With the „Cockpit“ software developed by Bluhm Systeme, it is no longer just labelling systems such as printers or coders that can be networked, monitored and controlled. In the spirit of the „intelligent factory“, Cockpit is increasingly being used to monitor the entire production process. The most recent example of its use is Bluhm's own labelling production at the Rheinbreitbach site.
On ten printing machines, Bluhm produces several billion labels a year from almost 40 million linear metres of raw material on behalf of customers: as rolls or sheets, as IT labels, for logistics or marketing purposes. For colourful labels with brilliant colours and attention to detail, a Eight-colour flexographic printing press available. „It's not always easy to keep an overview here,“ says Matthias Brandl, head of label production.
Networking, monitoring and control
In order to further optimise machine capacity utilisation, the systems have now been Cockpit software networked. This enables the Monitoring of the machines in real time and an exact determination of the individual running times. The aim is to systematically minimise downtimes and thus increase productivity. Determining the cost-optimised production speed also helps to successively reduce manufacturing costs and to always be able to offer customers attractive prices. Optimised throughput times also enable shorter delivery times.
Cockpit determines numerous different key production figures (KPIs: Key Performance Indicators) such as system availability, productivity and overall system effectiveness (OEE: Overall Equipment Effectiveness). The results can be graphically displayed in the form of pie charts, bar charts and line diagrams at the touch of a button for better evaluation.
„Because all the machines are clearly mapped, we can keep an eye on everything at all times,“ says a delighted Matthias Brandl.
Early warning system prevents production downtime
All individual systems are displayed in the overview on the cockpit start page. From here, the operator can quickly switch to the individual display of the respective machine and call up the current system status with a single click. The software determines all technical data relating to productivity, such as material levels, maintenance dates, etc.
„Every production standstill - for whatever reason - not only costs nerves, but above all money. What's more, there is hardly any time left for the really important tasks,“ explains Matthias Brandl.
Cockpit determined Sources of interference such as grid cracks or upcoming roller changes. The software can be used to define tolerance limits for these sources of interference, which trigger an early alarm if they are exceeded. The early warning system thus helps to avoid production downtimes. In the event of faults, the affected systems are highlighted in red so that the operator can recognise at a glance where action is required. After appropriate configuration, the software can independently generate a detailed Fault diagnosis carry out.
The next step is to connect the software to the ERP system „This means that customer orders can soon be automatically transferred to the machines,“ says Matthias Brandl happily. As the software is able to estimate the time required for the orders currently in production, it can optimally plan the product changeover accordingly and utilise the machines to their full capacity. This is how Bluhm Systeme is on the way to „SmartFactory“, in which the production systems monitor themselves, configure themselves and optimise themselves.
Cockpit is a web application and runs on all platforms. The software is therefore independent of the installed operating system and can be installed on different end devices such as PCs, tablets or smartphones. Individual access rights can be assigned to different users if required. All per Ethernet and WLAN devices can be integrated, mapped and even controlled. This also includes webcams for visual monitoring of sensitive production processes. Thanks to the intuitive user interface, no specialised IT knowledge is required.
Production, sales and service from a single source - system solutions for automation and identification
"Made in Germany" are the cross-industry system solutions from Bluhm Systeme for automation and identification. The labelling provider is part of the globally active BluhmWeber Group, headquartered in Rheinbreitbach, where several teams develop, design and manufacture new marking and labelling systems or improve existing ones. A dedicated software team deals with control and networking. The labelling systems are supplied to customers all over the world. Bluhm Weber has several branches in Europe and works with 56 partners worldwide.
