Production Intelligence Prod-IQ.basics - Siempelkamp

Maschinen- und Anlagenbau
Production Intelligence
Increased profitability by intelligent MES and Industrial IT
Prod-IQ.basics

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Reduction of the manufacturing costs
Prod-IQ® is a production ma-
nagement system tailored to the
specific requirements of the
derived timber products industry.
Conceived for production management,
quality assurance,
servicing and maintenance, it is
based on a wide range of
modules which have been
developed in close collaboration
with users in the timber industry.
The benefits are diverse, ranging
from improved cost transparency
and resource savings to increased
plant availability and reduced
production costs. Prod-IQ® is a
modern tool which enables
improvements in productivity to be
achieved systematically. This
safeguards the market position of
the operating company and offers
flexibility for future investments.
Basic principle
Prod-IQ® is divided into the separate
areas of Prod-IQ.basics,
Prod-IQ.business, Prod-IQ.quality
and Prod-IQ.maintenance.
Prod-IQ.basics features basic
modules such as data acquisition
and important evaluation tools, for
example. Downtime statistics and
the commission report are
included among the latter.
Prod-IQ.business features modules
which provide a high level
of transparency in the costs of
the production and business
processes. This enables evaluations
for products and commissions
with respect to pro-
duction costs, consumption,
reject rates and quality.
Prod-IQ.quality is a comprehensive
system for the online
quality forecasting of critical
board parameters such as
internal bond, bending strength,
thickness swelling and surface
soundness. From experience,
this permits savings on material
of more than 2.5% to be
achieved, with no loss of quality.
Prod-IQ.maintenance features
modules for the organization
and optimization of the maintenance
of all units in a plant.
This enables reduction of servicing
and maintenance costs
and increases plant availability
at the same time.

More transparency through characteristics (KPI)
The rapid availability of relevant
information results in more
transparency and the ability to
compare various locations, production
lines and commissions.
The number of boards produced,
their quality levels, manufacturing
costs, downtimes
and reject rates and their breakdown
according to individual
products are the basis for an
evaluation of efficiency within
the company. The availability
data provides at-a-glance information
about the machine's production
times and downtimes,
with the evaluations being generated
at separately adjustable
times. Thanks to online data
acquisition they are also
always up-to-date.
In sharp contrast to
manually generated
reports, these reports
save huge amounts of
time and contain considerably
fewer errors.
These characteristics thus form an
excellent basis for improving the
performance of a production line.
Increased efficiency
These characteristics can be
used to define clear-cut targets,
while the data from the Siempelkamp
Prod-IQ®-System provide
reference points for improvements.
The thorough examination
of the trending data or
the data from the laboratory
section acquisition, for example,
shows up the possible causes
for poor quality production and
rejects, or the comparison of two
commissions produces different
consumption data for the same
product. From this, measures for
improvement can be derived.
The success of these measures
is registered directly by
Prod-IQ®.
Improving plant availability
The systematic downtime analysis
has the objective to identify
preventable failures and their
causes. The standstill times are
automatically logged, and simplified
statements are assigned
to every downtime by the operator.
With the help of the
downtime statistics data is evaluated
using tabular overviews and
bar diagrams. The downtime
causes can be derived directly
from the operators' statements or
by retrospectively evaluating the
plant situations when the standstill
occurred. For this purpose all
stored process data is available.
If the cause is known appurtenant
counter measures can be
initiated, and their effectiveness
can immediately be monitored as
well with Prod-IQ.basics.
Installation and system
maintenance
Prod-IQ® is a modern production
management system that is
configured to suit the specific
conditions in a plant. The system
is supplied as a complete system
and handed over to the customer
completely installed. The only
maintenance work that needs to
be carried out by the operating
company is data maintenance.
Other administrative activities are
not required. This means that
programming knowledge is not
necessary.
Operation is simple and intuitive.
The personnel are trained
directly after start-up of the
system or an agreement can be
made for separate training.
Other modules can be obtained
directly through Siempelkamp.
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Prod-IQ.basics
An integral part of new Siempelkamp ContiRoll ® plants
Prod-IQ.basics is a complete
packet consisting of hardware,
software and the associated
engineering.
The production process for raw
board manufacturing is documented
in reports. This includes
the display of the current plant
efficiency and the traceability of
production situations.
The individual modules are
configured to display only the
data of interest to the target
process network OPC
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data base
Data acquisition
The cyclical acquisition of process
data lays the foundation for all other
functions. The data available on the
process network is acquired using
the open and standardized soft-
audience. Management, plant
managers and operators, quality
assurance, production planning
and process technologists all
Operator
Technologist
ware interface OPC. Depending on
their use, the process values
acquired for each parameter is
time stamped and stored either
permanently, or as a mean,
minimum, maximum or even an
event value in a database. All
Prod-IQ® modules utilize this
process image. This enables
prompt online evaluations and
historical reports over specified
periods.
Management
Rapid,
relevant
Information
Production Planning
receive the information that they
require in real time and tailored to
their individual needs.
Plant
Manager
Quality
Assurance
Acquisition and statistics
of downtimes
The integrated acquisition and
statistics of downtimes provides
comprehensive information that
can be used for continual plant
optimization. The reason for any
one downtime can be conveniently
selected from a predefined
range of standard downtime
reasons, on a plant- or
machine-specific basis.
The durations and reasons for
the downtimes held in the downtime
acquisition are grouped,
ordered and evaluated in downtime
statistics and the total
durations and frequencies of
certain downtimes are presented
in a bar chart.

