In Pursuit of Productivity

BMSvision PlantMaster feasibility study for NEUTROPLAST PT

1 Introduction

1.1 Document Purpose

The purpose of this document is to establish a feasibility study for the roll-out of a BMSVision MES
PlantMASTER and QMaster system @ NEUTROPLAST Portugal.
This document is in no case a commitment of detailed functionality delivery, pointing to the addressed
subjects. The document will serve as the reference for a detailed BMS price quotation. This document will
also serve as the reference for NEUTROPLAST indicating what features can offer which benefits and has
which shortages.

This document is subject to modifications.

1.2 Document History

v1.0 Jan De Rocker (BMSvision) 01/28/2020 -initial document

v1.1 Jan De Rocker (BMSvision) 14/02/2020 -addons Jan De Rocker
-corrections and adaptions input Paulo Barreto
V1.2 Jan De Rocker (BMSvision) 12/03/2020 -removing in-doc pdf files, replaced by file names
V1.3 Jan De Rocker (BMSvision) 28/04/2020 -correction 10.8 chapter - nr. Mismatch
-add in new entry
V1.4 Jan De Rocker (BMSvision) 12/05/2020 -general review and corrections.
V1.5 Jan De Rocker (BMSvision) 15/05/2020 -adding 8.4, BOM on product level
V1.6 Jan De Rocker (BMSvision) 27/05/2020 -removing carrier options, other modifications
V1.7 Jan De Rocker (BMSvision) 03/06/2020 -review, adding basic maintenance export info

NeutroPlast PT BMSvision PM & QM Feasibility study v1.7. [Link]

BMSvision

Cotton Park, Spinnerijstraat 99/1, Phone +32 56 262 611 [Link] - sales@[Link]
8500 Kortrijk, Belgium Fax +32 56 262 690 VAT BE 0892 063 765 - RPR Kortrijk
 In Pursuit of Productivity

2 Content

BMSvision PlantMaster feasibility study for NEUTROPLAST PT ............................................................. 1

1 Introduction .......................................................................................................................... 1
2 Content ................................................................................................................................ 2
3 Hardware .............................................................................................................................. 3
4 Server and client config .......................................................................................................... 6
5 Interface from PlantMaster to ERP, WMS, Planning system, and ticket system if applicable. ............. 7
6 Interface from ERP planning system to the PlantMaster............................................................... 9
7 Reporting options in the PlantMaster ...................................................................................... 10
8 PlantMaster configuration options ........................................................................................... 12
9 NEUTROPLAST available configurations concerning the standard PlantMaster modules .................. 14
10 Others ................................................................................................................................ 16
11 QMaster, optional module as a plugin on the PlantMaster system. .............................................. 21

BMSvision

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3 Hardware

Topics explained:
3.1 DU7 and DU11 tcp/ip config
Stakeholders: David Araújo, Paulo Barreto

Training, demo, workshop:

 Config via GUI touchscreen
 Config via HTTP connection to DU
 Config via serial cable connection with DU7
 Config via UDPconfig MAC address explorer on PlantMaster server

Remarks:
 N.a.

Conclusion:
 No open questions on IP configuration level.

Open issue:
 N.a.

3.2 DU7 and DU11, input and output differences

Stakeholders: David Araújo, Paulo Barreto, Paulo Gomes

Training, demo, workshop:

1. Overall explanation
 Explantation DU inputs via semi-Live unit
 Cycle time - counter + Run/Stop detection via K1
 Run/Stop detection via I1 input + parallel the cycles - cycle time via K1
 Scrap counter via K2
 Scrap counter via Declaration
 Scrap counter via I input indicator
 Status inputs via I3,… I6 (status inputs can be used parallel as counter – how many times
status input occurred).
 Status counter via Declaration
 Pullup / pulldown connection (support of the 2 common industrial connecting manners )
 Relay filter for debounce on signal level-input signals (inputs can handle noise on signal).
 Explanation DU Outputs
 Output status production (slow cycle time)
 Output scrap running (pieces OK left, Pieces NOK right)
 Output Barcode Scan OK / NOK
 Output SPC process out of limit (if the linked QMaster modules are purchased)
 Explanation DU7 power supply
 24VDC power before / after main switch machine – preferable before main switch.
 Power over ethernet power supply
 1 PoE UTP in connection, 2 UTP out connections to e.g. machine, printer or PC.
 Observe Power consumption versus addons on DU7 (Barcode Reader, Serial Ports, Lamp
trees). Verify Power consumption DU7 versus the load!

