for that Dependent Characteristic Linear Regression Analysis x 17 60 924 4 400 241 748 0 000 0 000 0 000 y 4 400 0 000 10 102 140 8 680 315 137 4 546 0 498 1 575 y 9 414 0 007 Linear Regression Analysis Results for Multiple Dependent Characteristics Advanced Tip 1 If you are performing linear regression analysis for more than one dependent characteristic you will see the results of the analysis in a spreadsheet see above Double click on any row in the spreadsheet to see the corresponding Scatter Diagram Alternately you can highlight the row in the spreadsheet that is of interest then press the Select button The Scatter Diagram will be displayed Copyright 1983 2004 7 165 810 0001 Rev C Mattec Corporation Linear Regression Chart Independent Characteristic Dependent Characteristic Number of Points x Bar Y Bar X Sigma Y Sigma Correlation Coefficient Significance Estimated Y GAP DIM A GAP DIM B
200. trol limits lower nominal and upper for Variable SQC Characteristics are specified on this page Advanced Tip 3 Web based Setup Sheets is an optional feature You may purchase this feature at any time by contacting the Mattec Sales Department To add a Variable characteristic to the Sample Sheet press the Specification tab Press the Add Variable button Enter the name of the Variable characteristic in the Prompt field Check the MIU Entry checkbox to permit data for this Variable characteristic to be entered at an MIU If this checkbox is disabled data entry for this characteristic will only be permitted at a computer terminal Enter appropriate specification limits for the Variable characteristic You may enter to 32 Variable Characteristics Press the Control tab Enter appropriate control limits for each Variable characteristic that has been entered ProStat can calculate appropriate control limits based on the actual sample data that has been entered Reference Section 7 14 for additional information Copyright 1983 2004 5 71 810 0001 Rev C Mattec Corporation Advanced Tip 4 If you have the ProStat SPC SQC option Automatic SPC sampling is always enabled for all jobs Advanced Tip 5 A Sample Sheet is used to enable Manual SPC Variable SQC and Attribute SQC sampling Advanced Tip 6 The System Administrator defines the process parameters that are associated with Manu
201. troubleshooting of PC boards will not be covered Who should attend Maintenance technicians Those users who are responsible for the hands on analog calibration and overall system hardware maintenance troubleshooting Copyright 1983 2004 1 8 810 0001 Rev C Mattec Corporation 2 Main Menu The Main Menu is used to launch most other applications in the system To launch an application using the Main Menu program follow these steps e Start the Main Menu To do this click on the Microsoft Windows Start Menu Click on the Programs menu click on the Mattec menu and select ProHelp EPM The Main Menu will be displayed e Single click the icon that represents the application that you wish to start ProHelp8 EPM A E Copyright 1983 2004 MATTEC Corporation Wersion 6 1 0 2 The Main Menu Advanced Tip 1 To determine which program will be launched when you press an icon on the Main Menu simply hover the mouse cursor over that icon A tool tip will be displayed Advanced Tip 2 If you have two or more facilities that each have their own ProHelp EPM system the System Manager can configure your PC to connect to each facility After this has been done the Main Menu will display a prompt asking you to select which facility to connect to whenever the program is started Configuring a PC to connect to multiple facilities is generally a simple process that can take less than 5 minutes Contact t
202. ts or cases Alternate Methods Users can enter scrap parts or cases and packed parts or cases for the current shift at the MIU Users can enter scrap parts and packed parts for the current shift or any prior shift via Edit Facilities Reference Section 5 8 for additional information To enter scrap parts or cases for a running job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired job and select Enter Scrap Parts The Scrap Parts Entry dialog will be displayed Scrap Parts Entry x Job Data Machine Number INJ 01 Job Number 01 Scrap Parts Entry Scrap Reason ASTAT Anti Stat Test y eee 5 Parts C Cases A Cancel Scrap Parts Entry Dialog e Enter the scrap part quantity and press Apply Copyright 1983 2004 3 28 810 0001 Rev C Mattec Corporation To enter packed parts or cases for a running job follow these steps e Start the Real Time Display To do this start the Main Menu and press the Launch Real Time Display icon e Right click on the desired job and select Enter Packed Parts The Packed Parts Entry dialog will be displayed Packed Parts Entry xi Job Data Machine Number INJ D1 Job Number J01 m Packed Parts Entry Packed fio s iu a Packed Parts Entry e Enter the packed part quantity and press Apply Advanced Tip
