is a specialized database application used by the ... software.pdf · production costs by...
TRANSCRIPT
Is a specialized database application used by the
manufacturing industry to reduce production costs by controlling
tool usage, inventory, rework and purchases.
Reduces production costs by:• Reducing tool inventory• Eliminating unknown tool quantities• Eliminating duplicate tooling• Eliminating poor tool storage practices• Reducing crisis tool changes• Optimizing tool life• Eliminating unreliable tool data • Minimizing down time• Increasing part quality
Variset 4 - Comprehensive Tool Management Features & Capabilities
• Central data repository• Options and privileges are configurable for multiple security
levels .• Easy import, export & creation of data• “At-A-Glance” Inventory management• Serialization – Auto generate or user specified• Rework tracking and management• Tool presetting & gauge interface• Scheduled & unscheduled tool change register and reports• Automatically sends e-mail & pager alarms•Can link to customer’s material requisition software• Tool costing – Unique to the industry• Works with bar code equipment & RFID code tags• Extensive browser based HELP
Keep Track of All Scrapped Items
Issue Tooling to the Factory Floor and
Monitor its Useable Life.
Total multiple crib monitoring and
management
Electronically Place New Orders and Keep
Track of Receives
Alarms
V4
Storage Place Orders and Receive New Items
V4
Factory Floor Tooling
V4
V4
Scrap
Send Components to Rework and Log Rework Statistics
Automatically Send Stock and Tool life
Warnings
Variset 4’s ProcessRework/PresetV4
System Overview
Variset 4 - Fully Configurable Security Levels
Variset 4 supports multiple languages
Users can log onto specific lines
Security level is based on user name
Categorized menu bar:All menus are customizable,screens may be locked out at
user/security levels
Large customizable button screen allows
rapid access to screens
Variset 4 - Easy to Navigate Buttons and Menu’s
Create and edit itemsImport &
export dataGauge tools
Variset 4 - Effortlessly Create & Edit Items
Item list
Item Navigator Search tab can filter items by
multiple criteriaItem type drop down list. Choose from Components, Tools, Kits, Containers
or the Variset Tree.
Category drop down list can automatically configure the information tabs for inventory,
rework and tool life tracking
Item information
Search through the plant structure with the Variset
Tree.Displays the tooling data in a way familiar to plant floor
personnel.
Help ButtonFunction Buttons:
Save, New, Copy, Rename, DeletePrint Button:Prints all the data for the
selected item
Wildcard search field LineOperation
Components in tool assembly
Unique location
Item number(Kit)
Info
Create/Edit
Customizable item specific
fieldsTool
assembliesin the kit
Variset 4 – Add Build-up for Assembly
Associate items together for assemble, disassemble and
inventory transactions.
These are all the components that make up the selected tool
assemblyDouble click on a component
to access its create/edit screens.
Build-Up
Create/Edit
Variset 4 Supports Multiple Graphic Formats
JPEG
GIF
CAD TIF
WMF
PNGBMP
Drawing
Create/Edit
Variset 4 – “At a Glance” InventoryPermits Easy Set-up of Inventory Centers
Define and view multiple inventory
locations
Sends high & low stock e-mail and pager alarms
View quantity at a location
View total plant quantity
View high & low stock quantities for each
location
Inventory
Create/Edit
Variset 4 - Calculates Tooling Costs
Tracks tool cost based on a departments actual consumption.
(Its portion of the tool usage)
Also allows for adjusting costs based on changes in current pricing.
Cost
Create/Edit
Variset 4 Interfaces with Royal and Other Presetting Gauges
Comprehensive data for proper gauging of tools
Nominal screen categorized and tabbed for easy maintenance of
gauge data
Nominal
Create/Edit
Variset 4 – Gauge Interface
• Full integration with Royal’s presetting gauges
• Full Functionality of the Industry Standard Variset III
• Real time gauging Screen
• Flying Box® edge location
Variset 4 - Complete Inventory Management
Inventory screen menu
Multi-Action Assemble/Disassemble/Rework:Floor to crib to rework, receive, scrap & container transactions
Rework:(Cutter grind management)Rework to crib transactions
Scrap:Removes items from inventory
To/From Rework:Crib to rework transactions
Check In/Check Out:Floor to crib transactions
Receive:Receive items into inventory
Assemble/Disassemble:Crib to floor transactions
Inventory
Variset 4 -“Receive” Inventory Screen
Quantity before receive
Quantity after receive
Receive to any inventory center
Quantity to receiveSelected component
Component information
“At a Glance”inventory buttons
Transaction button
Inventory
Variset 4 - “Multi-Action Assemble” Inventory Screen
Automatically receive needed
inventory
Pull stock from multiple
locations.