BMSvision

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2. General info
 Preferred DUtype : DU11
 DU11: 16 Digital inputs, 5 relay outputs, Touchscreen + HTTP webserver
 DU7E: 6 Digital inputs, 7 relay outputs, HTTP webserver
 DU7 & DU11: 2 serial ports available for e.g. analog /digital convertor, Modbus
communication, Barcode Reader, RFID reader (operator tracking),...
 DU7 & DU11: Support of Power over Ethernet supply (PoE), switch functionality: 1 ethernet
input, 2 outputs (for e.g. ethernet ticket printer, ethernet machine connection,..)
 DU7 & DU11: 1 USB port for e.g. Barcode Reader,…

Remarks :
 NEUTROPLAST may consider to purchase the DU11 instead of the DU7E (both types can
be connected via Ethernet to the NEUTROPLAST network). DU11 will be quoted in the final
quotations.
 NEUTROPLAST may consider to use RFID readers for operator tracking instead of Barcodes.

Conclusion:
 No limitations on HW level versus required functionalities referring to the DU11 data unit.
Special attention needed for Sopro machines with 2 moulds.

Open issue:
 Sopro machines running sometimes 1 job with 2 moulds, sometimes 1 job with 1 mould.
A machine having 2 moulds which produces parts for the same job is possible in the
PlantMaster via a workaround. Using a push button per mould, the plantmaster will be able
to printout the corresponding mould on the ticket for the corresponding Mould1 or Mould2
produced parts as the produced parts arrive mainly in separate boxes (except last box).
 NEUTROPLAST: decide how to Power Up the Data Units (DU11> 220VAC, 24VDC, PoE //
DU7E> 24VDC or PoE)

3.3 Machines status and production counting

Stakeholders: Paulo Barreto, Conceição Faria

 DU11 connection specifications, see PDF file.

“Implementation HW V2.0 [Link]”

Remarks :
 NEUTROPLAST has to supply all signals, Barcode Readers, printers and if still applicable in
a later stage, also the weighing scales. BMSvision will provide the necessary purchase-
advice where needed concerning brands, protocols,… referring to the Barcode Readers and
scales.

Conclusion:
 N.a.

Open issue:
 Sopro machines running sometimes 1 job with 2 moulds, sometimes 1 job with 1 mould.
We have to pay special attention to the support of the ticket printing per box in any case.
Double checking the operator(s) – To – Box assignment mould1 versus mould2 is also a
must in this case.

3.4 Master-Slave Data Units concept

Stakeholders: Paulo Barreto, Conceição Faria

Within the Cleanroom concept, 13 machines will be available in the clean room machine production
area. This part is only accessible for technicians, mechanical engineers,…which require DataUnit
access. The operators which will pack the plastic parts are located in the separate clean-packing-
room. They will also require to use the DU11. BMSvision will offer for this setup 13 extra SLAVE
DU11 units for a Master-Slave concept with the 13 Sopro and IMM machines at the ground floor
production. There is no need of a Master-Slave concept in the assembly production area.

BMSvision

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Remarks:
 The Master-Slave concept will allow per machine technicians, mechanical engineers,… to
use the DU11 as Master unit while the operators will us the other DU11 representing the
same machine as Slave unit.

Conclusion:
 N.a.

Open issue:
 N.a

3.5 Extra Data Unit for scanning the boxes on the pallets @ the Stock entry location.
Stakeholders: Paulo Barreto, Conceição Faria

Depending from the possible purchase of the ‘Custom applications 2- GUI-vB&P for Boxes and
pallets’, NEUTROPLAST will require an extra DU and extra HW to scan all boxes on a pallet and
print-export the pallet label. Inputs can be used, and one or more outputs in the DU can be set
related to the box-pallet validation which can control a lamp or buzzer (lamp or buzzer supplied
by NEUTROPLAST). The detailed functionality requirements of this Pallet-Scanning option is
available in the ‘Custom application 2 - GUI-vB&P for Boxes and pallets –‘ chapter of the
PlantMaster quotation. This optional custom application is quoted separately.

Remarks:
 This extra required DU is only applicable for the Pallet-Scanning&Printing location at the
stock entry location - production output hall where the pallets will be labelled.
 NEUTROPLAST will have to supply all needs to mount and connect the DU11 and deliver
the propriate BarcodeReader, lamps, buzzers, pushbuttons,… on advice of BMSvision.

