24-month Festo Didactic warranty → www.festo-didactic.com 38 39 Learning factories > Single workpiece flow > MPS 400 Brief description The main focus of the learning factory MPS 404-K is training in economic topics for the production environment. The learning factory offers a holistic view of economic production from sensors and the cloud to the SAP system. Productivity, efficiency and profitability are extensively addressed within the scope of the courses. The learning factory gives students a great impression of how production processes work in reality. The learning factory MPS 404-K is an expansion of the learning factory MPS 404-1. The original functionality and thus usability in technical teaching settings remain the same. While the hardware is identical, the software used in the context of the learning content addressed here differs significantly from the standard software of the MPS 400 systems. The standard software is also included with the learning factory. Process A production order entered in SAP is transferred to the system’s local SCADA system via the FORCAM IIoT (Industrial Internet of Things) platform in the cloud. The SCADA system communicates directly with the controllers in the system and starts the production process. The first Distributing Station Pro separates workpieces from the stacking magazine. The next station, Measuring Pro, checks the position of the workpiece using tactile height measurement. In the process, the Rotary/ lifting module moves the workpiece between the Measuring modules and the Conveyor module. The Joining station joins a top part to a workpiece. In the process, the station should be able to either add a simple cover or, after the appropriate conversion, an intelligent microcontroller to the basic body of the workpiece. The Sorting station Inline distributes the workpieces to one of two slides according to the quality control. MPS 404-K Productivity, efficiency, and profitability Analysis of production data The system continuously records feedback on quantities, quality data as well as order times. Via edge computing the data from the system is transferred back to SAP via the MES Cloud to analyze the order costs there. At the MES level, the operating data is linked to the machine data in order to be able to generate analyses. This allows the production figures to be communicated to the students in a way that is transparent and easy to understand. MES and SAP in the cloud The learning factory is connected to an industrial MES (FORCAM IIoT platform) in the cloud. The cloud system is supplied with production orders via an SAP client. The production orders contain planned quantities, material designations, raw material specifications and standard times, as well as any data relevant for production (screw times, measuring times, etc.). This operational data is supplied to the system via the MES functionality of the FORCAM IIoT platform and then processed. Track-and-Trace Another application realized using the FORCAM IIoT platform is a trackand-trace system that uses RFID to assign an individual serial number to each manufactured product. Here, students can experience the collection of process data during manufacturing at various data collection points in an easy-to-understand way. Extensive analysis is also possible here to show various application examples of the use of track-andtrace data. Learning factories > Single workpiece flow > MPS 400 MPS 404-K 8159379 Essential components: MPS 400 Distributing Pro System building block 8129394 MPS 400 MPS 400 Joining System building block 8129125 MPS 400 Measuring Pro System building block 8137077 MPS 400 Sorting Inline System building block 8129438 Recommended accessories: 1x Networks and IT Security, Equipment set TP 1333 → Page 132 1x Machine Safety, Equipment set TP 1321 → Page 204 1x Machine Safety mounting kit for MPS, Equipment set TP 1321 → Page 205 1x Energy efficiency package for MPS 403 → Page 139 FORCAM Bridge The FORCAM Bridge offers a special highlight, making it possible to further process system signals in different cloud solutions. This makes it easy for students to create their own applications using system data. A suitable connector to Microsoft Power Automate enables impressive solutions to be created in just a few minutes. In addition, applications in NodeRed, Microsoft Teams and Trello are also implemented. IoT data acquisition In order to show students additional possibilities of digitalization the Sorting station Inline is equipped with an IoT device and camera. This is used to monitor the fill levels of the slides during the production process. The device offers the possibility of integrating this data into custom solutions in order to make production processes smoother. Students can easily build dashboards based on this data to optimize logistics processes. Vertical Integration Whereas in the past, data used to flow linearly up and down from one layer to the next within the automation pyramid, today networks are created with complex data connections across multiple layers. Data can therefore be available to many nodes at the same time. Being able to deal with these digital data streams within production systems is a key skill set for future system operators. Students acquire knowledge of this comprehensive, network-like vertical integration in a fun way – and always within the context of the economic benefits for the company involved. Software The software used as part of the learning process includes: SAP, FORCAM IIoT platform, MS Teams, MS Excel, Siemens Technomatix Plant Simulation, Enterprise Cost Simulation UKoSim. An SAP client, Siemens Technomatix Plant Simulation and all Microsoft programs used (Teams, Excel, Power Automate, etc.) are not part of the offer and must be provided or purchased separately from the respective manufacturers if not already available. Training content – Learning about actuators, sensors and automated processes – Availability of a semi-automatic assembly station – Basics of reference data (main usage time, malfunctions, availability) – Simulation of a semi-automated assembly station, especially effects on the availability – Data acquisition with feedback ticket and acquisition of reference data – Automated data acquisition as well as determination of planned/actual variances of costs in SAP – Determination of various reference data for quality and effectiveness of a manual small series assembly – Determination of production order costs and basic principles of cost accounting (cost centers, production capacities, tariffs and production quantities) – Analysis of problem cases in automated series assembly in FORCAM reporting – Avoidance of downtime as well as optimization of information management of production facilities via IIoT. – Understanding the benefits of track-and-trace using serial numbers and RFID as an example – Simulation of changes in companies and analysis of the effects on production volumes and economic success
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