Development of a production statistic for concrete plants.

The company "Hess Group GmbH" was looking for a new system to capture the production data of their concrete block machines. The following criteria had to be satisfied by the system:

1. the system should be independent of the visualization system
2. no license costs
3. the data should be stored in a Microsoft SQL Server database
4. the data should be available from different locations
5. the system should work without maintenance

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The realization

The data is collected with the database interface IBU-DBI. The controllers and the database server communicate directly. The independence of the machine visualization is guaranteed.
The IBU-WebVisu is used as visualization system for the production statistics. This is a framework that is programmed in ASP.NET. It provides user control, language switching, adjusted screen resolution and other important functions for web applications in intranet areas. The data can be viewed anywhere, also on mobile devices.

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The following reports are provided:

1. graphical overview report with all key information for a selected data areas
2. graphical comparison overview report with all key information for two selected data areas
3. tabular shift analysis with all the information for a selected data areas
4. tabular charge analysis with all the information for a selected data areas

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The following data is collected:

1. number of 1. quality, 2. quality and waste
2. number of stacked pallets
3. the current state of the plant is logged at any time (production, downtimes, waiting times, ...)
4. assignment of the product name, item number and order to any charge
5. assignment of operators to each shift

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Additional functions:

1. automatic shift management for three-shift operation
2. manual shift management with an assignment for the operator
3. automatic charge management for product change
4. manual charge management
5. automatic database maintenance with a task planner
6. Archiving functions for older data