Conclusion:
 N.a.

Open issue:
 N.a

BMSvision

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4 Server and client config

Topics explained:
4.1 Minimum Server Specifications
Stakeholders: David Araújo, Paulo Barreto

Specifications:

Minimum SERVER specs, preferable more advanced, and preferable virtual:

 DELL PowerEdge
 Hexa Core Xeon E5-2620, 2.4 GHz
 16 Gb SDRAM
 3 x 300 GB 15K rpm SAS (Serial Attached SCSI) hot plug HD (RAID 5)
 1 x Gigabit Ethernet port - application + 1 x Gigabit Ethernet ports – backup
 license Windows Server 2016 standalone (US English) (x64bit)

 Server configured within the AD / Domain

 Server needs a domain user with FULL Local Admin rights (PlantMaster admin user).

Minimum CLIENT specs,

 Microsoft Windows 10 Professional or Enterprise
 Home & Basic editions are not supported
 Memory and CPU / speed requirements are depending from the BMSvision applications
that will be used (dashboard only, floor only, planboard – full, planboard – view,...). In
general any standard 8 giga memory pc with Microsoft Windows 10 Professional will
support all applications. The reaction speed will depend from the type of BMSvision
application, but also other applications running on the same PC. If the reaction speed of
the BMSvision applications is to slow, one can opt to allocate more memory or purchase a
faster client pc.
 A terminal server - citrix environment where the BMSvision client software is installed is
also a supported configuration.

Training, demo, workshop to understand the minimum client specs and security:

 Licenses View, full

 Security manager, read/write access in applications and reporting tool.
 Security manager, read/write access in PlantMaster management console

 Floor layout read/write on windows level

 Dashboard licenses

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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5 Interface from PlantMaster to ERP, WMS, Planning system, and ticket system if applicable.

5.1 Export production data from PlantMaster to ERP

Stakeholders: Paulo Barreto, Sothis (Nuno Miguel Gomes), WinSig ( Pedro Francisco)

 The PlantMaster can easily export production data (according to the available information
in the PlantMaster) to the ERP system via a simple text file. The most common export
format is CSV with semicolon as separator. Other separators (like fixed length, Tab
separator,…) are also possible. The data can be exported at regular base (e.g. every 10
min), at box start, box end, job start, job end, shift end, day end.

Remarks:
 The exported data can be simple or can include extended information but is always limited
to the amount of data which is set available in the PlantMaster.
 BMSvision will only export the data to the ERP system based on a mutual agreement and
possibilities of the ERP supplier and the Plant Master functionalities
 NEUTROPLAST wishes to avoid any manual interaction in this process.
 After training sessions, NEUTROPLAST will also be able to generate common exports to
any system.

Conclusion:
 No interface details are known yet. BMSvision therefore has foreseen in the quotation a
total of 2 days labor time credit for the all data export work required (Custom application
2, excluded).

Open issue:
 Receive the PlantMaster-to-ERP export requirements.

5.2 Export production data from PlantMaster to WMS

Stakeholders: Paulo Barreto, Sothis (Nuno Miguel Gomes), WinSig ( Pedro Francisco)

 The PlantMaster can easily export production data (according to the available information
in the PlantMaster) to the WMS system via a simple text file. The most common export
format is CSV with semicolon as separator. Other separators (like fixed length, Tab
separator,…) are also possible. The data can be exported at e.g. box full. The data can
also be exported at pallet full if the ‘Custom application 2 - GUI-vB&P for Boxes and pallets‘
module is purchased.

Remarks:
 The exported data can be simple or can include extended information but is always limited
to the amount of data which is set available in the PlantMaster.

Conclusion:
 No interface details are known yet. BMSvision therefore has foreseen in the quotation a
total of 2 days labor time credit for all data export work required (Custom application 2,
excluded).

Open issue:
 Receive the PlantMaster-to-WMS export requirements

5.3 Export production data from PlantMaster to a Ticket system

Stakeholders: Paulo Barreto, Conceição Faria

 If NEUTROPLAST chooses to let BMSvision printout the box tickets, as stipulated in the
the ‘Custom application 1 - GUI-vB for boxes- ‘, then no exports are required.

