TOMAI Factory System

is a powerful data acquisition and analysing tool for production environment. It allows complex analysis of the production process performance, allow for clear identification of potential improvment points and support decision making using customizable reporting tool.

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TOMAI Factory System

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The term smart factory almost always appears in studies concerning the concept of the fourth industrial revolution – Industry 4.0. Manufacturing innovations, new business processes and advanced information technologies create a range of previously unknown opportunities. It can be said that a factory in the SMART version is basically two factories – one physical, i.e. specific machines, infrastructure, etc. The second is digital (digital twin), i.e. a reflection of the physical one in data defining the state of the process and its individual components. Of course, digital twin also needs a specific IT infrastructure based on its own hardware resources or cloud solutions plus software. The software seems to be the key factor in the effective use of the potential of the huge data stream that is obtained in this concept of the factory operation.

TOMAI Factory System is a system implemented many times and constantly developed (continuous development) based on the “digital twin” paradigm. It consists of two modular applications: Monitoring and Web. The heart of the system is the Monitoring application, providing a rich set of functionalities, gathered in four modules.

SYSTEM INTEGRATION

Support for most PLCs
Custom protocols
Dedicated local DB
MES, MRP, ERP integrations
IoT / Cloud options

DATA ACQUISITION

Production data
Cycles and processes data
Operators work and downtimes
Global parameters values
Alarms and events

TRACEABILITY

Materials traceability
Real-time tracking
Fulll component history
Component traceability
Serialization

HISTORY ANALYSIS

Reference changes tracking
Events log
Production summary
Status pareto analysis
Parameters graphs

KPI MONITORING

Operators efectivity
Average working times
Time records
Optimization
Line adaptation

PRODUCTION SUPERVISION

Current line state preview
Detailed measurement data
Stats and reports
BOM tracking
Quick graphical info

MEDIA MONITORING

Media history preview
Media status reports

QUALITY ASSURANCE

Good manufacturing practises support (GMP)
Components full history
Easy recognition of quality issues

MAINTENANCE / CMMS

Performance analysis
Failure analysis
Causes identification
Downtimes, jams, delays
Predictive maintenance

USEFULL REPORTING

Reports history
Summaries, analysis, logs
CSV export
Great possibilities of adjusting reports to the client needs

WEB APP

Access to current and historical data from anywhere in the world
Configuration module
Reporting module

MULTISYSTEM

Any OS
Any webrowser
PC, IPC, HMI
Customization options

Data collection module provides flexible possibilities of integration with other customer systems, both when it comes to sending data influencing production as well as receiving production data. By means of connections with basically any PLC controllers (Siemens, Mitsubishi, Omron, Allen-Bradley, Beckhoff, etc.) or other systems, the module collects information about: production, cycles, processes, operator’s work, downtime, parameter values global, alarms and media consumption. Suchdata can be used for immediate analysis and can be stored in a local MSSQL database. The module provides monitoring and centralized management of production recipes (e.g. their comparison or synchronization). It also enables user authorization management, e.g. by logging in with RFID cards.

The module for viewing the current state of the line gives the possibility to track production in real time with details on measurement data, pending alarms, etc., and to create statistics and reports. You can follow the history of the currently produced part and its BOM. The summary view on the production line allows you to obtain quick graphical information on alarms and the production status at individual stations / units / modules.

The diagnostic and historical data analysis module provides a variety of reporting possibilities. The option of convenient personalization of reports and adapting the functionality to the specific needs of the client. The main task of this module is to facilitate the understanding of incoming data:

chart with parameter values in numerical over time
view of reference parameters changed by user
full production history for specific part
preview of individual parameters for selected stations
summary of work time, station downtime and event log
pareto status per station or day
production summary by pallet / slot number
report of global parameters, station status reports
view of history and analysis of media by status
data export (CSV)
predictive maintenance

The line efficiency and failure rate analysis module is a tool for comprehensive production analysis through the relationship between alarms on production modules, identifying bottlenecks, the most frequent causes of downtime, delays, jams or determining the sum of line delays broken down into different causes.

The additional KPI module for an operator’s work analysis helps determine the efficiency of an operator’s work, their average working times, records and provides valuable information to production engineers. The KPI module is implemented on new production lines at the customer’s request and adapted to specific requirements.

Thanks to the Web application, it is always possible to access current and historical data from anywhere in the company or anywhere in the world, any browser, any operating system. A configuration module and a reporting module are available.

TOMAI Factory System users appreciate its numerous functionalities, which are available by default without hidden costs, and professional expert support during implementation and service. It is a system created by engineers for engineers, it is an intelligent production management tool that fully represents the Industry 4.0 standards. It is worth noting that our lines and stations are designed to work with TOMAI Factory System – you get a comprehensive, fully integrated solution without the need for additional systems.

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