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FMS OPERATOR TRAINING
MMS5 2.0
© 2013 Fastems Oy Ab. All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose without the written permission of Fastems Oy Ab. Fastems Oy Ab policy includes sustainable product development. We therefore reserve the right to change and improve the products described in this document without notice. NOTE: Prior to any operations related to the system or the products, please read the safety instructions and warnings and make sure you understand them. The aim of this document is to describe all possible operations related to the system or the product. However, not all operations can be described due to the innumerable facilities of the system. Therefore, all operations not expressly specified as permitted are to be regarded as not permitted. For further information please contact: International contact - Fastems Oy Ab Tuotekatu 4 FIN-33840 Tampere Finland Phone +358 (0)3 268 5111 Fax +358 (0)3 268 5000 Email [email protected] Internet http://www.fastems.com USA - Fastems LLC 9850 Windisch Road West Chester, Ohio 45069 USA Phone 1-513-779-4614 UK - Fastems Ltd Hawley Mill Hawley Road Dartford, Kent DA2 7SY United Kingdom Phone +44 (0)7818 427133 Fax +44 (0)1322 282250 Service International Call Center +358 8000 8760 US phone 1-866-702-0611 Email [email protected] Original instructions 158666 – 2.0.2
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Contents
Course contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Components of the Flexible Manufacturing System - - - - - - - - - - - - - - - - - - - - 7
MMS5 user interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8Data manager............................................................................................................................................................................. 8
Overview ............................................................................................................................................................................... 8Master data........................................................................................................................................................................... 9NC programs........................................................................................................................................................................ 9Tools........................................................................................................................................................................................ 9Production ......................................................................................................................................................................... 10Reports ................................................................................................................................................................................ 10Settings ............................................................................................................................................................................... 11
Station Commander.............................................................................................................................................................. 12Loading station tab ........................................................................................................................................................ 12Material station tab......................................................................................................................................................... 13Cell tab ................................................................................................................................................................................ 13All devices tab .................................................................................................................................................................. 13
Dashboard ................................................................................................................................................................................ 14
Starting production - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15Work flow .................................................................................................................................................................................. 17
Master data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19Fixture master data................................................................................................................................................................ 19Part master data ..................................................................................................................................................................... 19
Device states and modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21Autopilot mode ...................................................................................................................................................................... 21Scheduling mode................................................................................................................................................................... 21Device mode............................................................................................................................................................................ 21
Loading station and material station ...................................................................................................................... 21Stacker crane .................................................................................................................................................................... 21
Device state.............................................................................................................................................................................. 22
Tips for operating the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23Before starting production ................................................................................................................................................. 23Scheduling................................................................................................................................................................................ 24Ordering pallets to stations................................................................................................................................................ 25Loading and unloading pallets ......................................................................................................................................... 25Ordering pallets to machine tools ................................................................................................................................... 26
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Interlocks and alarms- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27Interlocks................................................................................................................................................................................... 27Alarms ........................................................................................................................................................................................ 28
Examples of error situations ....................................................................................................................................... 28
Frequently asked questions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
MMS5 software options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33MMS-2000 Material pallet management................................................................................................................ 33MMS-2100 Automatic material delivery ................................................................................................................. 33MMS-3110 ERP interface .............................................................................................................................................. 33MMS-4000 NC program and tool data libraries ................................................................................................... 33MMS-4010 CAD/CAM interface.................................................................................................................................. 33MMS-4100 NC program transfer and tool checking .......................................................................................... 33MMS-4200 Tool data transfer to machine tool .................................................................................................... 33MMS-4210 Tool presetting station interface ........................................................................................................ 34MMS-4220 Tool identification .................................................................................................................................... 34MMS-4230 Operating panel for tool data management at machine tool ................................................. 34MMS-4240 TDM system interface ............................................................................................................................. 34MMS-4300 Central Tool Storage................................................................................................................................ 34MMS-5000 MMS Fadector............................................................................................................................................ 34MMS-5100 Remote monitor........................................................................................................................................ 35
Exercises - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37Device mode and state........................................................................................................................................................ 37Stacker crane ........................................................................................................................................................................... 38Remote monitor ..................................................................................................................................................................... 39NC program management ................................................................................................................................................. 40Fixture management............................................................................................................................................................ 41Part master data ..................................................................................................................................................................... 42Material management ......................................................................................................................................................... 43Running production ............................................................................................................................................................. 44
Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
Terminology - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
5Course contents
Course contentsOverview of the FMS system and the MMS5 user interface
FMS system
Data Manager
Station Commander
Managing master data
Fixtures
NC program library
Parts
Orders
Loading station
Operating the loading station with the Station Commander
Loading station and automatic operation
Machine tool
Automatic operation
Manual operation
Material station
Operating the material station with the Station Commander
Additional features in the Data Manager
Storage
MMS Fadector
Reports
Estimates
Fine schedule
Tool management
User management
Error situations
Stacker crane manual control unit
Exercises
6 Course contents
7Components of the Flexible Manufacturing System
Components of the Flexible Manufacturing System
1. Stacker crane
The stacker crane runs along the rail in the storage and transfers pallets between the different system devices and the storage. The stacker crane is controlled by the MMS software.
2. Storage
The storage works as a buffer between the loading stations and the machine tools. It also forms a general frame into which all the system components are integrated.
3. MMS software
The MMS automation software is an FMS control system which scales up to a factory level Manufacturing Execution System (MES). The MMS can control the production of a whole factory formed by several automatic or manual cells.
4. Loading station
Loading stations are used for handling machining pallets. Pallets can be ordered and sent with the MMS program.
5. Material station
Material stations are used for handling material pallets. Pallets can be ordered and sent with the MMS program.