BMSvision

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 Hence, if NEUTROPLAST chooses to printout all box tickets in a third party system where
NEUTROPLAST maintains the tickets and ticket layouts;
The PlantMaster can easily export box related production data according to the available
information in the PlantMaster to the third-party Ticket system via a simple text file. The
most common export format is CSV with semicolon as separator. Other separators (like
fixed length, Tab separator,…) are also possible. If the necessary PlantMaster options are
available, the data can be exported at box end. The data can also be exported at pallet
full if the ‘Custom application 2 - GUI-vB&P for Boxes and pallets –‘ module is purchased.
 Instead of exporting al pallet label data, BMSvision can also printout the A4 labels as
available in the quotation.

Remarks:
 The exported data can be simple or can include extended information but is always limited
to the amount of data which is set available in the PlantMaster.
 As quoted today, BMSvision will printout the tickets on box level.
 As quoted today, BMSvision will printout the data for the Pallet labels as described in the
‘Custom application 2 - GUI-vB&P for Boxes and pallets –‘ definition. An export of the label
data can also be set available.

Conclusion:
 N.a.

Open issue:
 N.a.

5.4 Export Planning data from PlantMaster to a ERP planning system

Stakeholders: Paulo Barreto, Sothis (Nuno Miguel Gomes), WinSig ( Pedro Francisco)

 The PlantMaster can export at regular base (e.g. every 1 hour), the recalculated start and
end times of orders of the planned queue per machine or even for all machines. Data like
this will inform the third party ERP planning system to initiate certain actions and
optimisations on planning level if required.

Remarks:
 The exported data can be simple or can include extended information but is always limited
to the amount of data which is set available in the PlantMaster.

Conclusion:
 N.a.

Open issue:
 Receive the requirements PlantMaster-to-ERP planning export.

5.5 Export Label data from PlantMaster to a WMS system

Stakeholders: Paulo Barreto, Sothis (Nuno Miguel Gomes), WinSig ( Pedro Francisco)

 If the Label printing applications is purchased, the PlantMaster can still, at printing out a
pallet label, export also the related pallet data to a WMS system.

Remarks:
 The exported data can be simple or can include extended information but is always limited
to the amount of data which is set available in the PlantMaster.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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6 Interface from ERP planning system to the PlantMaster

6.1 Importing ERP Planning Production Orders - Planning data:

Stakeholders: Paulo Barreto, Sothis (Nuno Miguel Gomes), WinSig ( Pedro Francisco)

 The PlantMaster can easily import planning data.

 The import layout will be defined by BMS, based on how the planning in the PlantMaster
will be eventually setup. The ERP planning system will have to export the data to the
PlantMaster system according to the BMSvision instructions.

 See file: “Download Manual [Link]”.

Remarks:

 It is not clear yet if Product, Tool, and any other related planning data will be send to the
PlantMaster, or if all data will be maintained manually into the PlantMaster by a
NEUTROPLAST user.
 The PlantMaster supports standard family moulding. Note that also the ERP planning
system should support family moulding to have a good working planning link.
 BMSvision can provide a 1-time import of e.g. product - material - tool data, when the ERP
system cannot offer within a continuous link all needed data. Note that NEUTROPLAST
should provide then a 1-time consistent data file in e.g. an XLS file. Note that it is possible
that NEUTROPLAST needs to maintain manually data in the PlantMaster system if the ERP
has no means to send to required planning-linkdata-information to the PlantMaster.

Conclusion:
 N.a.

Open issue:
 Define specifications together with the ERP supplier.

BMSvision

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7 Reporting options in the PlantMaster

7.1 Floor / Monitoring client:

Stakeholders: Paulo Barreto, Conceição Faria

 A user with a Full control license will be able to create the machine layouts. The same full
control user will be able to define NEUTROPLAST required data on the data blocks, create
filters, quick reports, a StopCauseMap report,… Each view user will require for this
application at least a view license to view the available machine layout and exploring the
short term machine data.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

7.2 Planboard reports directly in the planboard:

Stakeholders: Paulo Barreto, Conceição Faria

 A Full rights user which is able to planning and re-planning jobs in the planboard will also
be able to create planboard reports in the same application.
 A View user can only open the planboard in view mode and will also be able to view the
same type of planboard reports.

Remarks:
 N.a

Conclusion:
 N.a.

Open issue:
 N.a.

