HYDRA Process Data
HYDRA Process Data
Complex Production Processes
Superior products often require complex manufacturing processes and the utmost precision. Adhering to production parameters and evaluating statistics while striving for
continuous improvement is a guarantee for high product quality and low scrap rates.
While the continuous control of production parameters and process value is often carried out by modern machinery and system controls, the HYDRA Process Data (PDV) module offers significantly more advanced features. All MES applications are fully integrated in the central HYDRA database. This enables the user to conduct correlative evaluations including other data. Analyses of data pertaining to orders, products, batches, tools and process values can be used to optimize production processes.
Collection and Processing of Process Values
Process parameters to be collected are defined in the so-called list of characteristics (e.g. physical quantity, formulas to calculate the parameter derived from an imported value, random test intervals, maximum and minimum tolerance limits).
Allocating so-called logical variables determines the way data is imported into the system. In addition, it can be established how deviations of tolerance limits and action limits are to be logged and whether an alarm should be triggered. Furthermore, these data records are assigned a validity date which enables the system to manage different data collection and calculation rules.
Summary of individual process values pertaining to order- or productrelated collection rules.
Online Visualization of Process Data
Based on the individual requirements, HYDRA-PDV visualizes collected and processed data in real-time either directly on a shop floor data collection terminal, on large-format monitors in the production environment or on the desktop PCs of management staff. This is an essential tool to monitor ongoing processes during production and to rapidly intervene with relevant counter-measures if negative trends or critical issues become apparent.
The process monitor displays indicators of all selected parameters of specific machines or equipment. In addition to the current measurement reading, the monitor also shows
pre-defined tolerance limits. Therefore, the user sees at a glance whether a process is within the desired range or if measures need to be taken. Alternative methods to display
process data include bar charts, digital displays and gradient with chronological sequence.
Display of all actual parameters on the process monitor of the HYDRA office client.
Alternative method of display: A bar chart in the HYDRA shop floor client (e.g. shop floor data collection terminal).
Evaluating Process Data
HYDRA-PDV is able to store collected or transferred process data over unlimited periods of time in the database. The saved data can be analyzed to draw conclusions based on process parameters and the results can be used to optimize processes. Once again, the integrative characteristics of the HYDRA application play an important role. Underlying causes of problems often only become apparent when looking from different angles (e.g. machine or batch-related data).
For example, the graphical process analysis displays selected process data together with a machine time profile. Employees can compare both evaluations to determine which dependencies exist between process issues and machine behavior and resulting consequences.
Graphical process analysis displaying machine malfunctions for correlative analyses.
The advantage of selective and correlative analyses can also be illustrated by means of a process analysis with random checks. One can specifically choose process values that were randomly recorded during one production order. When comparing different parameters which are displayed with one or more curve progressions, it can be identified which interdependencies exist between individual values.
Control chart for the analysis of selected process parameters.
The Efficient Use of HYDRA-PDV
HYDRA automatically activates the order- or product-related measuring specification (including action limits and tolerance limits) during the selection of a production order at a shop
floor data collection terminal to prevent errors during manual input.
In addition, HYDRA-PDV can also be used as a data source for production control in HYDRA-CAQ (Quality Management). Collected process data is recorded, just as manually
entered data or data imported via test equipment, for storage or further evaluation in the form of spreadsheets or control charts.
Complete Documentation
Process data stored in HYDRA’s long-term archives is a substantial part of a complete documentation process as required by law or by customers within the scope of product traceability (i.e. TS 16949).