Shotscope

Shotscope Advanced Production and Process Control Detailed Overview

Table of Contents • Shotscope at a Glance • System Architecture • Shotscope Modules • Production Manager (Floor Screen) • Process Analyzer (Profile Analyzer) • Statistical Process Control/ Statistical Quality Control • Production Reporting • Production Scheduler • Preventive Maintenance • Operator Station • Summary

SHOTSCOPEProcess Monitoring Shotscope – An Integral Part of Moldflow’s Value Chain DASGroup MMSGroup

Beginning Control your Processes with Shotscope • Moldflow’s Shotscope process monitoring system provides a wealth of “at a glance” information to help you control your injection molding processes, improve productivity and minimize scrap and downtime. • Shotscope measures key process parameters and helps manufacturers manage their plant better because… “What can’t be measured, cannot be managed”

Beginning Solve Factory Floor Problems with Shotscope • Shotscope addresses key manufacturing issues such as: • Little or no real-time information flow for... • Process management (SPC & SQC) and reporting • Job scheduling • Scrap tracking • Difficult to document part manufacturing history (traceability) • Poor integration to enterprise-wide management systems (ERP, MRP) • …and many more!

Beginning The Shotscope Product Family • Shotscope • Comprehensive, plant-wide process monitoring system that helps manage high-volume manufacturing • Link between shop floor and front office • Shotscope FX • Single machine configuration, expandable to plant-wide solution • Move PC from machine to machine or connect it permanently to machine running a critical job • Available for injection molders and die casters

Beginning Shotscope Capabilities at a Glance • Shotscopeis a critical quality analysis technology designed specifically to prevent defective parts from entering the supply chain. • Automatically stores processing parameters on every shot from every machine in real-time • Monitors screw position, velocity, pressures, temperatures… • Displays real-time status of every job • Archives collected data • Creates intuitive shot profile graphs • Protects key information by limiting unauthorized access • Makes all information available across the network • Utilizes Moldflow Plastics Expert (MPX) data for set-up optimization (DOE)

Beginning Shotscope Benefits at a Glance • Establishes process control • Improves process stability • Maintains or improves current process control • Decrease cycle times • Improve quality and lower scrap • Reduce machine downtime • Simplifies reporting and expedites information flow • Increases plant utilization • Simplifies plant scheduling • Increase percentage of on-time deliveries • Document ISO 9000 conformance • Link process/production data to ERP systems

Beginning Table of Contents • Shotscope at a Glance • System Architecture • Shotscope Modules • Production Manager (Floor Screen) • Process Analyzer (Profile Analyzer) • Statistical Process Control / Statistical Quality Control • Production Reporting • Production Scheduler • Preventive Maintenance • Operator Station • Summary

4/8/16 ports Touch screen Beginning Plant-wide Configuration

Beginning Plant-wide Configuration (cont.) Flexible architecture allows one operator station per machine or multiple machines for each operator station.

A9800 Workstation Beginning Single Machine Configuration – Shotscope FX Portable Analyzer • The Shotscope FX portable version can be moved from machine to machine for set-up, troubleshooting, machine capability studies, and part quality checks. • Shotscope FX can be expanded easily into a plant-wide monitoring solution as necessary.

Beginning Architecture Details

Beginning Table of Contents • Shotscope at a Glance • System Architecture • Shotscope Modules • Production Manager (Floor Screen) • Process Analyzer (Profile Analyzer) • Statistical Process Control / Statistical Quality Control • Production Reporting • Production Scheduler • Preventive Maintenance • Operator Station • Summary

Beginning Production Manager - Real-time Monitoring • The Floor Screen provides “at-a-glance” real-time information regarding machine status through the use of color coded machine icons • Click on the Shot tab to get details on process parameters including out-of-limit conditions • Out-of-limit conditions trigger alarms and/or diverters • Track scrap and downtime and efficiency • A 24-hour log tracks changes that might impact process or product quality • A document viewer tab brings up instructions on job set up or QA procedures

Production Manager - Shop floor status at a glance Color-coded machine Status: green, yellow, red Yellow: at least 1 parameter out of limits Green: all parameters within limits Red: down for maintenance or other reason Tabs provide detailed information

Production Manager - Downtime List of machines on the shop floor Reasons for machine downtime Shotscope automatically detects downtime and prompts the operator for a code/reason.