6. Machine tool
Machine tools do the machining in the FMS. The MMS software takes care of starting the program. Pallets are buffered in the storage and the system automatically transfers them to the machine tool when a machine becomes available.
The system may also have additional devices, such as robots.
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8 MMS5 user interfaceData manager
MMS5 user interface
Data managerThe Data manager includes the following functionalities:
User interface for managing master data of manufactured parts; a template library where part routing and related manufacturing data is saved.
User interface for production order management and machine workload capacity evaluation. The user can see the total machining load created by the issued production orders. Grade of readiness is indicated online.
User interface for fine scheduling. Pallet task schedules are presented as Gantt charts for each loading station and machine tool. Time-stamped resource requirements to fulfill the schedule are also shown. New schedule is automatically recalculated when there is a significant event in the process context.
The Data manager user interface consists of a function bar (1) and workspace (2). Workspaces for different system management and production management functions are opened by clicking the function buttons in the function bar.
Overview
Control room. The system layout is displayed in the control room. Details on the status of each device can be viewed by clicking the information box for the device. The status of each device is indicated with the color of the information box.
Storage. Storage places and the pallets in the storage places are displayed in the Storage workspace. The storage can be viewed on both sides of the stacker crane aisle and from both sides of the storage. Details on the storage place and the pallet in it can be viewed by clicking the storage place.
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9MMS5 user interfaceData manager
Inventory. All parts and fixtures registered in the system are listed in the Inventory workspace with their location and status information.
Master data
Fixtures. Fixture master data defines the fixtures that can be attached to machining pallets. Fixture master data is managed in the Fixtures workspace.
For more information on fixture master data, see “Master data” on page 9. For instructions on adding fixture master data, see section Adding fixture master data in MMS5 operating instructions.
Parts. Part master data tells the system how to route manufactured parts and which NC program to use for machining. It also tells the system which fixtures are used for clamping parts. Part master data is managed in the Parts workspace.
For more information on part master data, see “Master data” on page 9. For instructions on adding part master data, see section Adding part master data in MMS5 operating instructions.
Group clamping. Group clamping can be used when one NC program is to be used for more than one parts, i.e. two different parts or two clampings of one part are machined using the same NC program.
NC programs
NC programs that can be automatically transferred to the machine tool and executed must be registered in the NC program library. The actual NC programs can be imported from machine tools or from the CAM system.
For instructions on importing NC programs, see section Importing NC programs in MMS5 operating instructions.
NC program library. NC programs are maintained in the NC program library. The NC program library includes program header data, such as program description, program version, programmer, run times, security class, and tool or subprogram lists. The actual NC programs can be exported separately.
Programs in NC. NC programs in the machine tool are listed in the Programs in NC workspace. Programs can be copied to the transfer folder and removed from the machine tool.
Tools
The MMS5 registers and tracks cutting tools of the machines tools. The system keeps track of the location of each cutting tool. Tools that are not in machine tool magazines are also kept in the inventory.
MMS reads information on the remaining tool life and tool status from the machine tool’s tool magazine.
For instructions on tool data management, see section Managing tools in MMS5 operating instructions.
Tool master data. The tool data library application is used to maintain the tools of the machine tools connected to the system. The application can also be used to maintain the information on tools that are outside the tool magazine.
Tool data management contains master data for all tool types. Master data includes the necessary information on nominal size, tool life, general classification, and optionally also machine tool specific parameters.
Tool instances. The individual tools and their locations are listed in the Tool instances workspace.
10 MMS5 user interfaceData manager
Production
Orders. A production order is the basis of manufacturing. Upon receiving a production order, the system creates the needed instances of the operation plans and process plans to carry out production. Production orders are either imported from ERP system or entered manually by the operator using the Orders workspace.
A separate production order is required for each ordered part. The assembly set consists of several orders, however, the order number can be the same for these orders.
For instructions on creating production orders, see section Creating production orders in MMS5 operating instructions.
Estimates. Released production orders do not automatically proceed if resources, such as fixtures, NC programs, cutting tools, or raw materials are not registered in the system or they are not available for some other reason.
The Estimates workspace displays the machining capacity of all machine tools in the system as well as all orders in the system and the fixtures and materials required for each order. Missing resources are also listed in the tabs of this workspace.
Fine schedule. The Fine schedule workspace is used to view all scheduled orders in the system and their grade of readiness. A task list is displayed for each machine tool and loading station. Planned tasks are displayed as a Gantt chart at the bottom of the workspace.
Reports
MMS Fadector. MMS Fadector registers the connected devices’ status signals and enables key figure calculations of the production equipment. The usual registered signals are on-line/off-line, cycle on, error/alarm.
The registered signals are used to calculate key figures of the devices. The main data calculated is:
Utilization rate
Availability
MTBF (Mean Time Between Failures)
MDT (Mean Down Time)
The charts and key figures are calculated separately for each device within the selected time interval.
Production logs. Device production events, pallet transfer, production and history events, as well as part transfer events for the selected period of time can be viewed in the Production logs workspace.
Remote monitor. Remote monitor is a program that runs on one of the computers connected to the FMS. It monitors the status of the system and its devices. When an error occurs, Remote monitor sends an SMS message or an e-mail to predefined phone numbers or e-mail addresses.
Remote monitor consists of a program and a GSM modem.
The remote monitor automatically sends the detected alarms to GSM mobile phones as SMS messages. The alarms can be sent also as e-mail messages.
With the remote monitor user interface, the user can:
register mobile users and their phone numbers.
select the alarms that are sent to the registered users from the MMS message repository.