7.3 Reporting tool (planning data, historical PlantMaster, and QMaster data):
Stakeholders: Paulo Barreto, Conceição Faria

 Users with a Full control license will be able to create reports for several different user
profiles and departments if applicable. Each view user will require at least a view license
to view the available reports per user. Using a Full control license, reports can also be
configured for automatic printing, exporting or even emailing at certain events (on a time
schedule, shift change, day change, job change,…) to others (not having a PlantMaster
client).
 A PlantMaster user will receive the necessary training for creating reports in the report
generator within the scope of the project.

Remarks:
 The same reporting tool is used not only for the PlantMaster but also for the QMaster
module.
 Paulo Barreto provided an extended set of reports currently in use at NEUTROPLAST via
all means and different sources. The NEUTROPLAST report set gives BMSvision a good
overview of the required reports BMSvision should try to deliver in the PlantMaster and
QMaster project.

BMSvision

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Conclusion:
 As far the reports are understandable in the received report set from NEUTROPLAST; the
BMSvision’s report generator is able to offer a lot of reports for as well the planning,
historical data, as Quality control data. Hence, not all reports as available in the
NEUTROPLAST report set will be delivered in the same format in the BMSvision reporting
applications. Note also that a mutual overview and detailed mutual analysis is required for
supplying a formal feasibility summary of the received NEUTROPLAST report set. Once a
mutual analysation is summarized, a decision can be made which reports can be delivered,
which reports can be delivered with the same or even more functional data, and which
reports can only partially or not be delivered. BMSvision confirms that at first site, most
of the data as in the NEUTROPLAST supplied report set, will be possible to reflect in the
PlantMaster reporting tool. Note that, if data cannot be set available in the PlantMaster or
Qmaster (e.g. ERP cannot deliver the data to the BMSvision concept), then also the
BMSvision reporting tool will not be able to show the data.
 See also the ODBC – PowerBI option in 7.5
 BMSvision has provided an optional 8 days report creation budget in the quotation.

Open issue:
 A mutual analysation of the NEUTROPLAST reports, if required by NEUTROPLAST involving
already a BMSvision project manager once the project purchased.

7.4 Dashboard (rotating report-production data for on big sized screen)

Stakeholders: Paulo Barreto, Conceição Faria

 The Dashboard option allows NEUTROPLAST to show several rotating pages with data on
several big screens. Each screen will require a digital Dashboard view license. Currently 4
licenses are included in the quotation.

Remarks:
 NEUTROPLAST can provide data from another system into the Dashboard pages based on
the specifications and advice of BMSvision.
 The Dashboard can also connect via IOT MQTT to any sensor or system having a IOT MQTT
broker option. This allows the dashboard to show external data (not collected from
BMSvision).

Conclusion:
 N.a.

Open issue:
 N.a.

7.5 ODBC connection for external reporting like PowerBI.

Stakeholders: Paulo Barreto, Conceição Faria

 The PlantMaster database is an open database. When providing a database structure

training, NEUTROPLAST will be able to make its own reports via an external reporting tool
like e.g. PowerBI.

Remarks:
 The ODBC connection should be a read only connection.
 If applicable, Database data structure training to be quoted separately.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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8 PlantMaster configuration options

8.1 Management console: general

Stakeholders: Paulo Barreto, Conceição Faria

 The management console is used for several applications.

- configuration of machines, related counting, machine shift patterns,..
- configuration of machine related setups like scrap, declaration tables,..
- Creation of tools, products, production orders,…
- Configuration and administration of maintenance periods and counters on tool and
machine level.
- ….
Remarks:
 Access and availability of any management console option is user configurable.

Conclusion:
 N.a.

Open issue:
 N.a.

8.2 Management console highlight: planning

Stakeholders: Paulo Barreto, Conceição Faria

 In the management console all editors are available for the planning related objects like
Materials, tools, jobs,...
 Basic planning can be done from in the Job editors in the Management console

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

8.3 Management console highlight: Maintenance {optional module}

Stakeholders: Paulo Barreto, Conceição Faria

 In the management console all editors are available for planning maintenance periods on
tool and mould level. These can be projected in the graphical PlantMaster Plantboard.
 Maintenance counters can be reset on application level or on DU level.
 In the same console, options are available for the configuration and administration of
maintenance counters on tool and machine level. De reporting tool can show the related
historical maintenance data.

Remarks:
 NEUTROPLAST concluded that this option will not fulfil their requirements. If needed and
applicable, the plantmaster can always export basic maintenance counters data to a third
party software, helping to reach the needs of NEUTROPLAST. By default cycles and
RunTime can be exported after each shift change, and after each job-mould change. Other
functionalities needs to be analysed and quoted separately.