203. ts in an Attribute SQC sample Compatibility np Charts are only available for Attribute SQC data They are not available for Automatic SPC Manual SPC or Variable SQC data To display the np Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 Select Attribute Soc in the Data Type field e Press the np Chart tab The np Chart will be displayed Ak ProStat SPC SQC 198 84 8 hey ON Attribute SQC np Chart Copyright O 1983 2004 7 182 810 0001 Rev C Mattec Corporation 7 19 4 c Chart A c Chart measures the total number of non conformities defects in an Attribute SQC sample Compatibility c Charts are only available for Attribute SQC data They are not available for Automatic SPC Manual SPC or Variable SQC data To display the c Chart follow these steps e Start the Main Menu and press the Launch ProState icon The ProStat program will be displayed Select the appropriate job as described in Section 7 3 Select Attribute Soc in the Data Type field e Press the c Chart tab The c Chart will be displayed Ak ProStat SPC SQC Attribute SQC c Chart Copyright 1983 2004 7 183 810 0001 Rev C Mattec Corporation 7 19 5 u Chart A u Chart measures the average number of non conformities defects in an Attribute SQC sample Compatibi
204. u and press the Launch Edit Facilities icon The Edit Facilities program will be displayed e Click on the Edit menu click on the Logs menu and select Machine Maintenance Log The select Machine Maintenance Log Edit Facility Will be displayed E Edit Facilities for Release 6 1 0 Machine Maintenance Logs Ma File View Edit Application Window Help le x tolo g Log Entries Machines 01 1 000 Ton Inje y Maintenance Codes All Codes From 3 1 03 Set Wate Henge 01 LEAKS 01 GREAS 6 10 01 GREAS 9 1 01 MAGN 01 FILL Machine Mainte r Edit record Run Time a cd Cycles EVs Employee ID Notes Maintenance Description Reason Time Logged Machine Number Maintenance Code Time Required minutes Save Cancel Print 134 hours 16526 cycles Administrator Misc Mech Explain fi 2 Machine Maintenance Log Edit Facility e To edit an existing machine maintenance entry locate the desired entry using the selection facilities on the left hand side of the display Press the Edit button Modify the machine maintenance entry as appropriate Press Save to save your changes Copyright 1983 2004 Mattec Corporation 5 79 810 0001 Rev C e To create a new machine maintenance entry press the New button Select an existing Machine Number and Maintenance Code Select the appropriate Run
205. v C Mattec Corporation 6 8 Unscheduled Jobs List The Unscheduled Jobs list is a convenient way to view all of the jobs that are available to be run but that have not been placed in the Job Schedule To view the Scheduled Jobs list follow these steps e Start the Job Schedule To do this start the Main Menu and press the Launch Job Schedule icon Select the Machine s that you wish to modify Press ok The Job Schedule program will be displayed e Click on the Tools menu and select Unscheduled Jobs The Unscheduled Jobs list will be displayed Scheduled Unscheduled Machine Number Al y a E NA a E 30289 90 DEL22078 2 51 000 07 13 2003 19 57 ao Mick 100P Mick 100p 256 000 09 21 2003 23 27 35571 1 BERTXx81619 Tx lt 81620 30 000 01 02 2005 20 56 B 0891 BERTX81619 15 000 03 07 2003 00 51 31512 34 LUK118795108 5 3 650 05 04 2003 18 42 31512 35 LUK118795108 5 4 800 05 05 2003 18 37 32619 51 VAL24022503 5 4 500 10 21 2002 17 06 32619 52 VAL24022503 5 13 200 10 28 2002 13 25 32619 53 VAL24022503 5 13 200 06 01 2003 12 16 32619 54 VAL24022503 5 13 200 06 01 2003 03 40 32619 55 VAL24022503 5 12 000 11 18 2002 13 47 32619 56 VAL24022503 5 13 200 11 25 2002 13 25 30760 42 LUK118795201 5 50 000 01 01 1980 11 58 500141 5011903114 18 000 06 01 2003 15 35 500195 5011823240141 50 000 07 18 2002 03 40 500211 5011854610139 24 000 08 19 2002 04 50 Unscheduled Jobs List Alternate Methods You can launch the Unscheduled Jobs list by pressi
206. y will be displayed e To start the Job Control program right click on a machine and select Job Control The Job Control program will be started with the machine number already selected e To start the Prostate program right click on a machine and select Prostate The ProStat program will be started with the machine number and job number already selected Advanced Tip 2 When you launch the ProStat program via the Real Time Display the ProStat program defaults to select All Dates for the specified Machine Number and Job Number and the program defaults to the Data Type Automatic SPC and the Parameter Cycle Time Copyright O 1983 2004 3 37 810 0001 Rev C Mattec Corporation 4 Reports ProHelp EPM provides more than 50 built in reports New users should plan to spend some time executing each of the reports in the system in order to familiarize themselves with the reports Advanced Tip 1 Mattec Corporation can write custom reports for you These reports can then be easily integrated into your system Contact the Mattec Customer Service Department for additional information Advanced Tip 2 Advanced users can create their own custom reports using an approved version of Seagate s Crystal Reports These reports can then be easily integrated into your system Contact the Mattec Customer Service Department for additional information or training To start System Reports follow these steps e Start the Main Menu

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