11MMS5 user interfaceData manager
Settings
User management. User accounts and user roles are managed in the User management workspace. There are built-in user accounts and roles in MMS5 and the customer can add customized accounts and roles. For the customized accounts and roles, a user license from Fastems is required.
Factory calendar. Device-specific weekly calendars can be viewed in the Factory calendar workspace. It is also possible to add exception days, for example national holidays.
The fine scheduler checks the factory calendar to see when each device can be included in the schedule creation.
Production settings. In the Production settings workspace, the operator can exclude loading stations and machine tools from production. This will remove all jobs scheduled for these stations or machine tools from their task lists and add them to the task list of other stations and machine tools.
This workspace is also used to define the source and target locations for the pallets to be loaded and unloaded in each loading station.
The operator can also control how the fine scheduling process checks the tool resources: if the remaining tool life is taken into account, if the system only checks that there is a tool of the needed type in the tool magazine, or if the system does not check tool resources at all.
12 MMS5 user interfaceStation Commander
Station CommanderStation Commander is a touch screen user interface for system operation. In systems, that include both, loading and material stations, loading stations and material stations as well as their protection doors and light curtains are grouped together into loading cells that are operated with the Station Commander.
The Station Commander user interface consists of the following:
Task schedule (1)
Device tabs (2) for all devices that can be operated with the Station Commander.
Workspace buttons for switching between the various workspaces (3)
Device workspace (4)
Manual control menu (5) at the bottom of the screen in the loading station and material station tabs.
Loading station tab
The loading station tab contains a workspace for loading and unloading tasks and workspaces for viewing machining pallet details. Pallets scheduled for the loading station are listed in the task schedule.
The manual control menu at the bottom of the screen is used to select movements of the station and door when operating the station manually.
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13MMS5 user interfaceStation Commander
Material station tab
The material station tab is used to add material to the system and to edit or remove existing material. Pallets scheduled for the station are listed in the task schedule.
The manual control menu at the bottom of the screen is used to select movements of the station and door when operating the station manually.
Cell tab
The cell makes it possible to keep parts registered in the system inventory even if they are not located on a pallet in the system. This means that when parts are removed from a pallet they do not disappear from the inventory but are registered in a cell. Parts registered in the cell are listed in the Cell tab and the operator can add, remove or edit parts in the cell.
All devices tab
The status of all devices in the system is displayed in the all devices tab. The operator can view the workspaces for loading stations, material stations, machine tools, the stacker crane, and the whole system. In the workspace of each device, the operator can for example switch the Autopilot on or off, view alarms and interlocks and other information on the device.
In the station and machine tool workspaces, the operator can also order pallets to the device and send pallets from the device.
14 MMS5 user interfaceDashboard
DashboardThe dashboard is a user interface that includes the following functionalities:
Control room display: 3D view of the system with online status information about device states and operational status.
Configurable widgets. Configuration is saved and each user is shown a personalized view when opening the control room.
Optionally, the dashboard can collect the status data of several systems and machines into one view.
15Starting production
Starting production
Add fixture master data.
Import NC programs.
Add part master data.
Create production orders.
Add fixtures to the pallet.
Check schedules and resources.
Load pallets.
Send the pallet to the machine tool.
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16 Starting production
Production is started based on the production orders that are either manually entered to the system or, in systems with the optional ERP interface, imported from the ERP system. The production order defines the produced quantity, earliest start time, and due date. MMS5 automatically calculates priority for each issued production order and sorts them on display using this criteria.
Adding production order requires master data to be entered for the part to be manufactured. Master data consists of fixtures, NC programs, and part operation chains.
For more information on production orders and master data required for the orders, refer to section “Master data” on page 19.
For instructions on adding master data, importing NC programs and creating production orders, see sections Adding fixture master data, Importing NC programs, Adding part master data, and Creating production orders in MMS5 operating instructions.
After adding the master data and production order, the fixtures required for manufacturing the parts must be registered on a pallet. A fixture registered on a pallet indicates that the pallet is ready for manufacturing parts that refer to the fixture in their process plan templates. The MMS5 fine scheduler uses this link to plan manufacturing jobs for pallets.
For instructions on adding fixtures to pallets, refer to section Adding fixtures to pallets in MMS5 operating instructions.
The MMS places released orders on the work list and automatically calculates the machine tool workload based on the issued production orders. The chart shows the machining capacity for each machine tool and each day separately. Capacity requirements are calculated two weeks ahead. The capacity chart shows if there is overcapacity or undercapacity in production on some days.
The fine schedule is calculated for a shorter time span. Scheduling process splits production orders to pallet tasks and then routes them through their manufacturing route. As a result, there will be a task list for each machine tool and loading station.
If the required resources, such as fixtures, NC programs, cutting tools, and raw materials are registered in the system and available, released production orders automatically proceed in the system.
For instructions on checking resources and schedules refer to sections Checking resources and Checking schedules in MMS5 operating instructions.
The fine scheduling process generates loading jobs for the loading stations. The loading station operator can see the loading and unloading jobs planned for the day as well as load and unload parts using the Station Commander user interface.
For instructions on loading and unloading, refer to Loading pallets in MMS5 operating instructions.
If the machine tool Autopilot is switched on, loaded machining pallets are automatically transported to the machine tool for machining.
For instructions on managing machining, refer to section Managing machining in MMS5 operating instructions.
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17Starting productionWork flow
Work flowThe presentation below describes the work flow of the flexible manufacturing system on a general level.
A An idle pallet becomes scheduled when a production order using the fixture(s) attached on the pal-let is added to the system.
B Parts are loaded on the scheduled pallet and the loaded pallet is sent to the route using the MMS5 control. The stacker crane picks up the pallet. The system now takes care of the automatic task cycle.
