Production Management FA System package

Features

System that visualizes the current status of the moulding plant

Y-MAPII is the application package developed especially for production control at plastics moulding plants. This system improves productivity by using various additional functions that support QC activities.

System that supports the overall production process

This production control FA system covers overall process from "Production preparation", "Scheduling", and "Progress control" to "Stock control". Also included are such functions like "control of each equipment" including take-out robots and "QC support".

For injection moulding machines and take-out robots

Even in the case a plant has injection moulding machines of several companies, our air-driven take-out robots or other brand's take-out robots, they can all be linked to the network for production monitoring.

Web Support

Remote production monitoring is enabled through Internet. Further, by installing a camera at the plant, animation can be transmitted immediately.

Supports QC activity

This system provides data with which you can carry out "QC activity" more effectively. QC support function screen

.

• This system sets person/equipment/material as objects of productivity analysis. Customers will set target figures for labor per person/moulding machine/material (kg). Then they will compare actual production figures with target figures and analyze it.
  
  

Supports quality / security control

We added new functions that help customers improve quality and production ratio, and perform maintenance works.

• Mould maintenance screen - Using the take-out robot controller, customers can check the mould maintenance record before starting production. Also, attaching the image data of relevant moulds allows customers to confirm the current status with more visual details and prevent false checking.

• Process check sheet screen - The take-out robot controller screen displays the check sheet used for the (random sampling) inspection of moulded products immediately after the moulding process.
  
  

Easy Operation for every user

• All-function menu screen - Even an excellent control system cannot be widely used at plants if it is visually difficult to handle. We, therefore, re-designed the frame of NEW Y-MAPII screen. Further, function icon buttons and all-function menu screen favored for take-out robots have been adopted, which allows customers who are not used to operation to easily display the desired screen.
  
  

System / function configurations by module

Specification /operation environment

Basic Specifications

Y-MAPII Operating Environment

FAQ's

What does it mean when you say that the take-out robot controller doubles as a operator station?

A1. In order to carry out production control, you need an "area control terminal" that is installed in the administrative office and compiles various types of production information from the workplace, and a "workplace control terminal" that carries out bi-directional communication of information. You need these for each moulding machine. With the Y-MAP II, the standard "E-touch" controller also acts as a operator station by switching screens. This reduces overall costs and saves space.

How does the system issue work instructions to the workplace?

A2. When it's time for production to start, the setup instructions are displayed on the screen of the operator station (= take-out robot controller), based on a planning chart. The operator follows the instructions displayed on the screen to change the mould. moulding conditions (optional), take-out robot teaching data, and stocker pallet information are all updated automatically.

How is production progress confirmed in the workplace? Also, we want to relay the results of random sampling inspections carried out in the workplace. Can the system do that? If so, how?

A3. Various types of information concerning the product being manufactured can be confirmed in real time on the production monitor screen. To confirm the results of random sampling inspections, a "quality classification" function can be used to determine the quality contents individually for each stack of pallets. That information is then synchronized with the products and relayed to the final inspection process.

Can the system handle centralized control of the equipment operation conditions and production progress conditions for all of the moulding stations in real time?

A4. The "moulding Station Monitor Screen" on the area control terminal installed in the administrative office displays the operation conditions for each of the moulding stations. The information is color-coded by status. Also, the current production progress conditions and moulding cycle values are displayed in real time.

Can optimum production planning be put together easily and in a short time regardless of the individual level of know-how?

A5. The "Production schedule" in the Y-MAP II automatically creates the optimum scheduling in a gantt chart, keeping numerous complicated conditions (delivery dates, moulds, moulding machine priority sequences, etc.) in careful balance. Separate delivery dates for each product are indicated by the perpendicular lines. (Green indicates that production is on schedule. Red indicates that production is running late.) The "Load Chart" at the bottom of the screen confirms and registers the load for each individual moulding machine. Changes of the plans can be easily done, simply by clicking the bar chart and moving it on the table.

Is this system effective in finding ways to discharge defective products and analyzing the causes of errors?

A6. If a station stops because of a problem, a message reading "Error cause input" appears on the screen of the operator station (the take-out robot controller). When the operator solves the problem and restarts operation, operator selects the reason for the stop. The system will not display the next screen until a reason has been selected. From the point at which operation stops until a cause is selected, the area control terminal recognizes that the system has been stopped and totals the time. It then automatically creates a graph showing the amount of time that operation was stopped based on the cause of the stoppage.

Can this production control system be used without installing Yushin robots?

A7. It can be installed with take-out robots by other manufacturers and for free-falling products. In these cases, however, a separate moulding station terminal (E type or S type) is required as a operator station.

Wouldn't it be difficult, if not impossible, in many cases, to use the Yushin robot controller (E-touch) with moulding machines fitted with robots from other manufacturers or moulding machines for free-falling products?

A8. If your firm uses Yushin servo robots in the future, we can deduct the cost of the controller from the cost of the machine. Also, the standard version of this controller comes with three ports for external terminals. On custom models, up to eight ports can be provided for external equipment (such as inspection machines). This lets you configure a more sophisticated, centralized control system.

We only want to introduce production control. Can the system be used only for this function?

A9. The Y-MAP II is divided into three modules: a moulding station, production control, and a distribution station. This makes it possible to configure a system that emphasizes control, such as scheduling, progress control, or inventory control, and doesn't include distribution.

Related Equipment

Transport Devices

YS-C55S

• This transports products between the stocker and the buffer stockyard (automated warehouse) in transport units of one stack (a given number of pallets stacked on top of each other).
• 1-stack transport type.
• Subject of stock equipment is ACS-EG-Decker.

YD-C65S

• This is designed to transport two stacks of pallets at one time. It is ideal for production plants where products are frequently transported.
• 2-stack transport type.
• Subject of stock equipment is ACS-EG-Decker.

YL-C65S

• This is ideal for transport if the stocker is the type in which empty boxes are loaded at the top and unloaded at the bottom (such as the EGS.Decker or KM.Decker by Yushin).
• Elevator type.
• Subject of stock equipment is ACS-EGS-Decker and ACS-KM-Decker.

Pallet Cover Opening / Closing Unit

This automatically opens and closes a specially-designed cover on the uppermost pallet in a stack at the entrance to the buffer stockyard (automated warehouse) to prevent dust from getting into finished products.

Pallet cover open/close device used with Y-vic (AGV) at the automated warehouse entry/exit point.

HI Pallets

The first step in saving labor in the facility is to standardize the shipping container.

Various sizes of pallets can be used in the same stockers, transport devices, buffer stockyard, and other elements in the distribution system. Using Hi pallets as the distribution unit makes it possible to use the same transport devices to transport, stock, and control products, even in plants where moulded products of different sizes are being manufactured.