Assembled Kits “To…” location
Components “From…” locationMonitor component
quantities available
Inventory
Variset 4 - “Multi-Action Disassemble” Inventory Screen
Kits“From…” location Non-Rework tracked
components go to “Crib”
Tracked components go to
“Rework”
Or, send components to different locations
Scrap components
Receive components
Inventory
Variset 4 - “Rework Center” Inventory Screen
Date/Time stampfirst in rework
Quantity in rework
Selected rework center
ScoreIncrements for priority above
Date/Time stamp
Assign item to a person or machine
Component/Container information
Inventory
Variset 4 - “Rework” Inventory ScreenSerialized Components
Color coded for warning and limit levels
Component information Quickly access additional information or drawings
without leaving the rework screen
Select an option from the drop down list,
“Move” or “Scrap”.
Warning and limit levels to prompt for scrapping
of overworked components.
Serialized tab is only accessible for serialized components
Inventory
Number of components being moved
“Move to…”location
Total quantity in rework
Automatically moves containers and all associated
components.
Scrap componentsfrom rework
Variset 4 - “Rework” Inventory ScreenInventory
Variset 4 - “Reports” Menu
Extensive Reporting Capabilities
Reports
Variset 4 - “Reports” Screen Filters on Multiple Criteria Providing Increased Reporting Flexibility
Report on a date rangeReport on a Department/Line/Operation
Report on an individual item
Reports
Variset 4 - Sample Reports
“Tools Not Changed Report”
Shows the top 10 tools that have not been changed and
graphically displays the top 5 reasons.
“Unscheduled Tool Changed Report”
Shows the top 10 tools that have had the most unscheduled changes and
graphically displays the top 5 reasons.
Reports
Variset 4 is configurable for both Comparative or Predictive tool life:
• Comparative:• Allows for tool change alerts to be signaled
based on reported production counts.• Maximizes tool life.
• Predictive:• Allows for tool change to be scheduled based
on reported production counts, expected future production counts, and the production schedule.
• Maximizes Production Up-time.
Variset 4 - “Tool Life” Screens
Items scheduled for change
Handles tools with multiple edges and varying expected
counts
Unique locations
Change:Tool has reached its
expected life and needs to be changed
Pull:A different part is to be run on the line. Pull the tool assembly from the
unique location and leave empty.
Fit:A different part is to be run on the line. Fit the tool assembly into the empty unique location
Sends tool change e-mail and pager alarms
Item’scurrent count
Item’spredicted count at change
time
Accommodates multiple parts machined on the same line.
Prompts personnel toChange/Pull/Fit
Tool life
•Auto Pilot Feature: (Comparison & Predictive)•Tool change frequency can be adjusted automatically using actual tool performance data collected. • Parameters for adjustment are definable by the user for each tool.
Variset 4 - “TCS” ScreensDesigned for the Factory Floor
Perform scheduled tool changesPerform unscheduled tool changes
Floor personnel can view the current tool counts
TCS screens aredesigned for mouse,
touch screen ortablet PC’s with
wireless network connection.
Variset 4 - “TCS Current Counts” Screen
Operationbeing viewed
Color coded fields for easy identification
Department/Linebeing viewed
Variset 4 - “TCS Unscheduled Change” Screen
Pick the button to process all tools with a change reason
Select reason for tools to be changed
Definable unscheduled change reasons
Variset 4 - “TCS Scheduled Change” Screen
All tools will be changed unless the operator selects a “Not
Changed” reason
Pick the button to process all tools without a “Not Changed”
reason
Definable not changed reasons
Royal’s automatic RF ID tag read/write station
Variset 4 – Supports Bar Code & RFID Code Tags
Tool holder
Read/Write head:Read/writes the data to and
from Variset 4
Tool holder RFID code tag(Not visible)
Scan bar codes to receive, scrap and move
items to and from inventory centers.
a
Examples of RFID code tag data:• Tool number• Tool holder serialized ID• Preset length (up to 4 edges)• Preset diameter (up to 4 edges)• Machine pocket number• Running totals per cutting edge• User definable fields
RFID code tagRead and write RFID code tags to pass tooling data to and from CNC machining
cells.
Variset 4 – RFID Code Tags
In create/edit the tool ID button brings up all the tools with a
tool ID micro-chips and selects proper tool.
On the rework screen the tool ID button brings the
component number
And, brings up the specific serialized component
Inventory
Variset 4 – RF ID Code Tags
Variset 4 does not allow un-maintained components to
return to the floor.
Inventory
Variset 4 – Extensive HELP Documentation
“How to” instructions
Hyper-linked image maps to quickly
move to the area of interest Hyper-links to
definitions
Help Document contains:
• Hyper-links to related topics
• Content sensitive index and search
• Training with Screen Cam® movies
Help
Hyper-links to instructional videos
Content sensitive search
Variset 4 – Extensive HELP Documentation
Sample Screen Cam® movie
Help