PlantRun Features

An outline of most of the major features available in PlantRun.

Note that some features mentioned are optional - not all features are included as standard.

• PC based : Operating System: Windows 10/11, 2016 Server, 2019 Server. Physical Server or Virtual Server. 
  • On premise PC based systems ensure highest data security, fully under user control.
• Real-time connection to any type, make or age of manufacturing asset - discrete or linked machines, lines, work cells, even manual operations.
• Information available enterprise wide across existing computer network, Ethernet LAN
• Data stored in MS Access or SQL compatible database for simple export to other enterprise software - ERP/MRP/MES/CMMS
• Range of operator interfaces - Outstation terminals, PC, Tablet and Touchscreen
• Flexible time planning - shift pattern, planned maintenance, holidays and overtime

System Displays

• Custom displays/dashboards show key information at a glance including:
• Live factory overview representational mimic with colour coded machine status
• Detailed displays of machines with KPI information
• Production Status, KPI and OEE , Scrap rate, Down time/Up time, Cycle times, Yield, Efficiency, Utilisation, Changeover/Set-up/Tooling time, Order progress etc.

Alarms (Alerts)

• Unlimited alarms
• Alarm limits can be set on any parameter
• Alarms can activate:

System alarm banner: sounders: beacons: andons: SMS text messaging to mobile phones: Email: Audio files to public address system/Tannoy, video recording/playback from enabled IP cameras.

Reporting

• Industry standard reports built in and ready to use
• Simple data export dialogue to csv or MS Excel format 
• Fully customisable - editing existing reports or create new ones
• Report formats: Text, Graphics, Trends or any combination
• Report Creation: Automatic (Timed or Event), On demand
• Report Generation: Display, Printed, Email, SMS Text Message, pdf for electronic storage
• Reports can display any monitored parameter in any combination required including :

Efficiency, Run time, OEE, Good production, Utilisation, Scrap rate, Capacity utilisation, Material usage, Set up time, Scrap by reason, Down time by reason, Custom defined parameters.

• Reporting By

Machine centre, Tools, Products, Reject/Scrap Rates, Machine Speed, Target Production Rates, Workcell , Operator, Multiple Operators, Shift, Batch/Works Order/Lot/Job etc.

Downtime

• All downtime events are recorded including all short or micro stoppages
• Downtime reasons are recorded for long stoppages
• Each asset has unlimited user defined reasons
• Flexible interlock option to ensure downtime reason selection
• Multiple sequential reasons can be assigned to downtime events
• Add comments to downtime events to aid analysis

Downtime Viewers/Dashboards

• View, analyse and manage downtime per machine or across any number of machines
• Tabular and Graphical Viewers
• Sort and filter events by time, duration, type and reason
• Edit - assign, split, combine or amend downtime events
• View and report downtime statistics by:

Totals, Percentages, Reason, Number, Level, Greatest time, Greatest count, Pareto analysis
Compare downtime between machines

Machine Speed Optimisation

• Machine operating speed continuously monitored
• Reasons assigned to slow speed running
• View, analyse and report like downtime

Graphs/Trending

• Graph any parameters in real-time or historically over any time period

Quality

• Automatic capture or manual entry of scrap count and reason
• Different categories of scrap can be handled
• Alerts for quality checks based on product count, time interval etc.
• Interlock can disable production until quality checks have been carried out

Andon Call Request

• Call for assistance from the asset (engineer/team leader,QC, materials etc)
• Track response and resolution times
• Supports Andon light stacks
• Call requests sent via SMS text message, email, public address, large screen displays (Display Node)

Paperless Work Instructions

• Paperless visual work instructions accessed from graphical interfaces, PC, touchscreen, tablet, smartphone
• Common document, image, video and sound files supported
• Run files from on screen button action or automatically (on product change etc)
• Centralised storage on the system or remote networked folder ensures version control

Plant Maintenance

• Call for engineer assistance from the asset
• Alert maintenance engineers by SMS text, email or public address messaging
• Track engineer response and repair times to breakdowns/stoppages
• Track machine run / cycle times for any number of machines
• Alert when maintenance is due based on actual machine usage
• Track maintenance and fault rectification durations
• Provides information database for storing maintenance & training documents;

Standard Operating Procedures, schematics, parts numbers, photographs, video images etc.

IP Video Camera Control

• Connect any number of IP cameras
• View live camera feeds remotely enterprise wide
• Record video for later analysis (manually or automatically triggered)

Read detailed article on IP Video Camera Control

Web Internet Access

• Any system displays and reports can be viewed securely over the internet
• Interactive system capability over the internet
• Smartphone/tablet capable

Recipe & Batch/Works Order/Lot/Job Facilities

• Unlimited recipes can be stored
• Full batch/works order/lot/job handling capability

Hardware

• Operator Terminals

Rugged terminals with wipe clean keypads and multi-line displays
Stainless steel version for food, pharma and clean environments

• PC, Tablet (Android, Apple IOS, Windows) and Touch screen interfaces
• Barcode scanners
• RFID & Swipe card readers
• Display Node - generate large format KPI and message displays on TV, monitor or projector

Security

• Data is held securely, fully under customer control
• User password protected
• User defined privileges delimit system access
• Machine use can be restricted by privilege - prevents use by untrained or unauthorised personnel 

Traceability

• Enhanced security capable of compliance to FDA 21 CFR Part 11 and equivalent standards
• Digital Signatures
• Audit Trail

Time & Attendance Tracking - Who is in?

• Track who is on site - staff/visitors
• Track who is at each asset
• Reporting & Analysis of time and attendance

Connectivity

• Driver Library / OPC Client - Server

Allows connection to thousands of industrial devices

• SNMP
• SQL Database
• Exchange data with third party software, ERP, MRP systems etc.

Custom Development

Feature not found above? We can probably develop it - please ask.