Economical production from ERP to sensor
The main focus of the training factory MPS 404-K is training in economic topics for the production environment. The training factory offers a holistic view of economic production from sensors and the cloud to the SAP system. Productivity, efficiency and profitability are extensively addressed within the scope of the courses. The training factory gives students a great impression of how production processes work in reality.
The training factory MPS 404-K is an expansion of the training factory MPS 404-1. The original functionality and thus usability in technical teaching settings remain the same. While the hardware is identical, the software used in the context of the learning content addressed here differs significantly from the standard software of the MPS 400 systems. The standard software is also included with the training factory.
A production order entered in SAP is transferred to the system's local SCADA system via the FORCAM IIoT (Industrial Internet of Things) platform in the cloud. The SCADA system communicates directly with the controllers in the system and starts the production process. The first Distributing Station Pro separates workpieces from the stacking magazine. The next station, Measuring Pro, checks the position of the workpiece using tactile height measurement. In the process, the Rotary/lifting module moves the workpiece between the Measuring modules and the Conveyor module. The Joining station joins a top part to a workpiece. In the process, the station should be able to either add a simple cover or, after the appropriate conversion, an intelligent micro controller to the basic body of the workpiece. The Sorting station Inline distributes the workpieces to one of two slides according to the quality control.
MES and SAP in the cloud
The training factory is connected to an industrial MES (FORCAM IIoT platform) in the cloud. The cloud system is supplied with production orders via an SAP client. The production orders contain planned quantities, material designations, raw material specifications and standard times, as well as any data relevant for production (screw times, measuring times, etc.). This operational data is supplied to the system via the MES functionality of the FORCAM IIoT platform and then processed.
Analysis of production data
The system continuously records feedback on quantities, quality data as well as order times. Via edge computing the data from the system is transferred back to SAP via the MES Cloud to analyze the order costs there. At the MES level, the operating data is linked to the machine data in order to be able to generate analyses. This allows the production figures to be communicated to the students in a way that is transparent and easy to understand.
Track and Trace
Another application realized using the FORCAM IIoT platform is a track and trace system that uses RFID to assign an individual serial number to each manufactured product. Here, students can experience the collection of process data during manufacturing at various data collection points in an easy-to-understand way. Extensive analysis is also possible here to show various application examples of the use of track and trace data.
The FORCAM Bridge offers a special highlight, making it possible to further process system signals in different cloud solutions. This makes it easy for students to create their own applications using system data. A suitable connector to Microsoft Power Automate enables impressive solutions to be created in just a few minutes. In addition, applications in NodeRed, Microsoft Teams and Trello are also implemented.
IoT data acquisition
In order to show students additional possibilities of digitalization the Sorting station Inline is equipped with an IoT device and camera. This is used to monitor the fill levels of the slides during the production process. The device offers the possibility of integrating this data into custom solutions in order to make production processes smoother. Students can easily build dashboards based on this data to optimize logistics processes.
Whereas in the past, data used to flow linearly up and down from one layer to the next within the automation pyramid, today networks are created with complex data connections across multiple layers. Data can therefore be available to many nodes at the same time. Being able to deal with these digital data streams within production systems is a key skill set for future system operators. Students acquire knowledge of this comprehensive, network-like vertical integration in a fun way – and always within the context of the economic benefits for the company involved.
The software used as part of the learning process includes: SAP, FORCAM IIoT platform, MS Teams, MS Excel, Siemens Technomatix Plant Simulation, Enterprise Cost Simulation UKoSim.
An SAP client, Siemens Technomatix Plant Simulation and all Microsoft programs used (Teams, Excel, Power Automate, etc.) are not part of the offer and must be provided or purchased separately from the respective manufacturers if not already available.
- In addition to the basics of mechatronics and automation technology, you also get quick, simple, and broad access to the most important Industry 4.0 topics.
- The high degree of modularity ensures a clear and manageable learning path made up of modules from stations through to a software-controlled training factory.
- The modular design allows you to make changes and extensions to the mechatronic system independently as part of project work.
- Comprehensive training documentation breaks down complex topics into small steps and learning units, allowing teaching to be designed in a structured yet flexible manner.
- The didactic software environment surrounding an MES specially developed for didactic use provides easy access to complex software topics in the factory automation environment.
- The learning process is supported by modern media such as QR codes and AR for provision of information as well as interaction with the learning system based on augmented reality.
- Operating pressure: 600 kPa (6 bar)
- Power supply: 110/230 V / 50/60 Hz
- Square/round workpiece dimensions: max. 40 mm
- Dimensions (W x D x H): approx. 2100 x 700 x approx. 1705 mm (variable height)
- Learning about actuators, sensors and automated processes
- Availability of a semi-automatic assembly station
- Basics of reference data (main usage time, malfunctions, availability)
- Simulation of a semi-automated assembly station, especially effects on the availability
- Data acquisition with feedback ticket and acquisition of reference data
- Automated data acquisition as well as determination of planned/actual variances of costs in SAP
- Determination of various reference data for quality and effectiveness of a manual small series assembly
- Determination of production order costs and basic principles of cost accounting (cost centers, production capacities, tariffs and production quantities)
- Analysis of problem cases in automated series assembly in FORCAM reporting
- Avoidance of downtime as well as optimization of information management of production facilities via IIoT.
- Understanding the benefits of track and trace using serial numbers and RFID as an example
- Simulation of changes in companies and analysis of the effects on production volumes and economic success