A MES system at the Zavolzhsky Motor Plant (ZMP)

In 2004 the SITEK company implemented the project on consolidation of 10 machines in a single information factory area network on JSC Zavolzhsky Motor Plant – one of the largest centers in Russia for production of internal combustion engines. In a project deliverable it was adjusted:

• Data management about production and the tool;
• Management of programs and data of the CNC;
• Coordination of scheduled and service works on machines;
• Remote diagnostics of machines.

The following system modules of production management of MCIS (Motion Control Information System) from Siemens were implemented:

1. TDI– Administration of the tool (Tool Data Information): Convenient survey access to all up-to-date data of the tool for the corresponding devices and shops of tools in a format of the conductor is provided to the end user. The overview represents the list of components from which the user can select necessary data. A wide choice of filters provides quick search of specific tools. In the detailed overview all data on the selected tool are displayed. TDI allows to define final requirements to tools. For this software approves data on shop of tools on the machine with the list of the tools necessary for production of a specific part. Then results can be transferred for postprocessing to such systems as stations of setup of tools or a management system for tools. The interactive mode of TDI, user-friendly, provides transfer, storage and data transmission about the tool, both on network, and by means of kodonositel in load time or unloadings. It is also possible closed reception-transmission of data on the tool with the minimum data entry manually.

2. DNC – Administration of the CNC programs (Direct Numeric Control): DNC provides consolidation in an information network of any CNC systems, irrespective of their age and the producer. The module integrated the SINUMERIK systems 810 D/840 Di/840D with Ethernet in factory network for receiving high-speed communication with jobs of technologists-programmers.

3. MDA – Management of production data (Machine Data Acquisition): The functional packet of MDA collects data and analyzes machine statuses and also specific data of counters of parts, automatically or manually. The broad spectrum of functions provides the analysis and assessment of these data.

4. RCS – Remote diagnostics (Remote Control System): Modern effective solution for reduction of expensive phone calls and increase in availability of information on the machine since RCS is a software module which provides remote diagnostics – round the clock and worldwide.

5. TPM – Management of maintenance (Total Productive Maintenance): The packet of TPM does the equipment less vulnerable to breakdowns and more reliable. This software module automates execution of works on preventive maintenance and optimizes on speed calls in the service center using "early warning system". A system reminds personnel of need of maintenance in advance. It prevents the outputs of the machine out of operation, increases equipment employment duration.