Finally, a Windows based production monitoring system that is easy to use and affordable
The Abacus production monitoring / data collection system for repetitive cycle manufacturing (injection molding, blow molding, stamping, etc.) has been created to provide the real time data organizations need to manage their operations, with a modest investment of time and money. Features include:
With a production monitoring / data collection system you will have answers to questions like: what is the true cycle time of a job, what happened last night on the third shift, and is either a malfunctioning machine or slow operators increasing cycle time? Shift supervisors can use the real time display to see and fix problems before they affect production. The end of shift and end of job reports give management the data they need to verify the profitability of jobs and track the performance of different shifts and machines. With the hectic pace of manufacturing, keeping up with the status of all the jobs in a facility can be challenging. With the Abacus, enter the number of parts required for a job and the real time display will indicate when the job has finished, reducing overrun. We have seen customers significantly increase production and save money by identifying and correcting the problems in their operation!
EASY TO USE
The Abacus production monitoring system is designed to be the easiest to use data collection system on the market. All actual data (actual cycles, actual cycle time, run time and last cycle time) is displayed, printed and logged automatically with no user intervention required. To track a wealth of other data, an easy to use job control screen allows you to enter job standards and requirements. Our philosophy is simple -- we understand you have plenty to do already, so we have designed a system you can use without days of classes or hours of reading user manuals.
Many production monitoring / data collection systems can have considerable errors in the data they produce for two simple reasons: all data is acquired by monitoring a single contact closure and one central computer monitors all the machines. The Abacus provides extremely accurate data by monitoring separate run and cycle signals with a small computer at each machine or process.
The problem with monitoring a single contact closure is that production will be counted when the machine is in Manual mode and the signal connected to the monitoring system is active. For example, if the injection forward signal on an injection molding machine is used as a cycle signal, production will be counted when maintenance or production personnel are purging the barrel, leading to errors in production counts and average cycle times -- two of the most important types of data collected by a monitoring system. Another problem with a single contact closure system is that the run time is determined by falling out of production after not sensing a cycle for a period of time. Every time the machine is stopped this timeout delay is added to the run time clock -- further corrupting the run time and average cycle time data. The Abacus production monitoring system solves these problems by adding a run signal that gates the cycle signal and the run time clock. With a gate on the cycle signal, production is only counted when the machine is in Auto or Semi-Auto mode, not when in Manual mode. With a run signal controlling the run time time clock, the timeout error is eliminated.
By recording data with a small computer at the machine, no data is lost if the main host computer is off-line temporarily. In fact, the only time the host computer needs to be on-line is at the end of shifts, and when starting or stopping jobs. With other production monitoring systems that collect all data at the host, if the host goes down (someone knocked the power cord out when walking by for example) no production is recorded until the host is put back on-line.
The cost of implementing a production monitoring / data collection system is often a major issue. Most systems are very expensive and include many features that most operations will never use. These unused functions tend to make the systems expensive and difficult to use, and further increases costs because of needed training. Competing low cost production monitoring systems may look inexpensive on the surface, but very often they utilize an inefficient wiring system, usually referred to as the star configuration, which greatly increases wiring and installation costs by requiring a separate wire to be run from the host out to every machine. The Abacus production monitoring system runs on a daisy chain network allowing up to 200 machines to be monitored with one wire, greatly reducing wiring and installation costs. The combination of single wire monitoring and minimal training requirements keep the true cost of ownership for the Abacus production monitoring system low.
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