We successfully integrated the SmartFactory system into the manufacturing process of a bolt O-ring assembly machine. The aim of the task was to ensure that product loading and compartment handling were fully controlled, error-free, and traceable.
The implemented functions
- Barcode product identification
Products arriving at the machine are identified by a unique barcode.
The barcode data is sent to the central server via the SmartFactory field communication module. - Real-time communication with the enterprise resource planning (ERP) system
The SmartFactory server component automatically forwards the scanned barcode to the ERP system, which responds that:
• the product is acceptable,
• the manufacturing operation is authorized,
• the product can be processed during the given period and under the given work instructions. - Compartment opening authorization check
By coordinating user and PLC-side logic, we have developed an intelligent compartment opening protection system that only allows access to product storage compartments when the ERP system returns an “okay” status.
This guarantees that:
• no defective or foreign products can enter the machine,
• mix-ups can be avoided,
• process safety is increased. - User interface for monitoring operations
The SmartFactory UI module displays the following in real time:
• scanned codes,
• ERP response,
• authorized/prohibited compartment access,
• relevant alarms and warnings.
Results
• 100% reduction in the possibility of incorrect product loading
• Full compartment access control and traceability
• Seamless PLC–ERP communication and process integration
• Significant improvement in meeting quality assurance and traceability requirements