C When a machine tool defined in the operation plan for the part(s) on the pallet becomes available, the pallet is moved to the machine tool.
D When machine pallet comes out of the machine tool, the stacker crane transfers it to the next step of the route.
E When all needed operations for the part(s) on the pallet are completed, the part(s) are removed from the pallet in a loading station.
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C
D
BF
G
E
18 Starting productionWork flow
F If machining could not be started, for example, due to NC program download failure or cycle start failure, the pallet is transferred to the storage and its status changes to Locked.
G If something has gone wrong with the machining, the pallet is transferred to the storage and its sta-tus changes to Error.
If the operator suspends a pallet, i.e. interrupts the processing of a pallet, the pallet is not included in the schedule until the operator releases it. However, unloading is still scheduled.
19Master dataFixture master data
Master data
Fixture master dataParts are clamped to fixtures on a machining pallet. One or more fixture positions can be registered for each pallet in the control system. A fixture position acts as a link between the pallet and the parts that can be manufactured using the pallet.
The position data is used to designate where the fixture is attached. Pallet configurations with more than one similar fixture on a pallet are possible.
For instructions on adding fixture master data, see section Adding fixture master data in MMS5 operating instructions.
Part master dataThe part masted data consists of the following:
Operation plan. The operations required to manufacture a part type are presented in the operation plan. The operation plan comprises a sequence of operations that cover all manufacturing stages of the part in the FMS system. Operations are numbered (0, 10, 20, 30, etc.). The operation number is displayed also in the Station Commander when loading and unloading parts. That is why it is recommended to add as descriptive a description for each operation as possible when adding part master data.
Process plan. The steps needed to complete between the operation stages are presented in the process plan. These steps could be for example Loading > Machining > Unloading. For each step, information about the required fixtures, NC programs, devices, etc. must be entered:
The loading stations that can be used for clamping the part to be manufactured on a machining pallet are defined in the loading step (LD). The user also needs to define the nominal loading time.
The NC program and possible machine tools used to machine the part are defined in the machining step (MACH).
The loading stations that can be used for unloading parts are defined in the unloading step (UNL). The user also needs to define the nominal unloading time.
If the step can be completed using one of several fixtures, NC programs, machine tools, pallet types, or loading stations, a process plan must be added for each of them.
OP0 OP10 OP20
LD Mach UNL
PP
FIX-2 NCP2345.NC
LD Mach UNL
PP
FIX-1 NCP1234.NC
20 Master dataPart master data
When adding parts to the system, the following options are available:
Manufactured partThe manufactured part has the same ID as the raw material part.
Manufactured part from different materialThe manufactured and the raw material part have different ID’s, i.e. the manufacturing is started with a raw material part that is first added to the system. This raw material part is then used to manufacture the ready part.
Raw materialA new raw material part to be added to the system.
For instructions on adding part master data, see section Adding part master data in MMS5 operating instructions.
21Device states and modesAutopilot mode
Device states and modesThe operating mode can be switched to manual or automatic for each device in the system. In addition to that, the autopilot can be switched on and off for each loading cell, machine tool, and the stacker crane. The autopilot and the operating mode are independent from each other. The autopilot enables full automatic operation while the operating mode represent the device’s readiness to participate in the production.
Autopilot modeAutopilot on. The operations are performed automatically according to the schedule, i.e. the stacker crane automatically transports pallets to the loading station or machine tool.
Autopilot off. The operations are performed on operator request, i.e the operator orders pallets to the loading station or machine tool.
For instructions on changing the Autopilot mode, see section Switching the Autopilot and scheduling mode on or off in MMS5 operating instructions.
Scheduling modeScheduling on. The device is included in the scheduling, i.e. pallet queues for the device are generated based on the orders.
Scheduling off. The device is not included in the order preparation.
For instructions on switching the scheduling mode on and off, see section Switching the Autopilot and scheduling mode on or off in MMS5 operating instructions.
Device mode
Loading station and material station
Automatic mode. The stacker crane transports pallets to the station automatically according to the schedule (Autopilot on) or on operator request (Autopilot off ).
Manual mode. The stacker crane cannot transport pallets to the station and no automatic movements are performed in the loading cell. The operator performs operations using the manual control switch in the Station Commander panel.
For instructions on changing the station operating mode and operating the station with the manual control switch, see section Changing the station operating mode in the MMS5 operating instructions.
Stacker crane
Automatic mode. The stacker crane is operated automatically with MMS5 system. The operations are performed either automatically according to the schedule (Autopilot on) or on operator request (Autopilot off ).
22 Device states and modesDevice state
Manual mode. The stacker crane cannot be automatically operated with MMS5 system. A manual control unit is used for operating the stacker crane. The manual control unit can be found on the holder on the CC2 control cabinet of the stacker crane.
Device stateWhen the device is in automatic mode, it can have one of the following states:
Other possible device states:
Busy The Autopilot is switched on for the device and it is processing jobs as part of the automation system.
Idle The Autopilot is switched on for the device and it is waiting to process jobs as part of the automation system.
Manual / Semi-automatic
The Autopilot is switched off for the device. Processing jobs automatically is disabled for the device but the operator can give commands to the device.
Semi-automatic mode is possible for machine tools and the stacker crane only.
Service The stacker crane can only be operated with the manual control unit.
The stations can be operated outside the usual limits.
Some safety mechanisms are deactivated.
Error The device is in error state and needs operator actions.
Unknown The device is disconnected from the system or switched off or the service is not running.
23Tips for operating the systemBefore starting production
Tips for operating the system
Before starting productionBefore starting production, check the following:
The required fixtures are registered in MMS5.
For instructions on adding fixture master data, see section Adding fixture master data in MMS5 operating instructions.
