Production systems integration (ERP, MES, PLC) and orders tracking

Solution description

A common problem in manufacturing is reporting. If the company is already using Vorne XL then reports, charts, tables, metrics are available through a web browser and any authorized employee can access this data in real time. It is possible to see production data on an ongoing basis or over a selected time range and generate this data as an Excel or PDF file. At this point, another problem arises, as often the collected production data needs to be entered into another system e.g., ERP. Entering this data usually involves manual transcription from Excel to the ERP/MES system, which often leads to mistakes and discrepancies between the data in the system and the actual state.

Vorne XL software manufacturer Vorne Industries has developed additional applications that can provide communication between the Vorne system and other database systems used by manufacturing companies:

1. API application - built-in functionality that allows simple data capture from external systems, based on the JSON language,
2. DataLink - application for real-time communication with external systems, PLCs and external systems such as MES/ERP. Allows data exchange in dynamic mode, based on C#,
3. Data Collector - an application for communication and storing data collected with the Vorne XL board in an external database,
4. OPC Server - an application for communication between XL810 boards and PLCs.

Vorne XL board has a built-in SQL Server database which allows very flexible possibilities to create communication between different systems, even with proprietary applications, created by company employees.

With the help of these tools and services provided by TQMsoft, you can create communications that will provide automatic:

1. Downloading information from the ERP system:
   1. list of products/references
   2. cycle time for a given reference
   3. list of production orders
   4. list of causes of machine downtime
2. Summary of the execution of the production order or on the fly completion of the order:
   1. production quantities in pcs, kg, meters, etc.
   2. Number of defective pieces
   3. Time of execution and % efficiency of order execution
3. Generation of labels for given production batches
4. Generation of a report for accounting/finance with time billing of the order

INTEGRATION TOOLS

OVERVIEW

A great way to use XL and streamline operations is to integrate it with other manufacturing systems.

Vorne XL is designed to work with almost any PLC, MES, ERP system. Integration of XL with any process is possible through an API or with our integration solutions.

Our integration partners will help you integrate XL quickly by combining extremely deep XL knowledge with standard software tools and custom integration services. They typically help with the following tasks:

• Importing XL data into existing reporting systems.
• Advanced data analysis across the enterprise.
• Linking XL to a production planning system.
• Linking XL with PLCs to automate data capture.

ENTERPRISE DATABASE

Using the data collection module, data from multiple XL devices can be automatically stored in a SQL database on a server.

• Archive production data in the SQL database.
• Eliminate manual reporting, integrating it with existing solutions
• Operating "behind the scenes" as a simple automated window service.

INTEGRATION WITH ERP

Using ERP Data Link, establish a direct connection between ERP and XL systems to transfer task information from ERP to XL and transfer production data from XL back to ERP.

• ERP knows your plan: Export production standards to XL.
• Vorne XL knows what you produce: import production data from XL into your ERP.

PLC CONTROLLER INTEGRATION

The Data Link tool transfers data from the PLC to Vorne XL systems on the shop floor. No programming required! Just browse through the tags and select various options to transfer data in real time.

• Reduce the need for manual barcode scanning by sending information from the PLC to the XL.
• Automatically activate failure causes or trigger different input data to eliminate manual data collection.
• Send other information (numeric or alphanumeric) from the PLC to the XL.

CUSTOM MESSAGES XL

Using PiXL software, create graphics and images on your computer for display in Vorne XL on demand or based on a specific metric.

• Create custom messages, such as "Great Job Team," or graphics, such as your company logo.
• Activate these graphics based on a specific metric - for example, display Great Job Team when a crew defeats a shift goal.

Some of the descriptions and graphic materials are from https://www.vorne.com/.