Conclusion:
 NEUTROPLAST will use the INFRASPEAK – maintenance tool.

Open issue:
 N.a.

BMSvision

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8.4 Management console highlight: BOM on product level

Stakeholders: Paulo Barreto, Conceição Faria

 In the management console, editors are available for defining the BOM on product level.
The PlantMaster offers with this functionality the possibility to show the required materials
(for a job, shift, day,..) based on the production order planning.
 This BOM functionality does not contain stock, neither reservations functionalities,… but is
purely for forecast purpose. If applicable, the BOM functionality can also be used for
defining packing requirements on product level concerning the Pallet label printing.

Remarks:
 N.a.

Conclusion:
 NEUTROPLAST prefers not to use this PlantMaster BOM option on product level as it is
lacking stock and reservation functionalities in this PlantMaster option. NEUTROPLAST
will handle the BOM in their own ERP system.

Open issue:
 N.a.

BMSvision

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9 NEUTROPLAST available configurations concerning the standard PlantMaster modules

9.1 Machine configuration:

Stakeholders: Paulo Barreto, Conceição Faria

 The following machine list will be configured in the PlantMaster system.

“NeutroPlast Machine List v2.0. [Link]”

Remarks:
 The machine list is not mandatory. It is easy in the PlantMaster to add and remove
machines, to disable and re-enable machines.
 Currently 20 physical machines, and 8 virtual machines will be monitored in this quoted
project. On 13 of the 20 physical machines, the Master Slave concept will be applied.

Conclusion:
 N.a.

Open issue:
 N.a.

9.2 Stop Declarations:

Stakeholders: Paulo Barreto, Conceição Faria

 A stop declaration list as in pdf document reference below, can be configured in the
PlantMaster system. The operators at the machine will be able to declare these reasons as
a stopstatus of a machine. The stopreason can be taken into account on all reporting levels
where applicable. The stop reasons can be included or excluded in the Availability OEE
calculations to the needs of NEUTROPLAST.
 See file “NEUTROPLAST PT Stop Declarations V1.0 [Link]”

Remarks:
 There has been no Run Status – declaration requested from NEUTROPLAST. Hence, it is
always possible during or after implementation of the PlantMaster to define 1 or more Run
Status declarations which allows analysing e.g. the Run and Stop time in ‘Test-mode’ or
‘Sample running’,… of a product or a machine. Note that this can have a huge impact on
reporting level and may have a lot of labour time consequences.
 Any simple modification request on declaration level, after the PlantMaster
implementation, can have no, a small or a huge impact on reporting level and may have
a lot of labour time consequences on reporting level.

Conclusion:
 N.a.

Open issue:
 N.a.

9.3 Scrap Reasons:

Stakeholders: Paulo Barreto, Conceição Faria

 The following PDF scrap reason list can be configured in the PlantMaster system. The
operators @ the machine will be able to declare scrap in pieces and in kilogram. The scrap
reasons can be taken into account on all reporting levels where applicable. The scrap
reasons can be included or excluded in the OEE (Quality) calculations to the needs of
NEUTROPLAST.
 See file “NEUTROPLAST PT Scrap Reasons v1.0 [Link]”

BMSvision

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Remarks:
 In the PlantMaster, 50 counters can be used for scrap reasons. If as well kilogram as scrap
pieces is a requirement for any reason, then only maximum 25 scrap reasons can be used
in the PlantMaster. Note that maybe other unknown wishes may occupy 1 or more counters
from the maximum of 50 in total.
 Any simple modification request on scrap level, after the PlantMaster implementation, can
have no, a small or a huge impact on reporting level and may have a lot of labour time
consequences on reporting level.

Conclusion:
 Although NEUTROPLAST may require more than 50 counters, it is not possible that
PlantMaster complies with this request on short term.

Open issue:
 N.a.

BMSvision

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10 Others

10.1 Machines with 2 moulds each 3 cavities:

Stakeholders: Paulo Barreto, Conceição Faria

 Some Sopro machines have 2 moulds having each 3 cavities. The cavity number is
marked as 1,2,3 - 4,5,6 on the bottles. A 2 mould-support versus 1 cycle signal is not
standard in the plantmaster, if feasible, we may have to configure 1 Mould-set
representing 2 moulds and verify if we reach the required specifications on box level
(which operator(s) (max2), which mould- which cavity number)

Remarks:
 Presumable also related to QMaster.

