Rebar processing automated!
PCM - Production Control Module
Machine allocation
Prioritization
Production packages
Bar cutting optimization
Master bundling
Online Machine downloading
Process flow
Schedule
- Entry/Import of schedules
- Starting automatic machine allocation
- Releasing schedules for production
Production unit
- Creating production unit
- Printing tags for non-PCM-controlled machines
- Releasing production unit for production
PCM
- Running constantly in the background
- Reacts on changes e.g. change of delivery date, machine breakdown
- In case of machine breakdown or maintenance, bar marks are automatically moved to next appropriate production line
- Automatic machine allocation checks all priorities
- Calculation of the production time for each production line
- Appropriate bar marks are allocated to the offcut cutting machine
- Integrated machine utilization and work load balancing
- Parallel optimization processes (running simultaneously)
- Various parameter sets (optimization parameters, box drawing, stock lengths, sorting)
- Continuous optimization with various bar mark combinations
- Configurable scoring system for rating the results
- Sorting of the delivery units and bar marks according to configured parameters (Loading time, delivery date, scheduled production time)
- Consideration of dependencies (Cutting and bending in two steps on different machines)
- Backwards calculation to determine the latest production start and finish for each individual bar mark
- Automatic combining of bar marks to bundles with defined weight, size and dimension
- Takes into consideration the actual logistic possibilities and builds bundles based on diameter, machine, delivery unit or even across several machines
- Handling of bar marks to be bent can be defined specifically (e.g. generally kept separately, but bundled together in case of sub bar marks and varying bar marks)
- Combination of the bar marks to production packages
- Configurable time frame and number of production packages (e.g. 12 x 2 hours)
- Forward calculation to determine earliest production start and finish for each individual bar mark
- Automatic, continuous downloading to the machines
- Receipt of production feedback
- Integrated heat management
Rebar processing partially automated!
POM - Production Optimization Module
Machine allocation
Automatic bundle creation
Work load balancing
Automatic optimization
Bundles & machine utilization
Manual interaction
- In case of machine breakdown or maintenance, bar marks are automatically moved to next appropriate production line
- Automatic machine allocation checks all priorities
- Calculation of the production time for each production line
- When the load balancing finished the bar cutting optimization is started automatically for all shearlines
- The optimization process run parallel and the system uses all pre-defined parameter sets to find the best possible result
- Identification of bar marks that have to be produced on one specific machine
- Creation of bundles for bar marks identified in step 1 and adding other bar marks if possible
- Creation of bundles for remaining bar marks
- Additionally, bar marks can automatically be re-allocated to another production line to further reduce the total number of bundles
- The re-allocation is based on the previously performed possibility checks and taking into consideration the time to produce on the corresponding production line
- The maximum bundle weight depends on the setting in the subsidiary, machine and on customers restrictions
- The bundle size can be further limited by the number of bars and diameter of the full bundle
- The results of the automatic master bundling is displayed in an interactive overview
- Beside the overview, the balanced out work load is shown in a machine utilization diagram
- Furthermore, the scrap and offcut summary of the selected best result from the bar cutting optimization appears per shearline
- After creation of the first bundle suggestion, the work load on the machine is balanced out automatically
- The system takes into consideration the shift working times and the individual machine productivity
- Appropriate bundles can be re-allocated the another production line when all bar marks of the bundle can be produced there
- The user can influence the rules of work load balancing with separate priorities
- Bundles can be re-allocate to other production lines by the user
- After a manual re-allocation the bundle optimization process as well as the bar cutting optimization is restarted for the specific machine