The master data for the part is added to the system, i.e. there is an operation plan for the part in the Parts workspace in the Data Manager.
For instructions on adding part master data, see section Adding part master data in MMS5 operating instructions.
The correct NC program is available in the NC program library. This can be checked in the NC program library workspace in the Data Manager.
For instructions on importing NC programs, see section Importing NC programs in MMS5 operating instructions.
An order is created for the part.
For instructions on creating orders, see section Creating production orders in MMS5 operating instructions.
24 Tips for operating the systemScheduling
A pallet with the fixture is available in the system and it is not suspended. Also check that the face the fixture should be attached on (0, 90, 180 or 270) and the position on the face (1 or 2) are in accordance with the part master data.
If no pallet has the required fixture, order an empty pallet to the loading station, attach the needed fixture on the pallet and register the fixture on the pallet in MMS.
For more information, see “Ordering pallets to stations” on page 25 and section Adding fixtures to pallets in MMS5 operating instructions.
The required raw material is available in the correct location. This can be checked in the Estimates workspace in the Data Manager. Missing material is indicated with a red square.
For more information, see section Checking resources in MMS5 operating instructions.
The required tools are available in the machine tool magazine. Missing tools are indicated with a red exclamation mark in the pallet queue in workspace of the machine tool in the All devices tab of the Station Commander.
To view missing resources, open the pallet data pane by touching the pallet symbol. Then, touch the Visits button.
If necessary, add the tools to the machine tool magazine according to the instructions in section Managing tools in MMS5 operating instructions.
The machine tools needed for the job are in automatic mode and the Autopilot is switched on. This can be checked in the workspace of the machine tool in the All devices tab in the Station Commander.
SchedulingFor the system to be able to calculate the orders and the pallet transports, the following conditions must be met:
At least one of the stations selected for the part must be in scheduling mode.
At least one of the machine tools selected for the part must be in scheduling mode.
All required fixtures must be available in the system and in the defined position, if the position is defined in the part master data, and the pallets may not be suspended.
The order must be active and its status may not be Suspended or Planned.
25Tips for operating the systemOrdering pallets to stations
Ordering pallets to stationsWhen ordering pallets to stations, the following conditions must be met:
The station is in automatic mode and there are no interlocks for the station that prevent transporting the pallet to the station.
The Autopilot is switched off for the station.
The Autopilot is switched on for the stacker crane.
Order the pallet to the station by touching the Order pallet button in the loading station workspace in the Station Commander.
Loading and unloading palletsThe following principles apply to loading and unloading pallets:
When the Autopilot is switched on for the loading station and the stacker crane, the stacker crane automatically transports pallets to the loading station.
When the pallet is in the loading station and the aisle door is closed, it is safe to open the operator door and unload or load parts.
When loading and unloading pallets, the following conditions must be met:
The order is active and not processed.
Scheduling mode is switched on for the loading station.
The correct fixture is attached on the pallet and the offset values are the same as the ones given in the part master data.
Material is available in the source location, for example the cell.
The correct pallet is in the loading station.
26 Tips for operating the systemOrdering pallets to machine tools
The pallet is not suspended.
For instructions on loading pallets, see section Loading pallets in the MMS5 operating instructions.
Ordering pallets to machine toolsWhen ordering pallets to the machine tool, the following conditions must be met:
The pallet to be ordered must be suspended.
The Autopilot must be switched off for the machine tool.
The machine tool must be in semi-automatic mode.
For instructions on ordering pallets to machine tools, see section Managing machining in the MMS5 operating instructions.
27Interlocks and alarmsInterlocks
Interlocks and alarms
Interlocks Interlocks prevent a single movement or block access to the device. They are used to prevent movements or functions that might cause breakages or malfunctioning. Interlocks are displayed in the workspace of each device and the system in the All devices tab in Station Commander.
The first part of the message tells the task or movement that cannot be performed and the second part tells the reason for this. For example:
SelectAuto > ErrorOnDevice
The device, for example the loading station, cannot be switched to automatic mode because there is an error on the device.
Rotate > TransferNotOK
The loading station pallet table cannot be rotated because the transfer movement is not in the correct position.
DriveCrEnd > CraneForksInDevice
The loading station pallet table cannot be transferred to the stacker crane end because the stacker crane forks are extended in the station.
CloseCrDoor > ActiveCraneTask
The door to the stacker crane aisle cannot be closed because the stacker crane is performing a task on the device.
ProgramStart > NoProgramEnd
The NC program cannot be started because the program end signal from the machine tool is missing.
APCMovement > CraneAreaNotOk
The automatic pallet changer movement is not allowed because the stacker crane safety area is not ok.
For instructions on removing interlocks, see section Removing interlocks in MMS5 operating instructions.
28 Interlocks and alarmsAlarms
AlarmsWhen an error has occurred, a red line is displayed for the device in error in the Station Commander tabs.
Alarms for each device are listed in the workspace of the device in the All devices tab of the Station Commander.
Examples of error situations
Emergency-stop button is pushed on the touch screen operating panel while the stacker crane forks are extended inside the loading station
The stacker crane stops and goes to error.
To recover from the error situation, proceed as follows:
1. Release the emergency-stop button.
2. Reset the emergency stop circuit for the system by pushing the system reset button on the CC1 control cabinet.
3. Turn the automation system mode selection key on the CC1 control cabinet to automatic position.
4. Push the automation system Start/stop button. The button will be illuminated.
5. In the Station Commander, select the system workspace in the All devices tab and reset the system error by touching the Reset alarms button.
6. Switch the loading station to automatic mode.
7. Select the stacker crane workspace in the All devices tab and reset the stacker crane error by touching the Reset alarms button.