Conclusion:
 N.a.

Open issue:
 N.a.

10.2 Moulds linked to different or same Boxes:

Stakeholders: Paulo Barreto, Conceição Faria

 On the machines with 2 moulds (for 1 cycle), pieces of the left mould are filled in the
left box. Pieces of the right mould, are filled in the right box. It happens that at job end,
the pieces of both moulds end up in the same box to deliver a complete box instead of
having 2 incomplete boxes. In this case the possibility should be verified if both mould
numbers could be printed on the label for the complete box having pieces from the 2
moulds (left and right mould).

Remarks:
 See Also:
‘Custom application 1 - GUI-vB for boxes- ’ in the PlantMaster quotation.

Conclusion:
 N.a.

Open issue:
 N.a.

10.3 Quality control, pieces not booked as scrap:

Stakeholders: Paulo Barreto, Conceição Faria

 The Quality control department selects for a QC check x pieces which are not scrap
pieces. After checking, the pieces are destroyed. These pieces should not be accounted
as scrap. Anyhow, these pieces need to be handled to have the correct amount of good
production counted. Also the material consumption data can be more correct as such.

Remarks:
 Note that only 50 counters are available for scrap related definitions knowing some
counters can be double used (Kg / scrap pieces), or are linked with other functionalities.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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10.4 Scrap pieces recycled, not recycled :

Stakeholders: Paulo Barreto, Conceição Faria

 Some scrap pieces can be recycled, and will be reused as raw material in the production.
If feasible, this scrap should not be accounted as material consumption when entering
them as scrap in the PlantMaster.
 Other scrap pieces cannot be recycled, these should be included in the material
consumption.

Remarks:
 Note that only 50 counters are available for scrap related definitions knowing some
counters can be double used (Kg / scrap pieces), or are linked with other functionalities.

Conclusion:
 N.a.

Open issue:
 N.a.

10.5 Virtual machine to plan ‘Quarantine’ Production Order:

Stakeholders: Paulo Barreto, Conceição Faria

 A virtual machine will be set available and used for planning a virtual ‘RE-INSPECT’
“Quarantined boxes” Production order. Operators will reinspect pieces one by one
related to e.g. quality complaints from e.g. the customer. This can be a task that is
finished after 1 hour, or can be a huge task from more then a week depending of the
amount of parts to reinspect.
Remarks:
 Quarantined pieces should not impact OEE (scrap) in history. This means the quality
factor is based on the instant input of scrap during production and not based on
Quarantined rejected boxes.
 The Production order start/stop trigger and the amount of pieces handled in that order
will be declared via a WebDU license.

Conclusion:
 N.a.

Open issue:
 N.a.

10.6 Operator names linked to each Box:

Stakeholders: Paulo Barreto, Conceição Faria

 At each box change, the actual operator is linked and printed on the related ticket for
the handled box. Due to an operator change e.g. at shift change or break time or… 1
box can cover 2 operators. It should be checked if both operator names - codes could
appear on the ticket. At the assembly machines, the PlantMaster needs to be able to
follow-up often 2 operators per box. At shift change maximum 2 x 2 operators need to
be printed on a box-ticket.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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10.7 Moulds linked to different or same Boxes:

Stakeholders: Paulo Barreto, Conceição Faria

 On the machines with 2 moulds (for 1 cycle), pieces of the left mould are filled in the
left box. Pieces of the right mould, are filled in the right box. It happens that at job end,
the pieces of both moulds end up in the same box to deliver a complete box instead of
having 2 incomplete boxes. In this case the possibility should be verified if both mould
numbers could be printed on the label for the complete box having pieces from the 2
moulds (left and right mould). Activating a flag setting on the DU11 screen may be the
most practical solution.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

10.8 Reports as available in the current NEUTROPLAST ERP system:

Stakeholders: Paulo Barreto

 In the current Neutropalst ERP system some Crystal reports are in use referring to the
production and quality control in the NON-BMSvision system. These reports are
partially or fully required in the plantmaster by Neutropalst. BMSvision will have to
review these reports into detail before a statement can be made about the feasibility
of the reports.

Remarks:
 Sometimes customers’ third-party reports cannot be reconstructed completely to the
customers wishes but often alternatives are found which offer eventually the same data.
 See also reporting chapter 7.3 in this document.

