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What does it mean when you say that the take-out robot
controller doubles as a operator station? |
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In order to carry out production control, you need an "area control terminal" that is installed in the administrative office and compiles various types of production information from the workplace, and a "workplace control terminal" that carries out bi-directional communication of information. You need these for each molding machine. With the Y-MAP II, the standard "E-touch" controller also acts as a operator station by switching screens. This reduces overall costs and saves space.
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How does the system issue work instructions to the workplace? |
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 When it's time for production to start, the setup instructions are displayed on the screen of the operator station (= take-out robot controller), based on a planning chart. The operator follows the instructions displayed on the screen to change the mold. Molding conditions (optional), take-out robot teaching data, and stocker pallet information are all updated automatically. |
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How is production progress confirmed in the workplace?
Also, we want to relay the results of random sampling inspections carried
out in the workplace. Can the system do that? If so, how? |
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 Various
types of information concerning the product being manufactured can be confirmed
in real time on the production monitor screen. To confirm the results of
random sampling inspections, a "quality classification" function can be
used to determine the quality contents individually for each stack of pallets.
That information is then synchronized with the products and relayed to the
final inspection process. |
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Can the system handle centralized control of the equipment
operation conditions and production progress conditions for all of the molding
stations in real time? |
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 The
"Molding Station Monitor Screen" on the area control terminal installed
in the administrative office displays the operation conditions for each
of the molding stations. The information is color-coded by status. Also,
the current production progress conditions and molding cycle values are
displayed in real time. |
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Can optimum production planning be put together easily
and in a short time regardless of the individual level of know-how? |
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 The
"Production schedule" in the Y-MAP II automatically creates the optimum
scheduling in a gantt chart, keeping numerous complicated conditions (delivery
dates, molds, molding machine priority sequences, etc.) in careful balance.
Separate delivery dates for each product are indicated by the perpendicular
lines. (Green indicates that production is on schedule. Red indicates that
production is running late.) The "Load Chart" at the bottom of the screen
confirms and registers the load for each individual molding machine. Changes
of the plans can be easily done, simply by clicking the bar chart and moving
it on the table. |
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Is this system effective in finding ways to discharge
defective products and analyzing the causes of errors? |
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 If
a station stops because of a problem, a message reading "Error cause input"
appears on the screen of the operator station (the take-out robot controller).
When the operator solves the problem and restarts operation, operator selects
the reason for the stop. The system will not display the next screen until
a reason has been selected. From the point at which operation stops until
a cause is selected, the area control terminal recognizes that the system
has been stopped and totals the time. It then automatically creates a graph
showing the amount of time that operation was stopped based on the cause
of the stoppage. |
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Can this production control system be used without installing
Yushin robots? |
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It can be installed with take-out robots by other manufacturers
and for free-falling products. In these cases, however, a separate molding
station terminal (E type or S type) is required as a operator station. |
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Wouldn't it be difficult, if not impossible, in many cases,
to use the Yushin robot controller (E-touch) with molding machines fitted
with robots from other manufacturers or molding machines for free-falling
products? |
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If your firm uses Yushin servo robots in the future, we can
deduct the cost of the controller from the cost of the machine. Also, the
standard version of this controller comes with three ports for external
terminals. On custom models, up to eight ports can be provided for external
equipment (such as inspection machines). This lets you configure a more
sophisticated, centralized control system. |
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We only want to introduce production control. Can the
system be used only for this function? |
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The Y-MAP II is divided into three modules: a
molding station, production control, and a distribution station. This makes
it possible to configure a system that emphasizes control, such as scheduling,
progress control, or inventory control, and doesn't include distribution. |
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