Production Manager - Shots Screen List of machines on the shop floor Shot Parameters for machine M01 Quick check for limit violations Lower spec. limitCurrent value Upper spec. limit

Production Manager - Scrap List of machines on the shop floor Parts on machine M02 Quick glance to determine major scrap causes Scrap reasons

Production Manager - Efficiencies List of machines on the shop floor Cycle Efficiency = (standard cycle time/average cycle time) x 100 Yield Efficiency = (part yield x cycle efficiency) x 100 or… (Part yield x cycle efficiency) x (parts produced/ standard cavities x number of shots) Machine Efficiency = (job operate % x yield efficiency) x 100 where job operate % = (1-(job downtime/cumulative job time- non production downtime)) x 100

Production Manger - 24 Hour Log Log changes to the system for last 24 hours Downtime events Note: A separate system log keeps track of all changes indefinitely

Document Viewer • HTML//Word Document Viewer • Process setup sheets • Part defect examples • Machine schematics • Material spec sheets • Tooling diagrams

Table of Contents • Shotscope at a Glance • System Architecture • Shotscope Modules • Production Manager (Floor Screen) • Process Analyzer (Profile Analyzer) • Statistical Process Control/ Statistical Quality Control • Production Reporting • Production Scheduler • Preventive Maintenance • Operator Station • Summary

Beginning Process Analyzer • Displays analog traces of screw position, screw velocity, hydraulic pressure and cavity pressure. • Used for job set up • Overlay new job profiles on a reference profile to help set up jobs that have been run before • Useful for troubleshooting • Compare to reference profile • Analyze profiles for problems • Store profiles that exceed limits • Keep process under control

Beginning Process Analyzer Position Velocity Hydraulic Pressure Cavity Pressure

Beginning Process Analyzer Example - Cold Slugs • Nozzle can freeze up due to… • Improper control settings • Poor, or malfunctioning temperature controllers • Bad Thermocouples • Parts not removed quickly enough • Stuck parts • Cold ambient air • Process interruptions that keep the machines from cycling at a consistent rate

Look for… Flat spots on the screw position curve Near zero velocity on the velocity curve well before transfer High, sustained hydraulic pressure also well in advance of transfer (usually “maxed-out”) Beginning Process Analyzer Example - Cold Slugs Note the large difference in Transfer Position between the two shots which is indicative of the process variance

Increasing the nozzle temperature eliminated the cold slug Two shot traces are overlaid, but are now identical Uniform screw movement, lower peak pressure and repeatable transfer position Beginning Process Analyzer Example - Cold Slugs Eliminated

Table of Contents • Shotscope at a Glance • System Architecture • Shotscope Modules • Production Manager (Floor Screen) • Process Analyzer (Profile Analyzer) • Statistical Process Control / Statistical Quality Control • Production Reporting • Production Scheduler • Preventive Maintenance • Operator Station • Summary

Beginning Statistical Process Control • Collect up to 50 parameters on every shot and retrieve them for later analysis using: • Run charts, Histograms, X-Bar & R charts , Scatter diagrams • Automatically calculates Cpk (process capability index) • Review process parameters for up to 100,000 shots • Display & compare up to 4 parameters • Relate process variables to physical part measurements • Use assignable cause to annotate events

Beginning Statistical Process Control - Run Chart Display 1, 2 3 or 4 run charts Comparing four parameters Move cursor to examine and compare each shot Digital readout of values

Beginning Statistical Process Control - X-bar & R Cushion Length Average Cpk Calculation Range

Beginning Statistical Process Control - Histogram Normal distribution curve overlay Process limits Histograms show the history of past measurements

Beginning Statistical Process Control - Scatter Diagram Automatically calculates correlation Used to correlate physical part measurements to process parameters

Beginning Statistical Quality Control (SPQ) • Prompts the operator through the physical measurement of parts • Dimensional variations can be linked to process parameters using scatter diagrams and the correlation is automatically calculated • Accepts manual input and inputs from automatic gages

Beginning Statistical Quality Control (SPQ) The same measurement is made on a sample of 5 parts from cavity 1 Alternatively, this screen can be set up to prompt the operator to take several measurements on one part before moving on to the next. Alerts operator that this measurement is out of tolerance. The operator is prompted to take a second reading.

Beginning Production Reporting • Create flexible production reports that… • Provide critical information so informed business decisions can be made. • Present data in a variety of formats: • Tabular, Pareto or Pie Charts • Allow information exchange between other plant-management systems including ERP/MRP systems via Shotscope’s ODBC compliant database • Meet documentation requirements for industry standards like ISO 9000

Downtime by job Downtime by machine Scrap by job Scrap by machine Scrap by tool Scrap by part Scrap summary Production by machine Production by part Job Summary Daily efficiency Beginning Production Reporting - Typical Reports Tabular Reports, Pie Charts, and Pareto Charts Use commonly available tools like Microsoft Access and Excel to build custom reports

Beginning Production Reporting - Charts Pareto Chart to analyze downtime by cause Pie Chart to analyze scrap by cause

Beginning Production Reports - Tabular Report Job Summary

Beginning Production Scheduler • Easy drag and drop scheduling using Gantt chart • Store unique combinations of machine, material, and mold as a template • Recall template to run job a second time • Download jobs from ERP system to avoid double entry • Takes holidays, week days and multiple shifts into account • Move jobs from machine to machine

Beginning Production Scheduler Late Jobs Machine Running job 1st job in queue Job completed on time Current date Scheduled Preventive Maintenance

Beginning Preventive Maintenance • Provides the maintenance status of every tool and machine in your facility • Eliminates unplanned downtime due to missed maintenance activity • Lets you know when maintenance is due and provides a time estimate and cost. • Inventory is updated after maintenance • Lists parts needed for each maintenance activity

Shotscope

Shotscope

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Shotscope