Conclusion:
 N.a.

Open issue:
 Verify the feasibility of these reports setting them available in the PlantMaster or
setting them available via a third party reporting tool.

10.9 An admin input for lot number raw material

Stakeholders: Paulo Barreto, Conceição Faria

 An admin input can be configured on the DU11 / DU7 allowing NEUTROPLAST to enter
the Lot number of e.g. the raw material. This lot number can then be stored on box
level in the historical data. The admin input can be enabled / disabled for the users
that should be allowed / not allowed to use this admin input.
 BMSvision will look together with NEUTROPLAST to a possible solution how to store
raw material lot numbers in case of Subcontracting – Job data registration via WebDU
for virtual machines.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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10.10 Optional custom application 1, Barcode scanning and box ticket printing + GUI-vB
for boxes
Stakeholders: Paulo Barreto, Conceição Faria

 To fulfil the needs labelling each produced box with a ticket, an optional Custom
application 1 can be developed by BMSvision according to the recorded specifications.
 Detailed description:
‘Custom application 1 - GUI-vB for boxes’ in the PlantMaster quotation.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

10.11 Optional custom application 2, Barcode scanning and pallet ticket printing + GUI-
vB&P for boxes and pallets.
Stakeholders: Paulo Barreto, Conceição Faria

 To fulfil the needs labelling pallets after they are stacked with boxes, an optional Custom
application 2 can be developed by BMSvision according to the recorded specifications
as an addon to the optional custom application 1.
 Detailed description:
‘Custom application 2 - GUI-vB&P for Boxes and pallets’ in the PlantMaster
quotation.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

10.12 Other:
Stakeholders: Paulo Barreto, Conceição Faria, Micaela Mateus

 Samples to be delivered at the customer during production, needs to be registered on

the DU as ‘Customer Sample-scrap’. The remaining production needs to be extended
as these good produced pieces are already accounted on the active job. These pieces
will not be returned into production hence, it consumed raw material.

Remarks:
 Note that only 50 counters are available for scrap related definitions knowing some
counters can be double used (Kg / scrap pieces), or are linked with other functionalities.

Remarks:
 A DU11 option will be set available to print a ‘sample’ ticket.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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10.13 Admin input for maintenance purpose

Stakeholders: Paulo Barreto, Conceição Faria

 BMSvision can provide an export file to a third party maintenance application based on
an admin input. The labour time for this action will be quoted separately if the project
is surpassing the labour days as available in the detailed calculations of the quotation.
 Example: A DU11 admin screen input can be configured allowing NEUTROPLAST to
trigger a maintenance event when e.g. a technician activates the DU11 admin option.

Remarks:
 The labour time for this action will be quoted separately if the project is surpassing the
labour days as available in the detailed calculations of the quotation.

Conclusion:
 N.a.

Open issue:
 Specifications to be defined.

BMSvision

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11 QMaster, optional module as a plugin on the PlantMaster system.

11.1 Topics explained via a live demo:

Stakeholders: Paulo Barreto, Micaela Mateus

 The QMaster configuration module

- Inspection plan
- Inspection rules
- Inspection orders
 The QMaster link with the PlantMaster, possible automatic start of an inspection order
@ start of a production order.
 The QStation, a web based input screen for each QC inspector entering inspection data
in the inspection order.
- Manual entry inspections, via keyboard
- Automatic entry of data, via IMBus – IBR Measuring BUS connected tools and
measuring devices.
 QStations can be geographically linked with machines
 QMaster reports in the reporting module
 The Certificate of analyses report; templates for different customers possible.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

11.2 Quality check on cavity level for 2 moulds for Sopra:

Stakeholders: Paulo Barreto, Conceição Faria, Micaela Mateus

 Some Sopro machines have 2 moulds having 3 cavities each. The cavity number is
marked as 1,2,3 - 4,5,6 on the bottles. A 2 mould-support versus 1 cycle signal is not
standard in the plantmaster, if feasible, we may have to configure 1 Mould-set
representing 2 moulds. In this case the QMaster can support inspection plans where
inspections can be entered on cavity level (e.g. 5 inspections for cavity 1, 5 for cavity 2
… 5 for cavity 6). This will allow the stakeholders to verify the quality on cavity level
and detect possible problems in a certain cavity, based on the parts inspected.

Remarks:
 N.a.

Conclusion:
 N.a.

Open issue:
 N.a.

BMSvision

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