The recovery wizard is opened. You can now select one of the following options:
Continue the active transport task.
29Interlocks and alarmsAlarms
Reverse the transport task to the initial position.
Do not perform any recovery operations.If this option is selected, the stacker crane remains in its position and has to be recovered manually with the manual control unit.
After recovering from the emergency-stop, all other stations are in manual mode and must be switched to automatic mode. After performing the selected recovery operation with the recovery wizard, the stacker crane is in semi-automatic mode. The Autopilot must be switched on for the stacker crane to continue automatic operation.
The beam of the light curtain is interrupted while the stacker crane forks are extended
The stacker crane stops and goes to error.
To recover from the error situation, proceed as follows:
1. Reset the light curtain with the reset button on the Station Commander.
2. Reset the stacker crane safety circuit with the Stacker crane reset button on the CC1 control cabinet.
3. Reset the stacker crane alarms by touching the Reset alarms button in the workspace of the stacker crane in the All devices tab of the Station Commander.
You can now select one of the following options:
Continue the active transport task, i.e. loading pallet to the stacker crane or unloading pallet form the stacker crane.
Reverse the transport task to the initial position.
Do not perform any recovery operations. If this option is selected, the stacker crane remains in its position and has to be recovered manually with the manual control unit.
4. Reset the loading station alarms by touching the Reset alarms button in the workspace of the station in the All devices tab of the Station Commander.
5. Push the automation system Start/stop button on the CC1 control cabinet. The button will be illuminated.
6. Change the station operating mode to automatic.
7. Switch the Autopilot on for the station and stacker crane to continue automatic operation.
30 Frequently asked questionsAlarms
Frequently asked questionsThe pallet is not transported to the loading station
Check the following:
The loading station is in automatic mode.
The stacker crane can access the loading station.
The pallet table is at the correct end of the station.
The rotation is 0°.
The operator door is closed.
The light curtain is reset.
The pallet is not transported to the machine tool
Check the following:
The machine tool is in automatic or semi-automatic mode when ordering pallets to the machine tool manually.
The pallet is in the pallet queue of the machine tool.
The stacker crane can access the machine tool.
There are no interlocks for the machine tool. See section “Interlocks” on page 27.
The NC program is not started in the machine tool
Check the following:
The machine tool is in automatic mode.
Scheduling mode is switched on for the machine tool.
The security class of the NC program is Free to run.
There are no interlocks for the machine tool. See section “Interlocks” on page 27.
Parts cannot be loaded
Check the following:
The order is active and not processed.
The start day for the order has passed.
Scheduling mode is switched on for the loading station.
31Frequently asked questionsAlarms
The correct fixture is attached on the pallet and the offset values are the same as the ones given in the part.
Material is available in the source location, for example the cell.
The correct pallet is in the loading station and the pallet is scheduled for this loading station.
The pallet is not suspended.
32 Frequently asked questionsAlarms
33MMS5 software options
MMS5 software options
MMS-2000 Material pallet management
The MMS-2000 module adds automatic material pallet management functionality to the flexible manufacturing system. Additionally, the module provides user interfaces for material stations and conveyors and expands the cell functionality to cell storage.
MMS-2100 Automatic material delivery
Automatic material delivery is designed to speed up loading and make material handling easier. The basic principle of the function is that when a machining pallet arrives at the loading station, the system automatically orders a material pallet to the material station next to the loading station for reclamping or storing the unclamped parts. Automatic material delivery also supports the possibility that ready, unclamped parts are placed on a storage pallet that has been automatically called to the material station.
MMS-3110 ERP interface
The MMS-3110 ERP interface module makes it possible to import production orders from the customer's enterprise resource planning system (ERP) to the MMS.
MMS-4000 NC program and tool data libraries
MMS-4000 provides the fundamental resource management libraries for NC programs and cutting tools. NC program and tool data libraries are also mandatory data repositories for additional NC program and tool data options.
MMS-4010 CAD/CAM interface
With the MMS-4010 CAD/CAM interface, the NC program header data can be filled in automatically. The data is read from the beginning of the NC program file when the program is imported into the NC program library. With this NC program header scanning, the program file comment rows are used to specify the needed information about the program.
MMS-4100 NC program transfer and tool checking
The interface is used for transferring NC programs and tool data.
MMS-4200 Tool data transfer to machine tool
MMS-4200 tool data transfer is an extension to the machine tool DNC interface. It is used to automatically download actual tool geometry (offsets) to the machine tool. Actual tool geometry is maintained in the MMS tool data library and transferred to the machine tool when the tool is placed into the magazine. This feature also makes it possible to keep tools outside the tool magazine temporarily while still keeping their status and data in the system database.
34 MMS5 software options
MMS-4210 Tool presetting station interface
When a tool presetter is connected to the MMS, the active geometrical values can be automatically transferred to the machine tool control via the MMS tool data library, thus avoiding the error-prone manual entering of values.
MMS-4220 Tool identification
Tools are equipped with a code carrier chip. These chips are used to automatically identify the tool. Tool identification is used at a machine tool when tools are placed in or taken out of the tool magazine.
MMS-4230 Operating panel for tool data management at machine tool
The operating panel for tool data management provides the functionality to register new tools into the tool magazine and worn or obsolete tools out of the magazine. The operating panel is located close to the machine tool magazine.
MMS-4240 TDM system interface
The TDM system contains tool master data and MMS requests this data if it is needed. The presetter is interfaced to the TDM system and it acts as a broker MMS tool requests.
MMS-4300 Central Tool Storage
The MMS-4300 CTS Management module provides tools for managing automatic tool transport between tool magazines and the central tool storage.
