The ideal factory... tailor-made for all needs. A fully fledged integrated system managed by an efficient information technology system able not just to change a company's way of working, but also its relationship with the end user.
The industrial world is subject to constant innovation: both in terms of technology and methodology. Thus, company choices fall on solutions that can guarantee the greatest rapidity and efficiency. In this sense, the Emmegi group was the first company in its sector to present a totally new concept for window and door manufacturers - DOT.LAB. We are talking about the now famous ‘ideal factory’, designed with the synergic combination of elements including automation, robotics and telecommunications. A fully fledged integrated system managed by an efficient information technology system able in practice not just to change a company's way of working, but also its relationship with the end user. The DOT.LAB project today takes a further step forward with the introduction of a new strategic function, DL Solution. This consists of various technical devices which transversely connect all elements in the company's cycle (men, programmes, machines, materials etc.) by means of sophisticated data processing infrastructure.
A transversal language So where does the originality of the DL Solution lie? Basically the proposal includes two lines so users can adopt different approaches: DL Neural Solution and DL Kit Solution. DL Neural Solution is based on the Neural Operating System, a computerised system developed with the most modern software technologies - to manage communications and the exchange of data with peripherals; sort chronologically, combine and process the basic information acquired in the field; interface with external management software and guarantee both coexistence and synchronisation. Neural Operating System runs on a dedicated server and is connected to the latest generation Cell hardware via cable or Wi-Fi.
The heart of the system Emmegi designed and developed Cell to support standard technologies like digital I/O, RS 232/485, CANBUS, and it comes with its own operative system and specific drivers for bidirectional dialogue with the widest variety of equipment. On the one side, Cell is fitted on the workstations being monitored and collects pulses consisting of all the data, events and signals generated during the shop floor cycle (times and volumes produced, machine status, anomalies, malfunctions, alarms etc). These can then be used to provide useful information on production, performance, critical points and action taken. Cell also provides operators with indispensable input enabling them to proceed correctly and take the decisions required to manage their work appropriately.
The information collected is then made available in various forms depending on the role of the user and data can be displayed by means of a special Web console. So this can also be done from any PC workstation, on the company network or via the Internet, through a standard web browser, in other words without specific configurations or software programmes. The programme can perform more or less detailed analyses depending on how many collection points (Cells) are connected. One of the special strengths of the system lies in the simplicity of its use. It masks its complexity to operators by requiring them to make small actions that do not have a significant effect on their working habits. They can use an iButton to confirm their attendance; this is a special personal identification device with a unique, non-duplicable code that is extremely handy (because it is small) and highly resistant to shock and chemical agents due to its stainless steel casing.
The iButton and the other user interaction devices (barcode readers, touch-screen display, labelling machines etc.) together complete the overall vision of the activities carried out on the shop floor, tracking the operator who performed a given process: when this was done and how long it took, the machines/complementary equipment used (cutting-off machine, working centre, bench etc.), and the product machined (profile, sash, frame, door/window) within a specific job order.
DL Neural is also accessible via a dynamic web portal. Each user enabled through authentication can access the software modules that the system administrator has associated to their profile. The basic solution includes the data analysis module that can be used to visualise the most important indicators for production control and optimisation through a series of statistical reports. SCHEDULER, the “virtual secretary” can be used once and for all to configure the most significant reports and how often they are generated; the operative system will then automatically send them as PDF attachments by email. TIMETRACK is the software module used to manage personnel attendance, who can now also use their iButton to “clock on”. ZOOMER is the virtual graphic representation that makes it possible to control the real-time status of the shop floor: who is working, what jobs are active, what the machines are doing and the overall performance of the whole production system. Lastly, we announce the upcoming marketing of DL MAP, an extension of the DL NEURAL system for GPS fleet management. Likewise based on web technology, the system allows real-time tracking of the vehicles during deliveries and installation thus ensuring constant supervision of all stages in the production order.
The management software DL Neural is natively integrated with EmmegiSoft software packages dedicated to specific company functions and requirements: FP Pro for design and FP Gest for production planning and management. But the system can also be interfaced with software of other manufacturers, using standard and user-friendly technologies.
Tailor-made packages for all needs The DL Kit Solution completes the product range; a line of kit solutions configured in advance to manage some specific issues and problems in the production process. So it is possible to gradually introduce technological innovation into routine working habits, without precluding the possibility of future expansion of the information technology system on the shop floor, and recovering investments already made. The “personal assistant” functions performed by the DL Kit systems head in this direction:
DL Quality, assistant for CE marking
DL Stock, assistant for picking up materials from stock (profiles and accessories)
DL Cut, assistant for cutting
DL Line, assistant for assembly
DL Roto, assistant for packaging and labelling of the finished product
DL LINE / ROTO
Incessant research and development DL Technical Solution reflects the mission of the Emmegi group to invest in continuous innovation. So, the Research & Development division plays a particularly important role that does not stop at mechanical technology alone, as we have seen, but that also continues into the software sector, where the highly professional company staff is encouraged to come up with constantly new solutions based on the needs of the customers. The company is committed to working closely with its customers at all times and its partnership with them is based on the indispensable value of joint development.