Trending
The trending module displays
and monitors all process data
online according to configurable
time lines. Trends are detected
at an early stage when viewing
the complete process. By
querying historical data from the
central database, evaluations
can be made over any time
period and cross-referenced to
quality data and process
The material flow tracking integrated
in the Prod-IQ.basics
assigns the process data to the
final product or the laboratory
section according to time i.e.
taking into account plant speeds,
bunker filling levels and transport
paths. This allows the manufac-
variables (historical trending).
The configuration of trend
windows is easy and flexible,
with critical process parameters
presented clearly,
according to importance and
cross-referenced to relevant
data.
Material flow tracking / Laboratory report Commission evaluation
turing history of the laboratory
section to be accurately documented
and the laboratory results
are then added to this data set at
a later stage.The direct relationships
between the process
settings and the quality can thus
be recognized.
Furthermore, board
parameters such as
internal bond, bending
strength, thickness
swelling and surface
soundness can be
continually forecast
with the help of the
Prod-IQ.quality option
module.
The commission evaluation
includes the most important data
- such as board type, amount
produced, production times and
down-times, raw material consumption,
etc. - for each commission.
Once the commission is
completed, this data is
immediately available in a clear
report. Production times, reject
figures and material consumption
are used to produce a quick
technical and commercial evaluation
of the order. With the help
of the trending or downtime
statistics integrated into the
Prod-IQ.basics, more in-depth
analyses can be made for
improving the process.
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The process data is registered
directly via an OPC interface
from the controls of the
individual plant components.
ERP System (Customer)
Prod-IQ.basics
Operation &
Observation
Open and
Closed-Loop
Control
Windows network
Prod-IQ.basics is an integral
part of new ContiRoll ® plants
and is activated during plant
Project planning
Typical Project Flow / Timeline
The Prod-IQ.basics hardware
consists of industrial PCs with
interface
exchange.
cards for data
process network
(TCP/IP)
commissioning.
The plant personnel are trained
either directly after commis-
* Commissioning: Acquisition of data and downtimes, trending, commission report, laboratory report
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Technical implementation
VISU
The progress of a project
Benefit
Spare place for other
visualization stations
(e.g. for Prod-IQ.quality)
Commiss.*
Data
acquisition
We recommend that you set up
the PC system for operating and
displaying in the control room.
Server
Ein-
VISU VISU gabe VISU VISU VISU
PLC PLC PLC
sioning of the system or an
agreement can be made for
separate training.
Training/
Consulting
Optional interfaces
e.g. SAP
approx. two weeks after the first board deadline
Press control

Options
Prod-IQ.basics - future extensions made easy
Thanks to the modular structure
of Prod-IQ®, individual functions
can be put together to meet
specific customer requirements.
This has the advantage that the
Ordermodul raw
boards
Orderlist, -management
and feedback of
production data to ERP
Cost trending
Calculation of production
costs based
on current settings
Laboratory
interface
Interface to laboratory
based on Comma-separated
files (csv-files)
... for other plant areas
Sanding line modul
- Data-/Downtimeaquisition,
-analysis
- Commission-, Shift-,
Day- and Month-reports
Ordermodul sanding
line
Orderlist, -management and
feedback of prod. data to ERP
... others
system can be fine-tuned in
accordance with key tasks. The
priority of the tasks is generally
defined on the basis of the
specific commercial or income
Prod-IQ.basics
Data acquisition
Acquisition of process data
and their central storage in a
database.
Material flow tracking
Lab report with process
values according to the
material flow.
Downtime acquisition /
statistics
Module for systematic identification
of downtimes and
their causes.
Commission
evaluation
Summary of the most important
production and consumption
data.
Availability
Calculation of availability for
selectable days.
Trending
(online + historical)
All process data in a time
line diagram for monitoring
the process.
...prepared for options and
additional software packages
situation of the operating
company. Prod-IQ® therefore
allows great flexibility and can
be quickly adapted to individual
needs.
Prod-IQ.business
PROMACS
- Shift management
- Shift, daily and monthly
reports (incl. WEB and
data export)
- Panel type evaluation
with specs /
adjustments
Prod-IQ.quality
SPOC
- Technology support
- Modelling
- Online quality forecast
and control
(incl. Hardware)
Prod-IQ.maintenance
PLM
- Plant tree
- Time related maintenance
- Condition based maintenance
- History
- Feedback (planned /
unplanned)
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