MMS-5000 MMS Fadector
The MMS Fadector is an MMS integrated version of the Fastems Fadector ADC software. Fadector registers the connected devices status signals and enables key figure calculations of the production equipment. The usual registered signals are:
on-line/off-line
cycle on
feed on
error/alarm.
The available signals depend on the device. If a device does not provide all signals, it is not possible to receive all status information from all devices.
The registered signals are used to calculate key figures about the devices. The main data that is calculated is:
utilization rate
availability
MTBF (Mean Time Between Failures)
35MMS5 software options
The charts and key figures are calculated separately for each device within the selected time interval. The results of the calculations are displayed by using charts.
MMS-5100 Remote monitor
The remote monitor automatically sends the detected alarms to GSM mobile phones as SMS messages (text messages). The alarms can be sent also as e-mail messages. With the remote monitor user interface, you can:
register mobile users and their phone numbers
select the alarms that are sent to the registered users from the MMS message repository
36 MMS5 software options
37ExercisesDevice mode and state
ExercisesIn the following exercises, the Siemens format is used for NC programs. If another control system is used, use the format for that particular system.
Device mode and stateTask 1. Open the loading station doors and close them. The loading station is switched to manual mode. Change the loading station back to automatic mode.
Task 2. Push the emergency stop button on the Station Commander. Reset the emergency stop and change all devices back to automatic mode.
38 ExercisesStacker crane
Stacker craneTask 1. Switch the Autopilot off for the stacker crane and the loading station. Order a pallet to the loading station. See how the situation looks in the loading station and the stacker crane tabs. Switch the Autopilot back on for the stacker crane. The pallet continues its route.
Task 2. When the stacker crane is transporting a pallet, push the emergency button. Then, correct the error situation so that the transportation is completed.
Alternative for task 2. Push the emergency stop when the load handling device is moving.
Task 3. Move the stacker crane forward and backward with the manual control unit.
39ExercisesRemote monitor
Remote monitorTask 1. Configure the remote monitor to send a message to the cell phone of a trainee when the stacker crane goes to error state.
Task 2. Test the configured functionality by creating an error on the stacker crane.
40 ExercisesNC program management
NC program managementNC programs have been transferred from the CAM system to be placed in the NC program library.
Task 1. Create folder CASE123 and move the main program C123.mpf and subprograms SC123-1.spf and SC123-2.spf into this folder. Check and update the header data so that the programs can be executed in automatic production. Move the programs into the NC memory of the machine tool.
Task 2 . Move programs C123-2.mpf, C123-B0.mpf, C123-B90.mpf, C123-B180.mpf, and C123-B270.mpf into the CASE123 folder. Check and update the header data so that the last four are labeled as parameter programs and the first is labeled as main program.
41ExercisesFixture management
Fixture managementTask 1 . Add master data for fixtures F123 and F123-2.
Task 2 . Order pallet 10 to the loading station and register fixture F123 to be mounted on pallet. Send the pallet to the storage and order pallet 11 to the station. Register four fixtures F123-2 to be mounted on the pallet, one at each face of the cubic tower. Register offset programs C123-B0.mpf, C123-B90.mpf, C123-B180.mpf and C123-B270.mpf on fixtures starting from the fixture on the B0 face.
42 ExercisesPart master data
Part master dataTask 1. Create master data for part CASE123. There is only one clamping. Needed fixture is F123 and needed NC program is C123.mpf. The raw material ID is the same as the ready part ID, one part is clamped on the fixture.
Task 2. Create master data for part CASE123-2. There is only one clamping. Needed fixture is F123-2 and needed NC program is C123-2.mpf. Two parts are clamped on the fixture.
43ExercisesMaterial management
Material managementTask 1. Find the material pallet that contains parts R2222 and order it to the material station. Once the pallet is in the station, move two parts to the cell and add 20 pieces of part R3333 from outside to the pallet. Send the pallet back to the storage.
Task 2. Order a material pallet to the material station and add 10 pieces of raw material CASE123 to the pallet. Send the pallet back to the storage.
44 ExercisesRunning production
Running productionSix pieces of part CASE123 should be manufactured by tomorrow. There is no need to register raw material or ready parts in the system.
Task 1: Create a production order. Run the order with Autopilot ON. Check reporting to see that manufacturing events are registered in production logs.
Additional task 1. You cannot be sure that the NC program is properly designed. Run one machining cycle of the production order by manually sending the pallet to the machine tool, command a pallet change and release the pallet to let MMS5 continue.
Additional task 2. Before unloading, you notice that a part is defective but can be remachined. Rewind the machining step and send the part to machining.
45ExercisesRunning production
Additional task 3. Run one pallet cycle by switching the Autopilot off for the loading station and machine tool.
Additional task 4. Change a pallet state to suspended. Notice the changes in the schedule and resume manufacturing by changing the pallet state back to scheduled.
Additional task 5. Add a tool that does not exist in the magazine to the tool list of a NC program. Notice the changes in the schedule. Resume manufacturing by adding the tool to the machine tool magazine or by removing the tool from the list. Alternatively, change settings so that the tool check is not valid for the machine tool.
Additional task 6. Change the factory calendar settings so that the loading station is not manned at the moment. You will see that the pallet job schedule of the loading station disappears.
46 ExercisesRunning production
Configuration variation 1. Raw material must be added to the storage. Ready parts need to be registered in the cell.
Task. Change part R123 master data accordingly. Change the part acquisition settings. Add raw material R123 on the material pallet and send it to the storage. Create a production order and run it. Check that ready parts are registered in the cell and that the raw material is consumed.
