PRODUCTION – PROCESS MONITORING SYSTEM
Every process is composed of five BASIC operations as illustrated below. The process is performed
manually or automatically, however the operations remain same.
FEED – is an operation required to provide the raw material to process the outcome
RETURN – is an operation required to manage the remaining of FEEDs not used during process
WASTE – is an operation to record the wastage collected during a process to produce the outcome
PRODUCTION – is the actual outcome of the process performed and referred as “Product”
ASSET – defines the resources required to perform an operation to produce the product.
PMS Objectives
Logging Physical Properties (a) Accurately and (b) Timely
Physical Properties Integration Over Time & Process
Interconnects Processing Machines & Instruments
Minimizes Data Collection Errors & Problems
Maximizes Operational Performance via Data Analysis
The “Physical Properties” - are measured using sensors; like weight of raw material, volume of packets,
flow of liquids and many other physical properties depending on raw material used. Other physical
properties can also be connected to collect more precise data of the product being moved on factory floor
including the EPC for proper identification of the container, plastic cans and packets.
PMS Explained
Every process during production; starting from intake of raw materials to finished products into
deliverable form are covered by PMS (Process Monitoring System). The processes can be created to any
number of stages. A “Process” is divided into five segments. Each segment collect physical parameters
automatically from machines without human intervention and presents to console operator, so it can be
interlinked with processing job under operation at that location.
Process Monitoring System
Each segment of the process is connected with weigh scale & barcode scanner and any other sensors to
monitor materials movement from receipt of items to processing area to production floor to dispatch in
near real-time.
The system is strictly based on;
- Weight, Liters, Volume and/or Quantity of Materials
- Assets Identification.
- Resources Monitoring, like kVA consumption
This automated system is referred as PMS, Process Monitoring System. PMS is composed of three units;
(a) Back-Office Data Center
(b) Factory Floor Units
(c) Inter-Connectivity between [a] & [b]
Following pages explain the parts of PMS with its operation and sample UI to manage the process.
Application Engineer: Gohar Noor [email protected]
Process Monitoring System (cont)
Back-Office Data Center
The back-office data center is composed of Intel based computer running Microsoft Windows with Internet
Information Services along with Microsoft ODBC compliant database. The back office can also be
connected to any Enterprise Data Center, like SAP and ORACLE.
Factory Floor Units
The “Factory Floor Units” collects data from weigh scale and material identification code from barcode
scanner. Following equipment forms a single “Factory Floor Unit”;
(a) IOTA41 (Internet of thing for Android, 4-Channels)
(b) Sensor Integration with IOTA41
(c) Operator Console
IOTA is a “Publisher” that connects sensor like (a) Weigh scale (b) Barcode Scanner and (c) Other Sensors to
collects data from equipment and publishes it to “Broker” after re-forming the incoming data to more
generalized form suitable for PMS system. Operator Console; is an Android application acting as a “Broker”
for PMS that manage incoming data from “Publisher” and provides the same to “Subscriber”, in PMS system
the subscriber is “Server Side Application” running on IIS with Database.
Inter-Connectivity between Back-Office Data Center & Factory Floor Units
Three types of inter-connectivity is in operation for PMS; (a) Ethernet WiFi between Operator Console &
IOTA (b) Ethernet between Operator Console and Back-Office Data Center and (c) RS232/422/TTL between
IOTA and connected sensors.
About IOTA41
IOTA41 – is designed and developed by us (as illustrated below). Capable of connecting one machine to
KIOSK. The following list gives short description and commercial value with its deployment status.
PMS COMMERCIAL VALUE
Sr Item # Description Price (PKR)
IOTA41 Data Collection & Broadcasting Equipment
Technical Specification;
01. Universal Power Supply 230VAC @ 50Hz
65000
1 Hardware 02. Ethernet & WiFi Connectivity
Per IOTA41
03. Sensor Connectivity: RS232, RS422, TTL
04. Fail Safe Control Board with Auto-Restart Capabilities
05. Auxiliary Power Sources for Sensors
IOTA41 Sensor Integration
35000
2 Services Firmware design & development services are required here to integrate
Per Sensor
applied sensors for data interpretation and filtration.
Operator Console (HMI) 46000 (min)
3 Hardware Industrial grade Android 7” Tablet, including IP67 & IP22 Wall-Mount 175000 (max)
Metal Enclosure. One year official warranty from distributor Estimated Value
Operator Console Application (HMI)
Android APK specifically designed for process being monitored. Its 120000 (min)
4 Services skeleton is ready to use, however processing and presenting data on HMI 220000 (max)
needs design & development services according to applied process that Estimated Value
varies from industry to industry.
Total
Advance 80% (rounded)
Cash on Delivery
GST As Rule
Estimate prepared by: Gohar Noor_____________________________________________________________________________________________________
TERMS OF SERVICES
[1] Lead Time: 45 working days after receiving “Cash Advance”. Safety Margin 15 extra working days.
[2] Hardware Warranty provided for one calendar year by Manufacturer NOT by re-seller
[3] Consumables items and Installation charges are not included
[4] Electrical burning & physical damages are not supported
[5] Prices are exclusive of any applicable taxes
[6] GST & Income Tax Invoice will be available from parts supplier
[7] Mode of Payment CASH
[8] Imported items are quoted in foreign currency (Pak Rupee quotation will be updated one day earlier before confirmed purchase order)
[9] Lead Time may vary due un-avoidable circumstances
DOCUMENT REV 3.0 DATE: 2019-02-02
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