Barco PlantMaster User Manual

PlantMaster
Barco’s leading MES system for discrete manufacturing, PlantMaster monitors and synchro-
nizes manufacturing activities from independent operations to globally distributed plants.
PlantMaster is designed to seamlessly integrate with the company’s ERP system.
Using the Microsoft Windows
®
operating system and Oracle
®
database, PlantMaster
offers a collaborative suite of application modules. PlantMaster meets the needs of spe-
cific manufacturing environments such as plastic processing, engineering and assembly
operations.
The result is a powerful and flexible management tool providing managers with real-time
visibility on all Key Performance Indicators (KPI), enabling them to achieve operational
excellence and rapidly respond to changing conditions.
Manufacturing Execution System (MES)

Barco PlantMaster Specifications

General

Display Technology	LCD
Typical Brightness	250 cd/m²
Brightness	250 cd/m²
Contrast Ratio	1000:1
Response Time	5 ms
Viewing Angle	178° horizontal, 178° vertical
Operating Temperature	0°C to 40°C
Storage Temperature	-20°C to 60°C
Input Connectors	VGA, DVI-D

Summary

Manufacturing Execution System (MES)

PlantMaster Client - Server Concept

Software Modules

Overview of system modules for monitoring, planning, quality, traceability, and maintenance.

Connecting Remote Sites

Details on linking multiple plants to a central server for integrated reporting.

ERP System Integration

Explains how PLANTMASTER integrates with customer ERP systems for data exchange.

Connecting Machines to PlantMaster

DU8P: User Friendly Machine Interface Unit

Details on Barco's standard data collection terminal for monitoring and operator input.

TSDU: Touch Screen Data Unit

Information on the high-end data collection terminal with touch screen capabilities.

System Requirements

Specifies the operating systems and database versions needed for PlantMaster.

Production Visibility and Analysis

Real-time Machine Monitoring

Describes the "PlantView" tool for color-coded machine status and alarm display.

Reporting

Explains data storage in Oracle DB and creation of personalized dashboards for KPI analysis.

Auto Flagging & Messaging

Covers continuous parameter/KPI comparison with limits and alarm/message triggering.

Managing Job Schedules

Real-time Job Schedule

Details the plan board for checking delivery dates and optimizing job sequences.

Kan Ban Support

Describes PlantMaster's support for Kan Ban (pull) planning functionality.

Planning Reports

Information on reports for planning, production, and set-up crew, including forecasts.

Tool Configurator

Explains the tool for configuring and monitoring tools using "tool frames" and inserts.

Tracing from Raw Material to Finished Product

Integrating Traceability with Monitoring

How PlantMaster uses existing hardware and barcode scanners for identification.

Process Routing

Defining a "routing" for each product with necessary production steps and data collection.

Traceability Reports

Reporting module for forward/backward tracking and search for causes of complaints.

Statistical Process Control (SPC/SQC)

Quality Monitoring

How the SPC/SQC module maintains process quality and generates documentation.

Real-time Data Collection

System samples and stores process parameters and part-related data automatically.

SPC/SQC Reporting and Quality Certificates

Overview of reporting tools, charts, and certificate generation.

Other Optional Modules

Preventive Maintenance

Module for generating maintenance schedules based on runtime and intervals.

Operator Tracking

Software for logging operators on/off machines to track production by operator.