Configuration variation 2. Part volumes are rising. Therefore, fixtures are redesigned so that there are four individual fixtures on a main fixture cube, one on each face. Each fixture takes two parts. Fixture ID is now F123-2 and NC program is C123-2.nc. Manufacture 10 parts for tomorrow. Use fixture offset programs to make sure that the same NC program can be used on each cube face.
Task. Change master data accordingly. Assign fixtures on the pallet with offset programs. Create a production order and run it.
Additional task. When loading parts, do not commit loading on all positions.
47Abbreviations
AbbreviationsAPC Automatic pallet changer
C Conveyor
FMS Flexible Manufacturing System
LS Loading station
MC Machine tool
MDT Mean down time
MLS Multi Level System
MS Material station
MTBF Mean time between failures
SC Stacker crane
WIP Work in process
48 Terminology
TerminologyAisle The area inside the FMS where the stacker crane moves.
Automatic pallet changer A component of a machine tool with which pallets are placed inside the machine tool. Usually contains two pallet places: a pallet can be loaded on the pallet place outside the machine tool, while another pallet is being machined inside the machine tool. (APC)
Autopilot mode Autopilot can be switched on and off separately for the stacker crane, each loading cell, and each machine tool. When the Autopilot is on, operations are performed automatically according to the task schedule, and when the Autopilot is off, the operator can request the operations in the schedule or outside the schedule to be performed in desired order.
Dashboard Dashboard is an optional user interface for viewing and monitoring system operation. It shows the status of all connected devices in one view.
Data manager Data manager is used to manage the master data needed to operate the system.
Data manager user interface consists of a function bar and workspace. Workspaces for different system management and production management functions are opened by clicking the function buttons in the function bar.
Fine schedule The fine schedule lists the production orders that are contained in the schedule. Allocated pallet tasks for each system device are also represented as a gannt bar presentation.
Fixtures Fixtures are mounted on machining pallets, and parts are then clamped in the available clamping positions with clamping elements.
There can be universal fixtures (several part types can be manufactured using one fixture position) and special fixtures (one part type can be clamped to one fixture position).
Flexible manufacturing system A manufacturing system in which there is some flexibility regarding product types and production order. Fastems flexible manufacturing systems include at least a storage rack for machining pallets, a loading station for the operator, a stacker crane for pallet transportation and an integrated machine tool for machining. (FMS)
Loading cell In MMS5, loading stations and material stations and their protection doors and light curtains are grouped together into loading cells.
Loading station Loading station is a device in a flexible manufacturing system on which the operator loads and unloads workpieces.
Main control cabinet CC1 The main control cabinet CC1 includes the main switch of the system and the master controller.
Material station Material station is a device in a flexible manufacturing system used for handling material pallets.
Mean down time The average time that a system is non-operational (MDT).
Mean time between failures The average time between failures of a system (MTBF).
MMS Fadector An optional module in the MMS software used to collect status data from production machinery.
NC program A program that controls the machining operation.
49Terminology
Operation plan A manufacturing template that presents how a single part or group of similar or dissimilar parts is manufactured. The operation plan is a data structure that tells the automation system how to manufacture parts. It comprises a sequence of actions that cover all manufacturing steps of a part or set of parts in the FMS system. It is composed of one or more successive job sequences. An operation plan can not contain external operations, thus, the part needs more than one operation plan if it has external operations between FMS operations (i.e. clampings).
Pallets There can be two types of pallets in the system: machining pallets (a pallet used by machine tools) and material pallets (a pallet on which materials can be stored, for example a regular wooden pallet).
There are various types of material pallets, the most common of which is the EURO pallet (ISO 1, 800 mm x 1200 mm).
Process plan Process plan consists of the steps needed to complete before the part can proceed to next operation stage. For example, these could be loading step, machining step, deburring step, washing step, and unloading step. External operations consist of just one step as the internal progress is not measured by the system.
Production order A production order is the basis of manufacturing. Upon receiving a production order, either from ERP system or entered manually by the operator, the system creates the needed instances of the operation plans and process plans to carry out production.
Remote monitor An optional module in the MMS software with which the operator can receive status messages via email or SMS.
Scheduling mode When the scheduling mode is on for a production device (machine tool or loading station), pallet jobs can be planned and scheduled for the device. When the scheduling mode is off for a device, the device is skipped when planning and scheduling production.
Stacker crane The stacker crane is a device that transfers pallets between the different devices and storage places in the system. The stacker crane is usually controlled through the control system, but it can also be controlled manually with the manual control unit.
Main components of the stacker crane are:
Lifting carriage: frame structure moving along the masts, which is equipped with the load handling device [FEM 9.101:1996, 3.1.3]
Load handling device: part of the machine for carrying the specified loads [SFS-EN 528:1996, 3.3]
Travel carriage: a component of a device that moves the entire device
Masts: vertical structural member of solid wall, profile section, tubular or lattice design guiding the lifting carriage during its lifting and lowering movements [FEM 9.101:1997, 3.1.1]
50 Terminology
Station Commander Station Commander is the user interface for operating the loading cells.
Station Commander user interface consists of the task schedule on the left side of the screen (a pallet list can also be opened from there) except for the all devices tab where it is replaced with a device list, device tabs at the top of the screen, workspace buttons for switching between the various workspaces, device workspace that occupies the majority of the screen, and manual control menu at the bottom of the screen.
The hardware buttons on the panel are the emergency-stop button, manual control switch, and light curtain reset button.
Storage rack Pallets are stored in the storage places on the storage rack. The mesh wall around the storage rack also houses the aisle, in which the stacker crane operates.
User interface The MMS5 user interface consists of multiple applications: Dashboard, Data manager, and Station Commander.
Work in process Partly refined parts that have been unloaded from pallets and wait for future clampings (WIP).
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