From cooktops to innovative high-tech materials: SCHOTT AG has proven expertise in the manufacture of specialty glass and glass ceramics. As processes and materials are quite demanding, operators must perfectly execute the complex processing steps to ensure that product quality is constantly at a high level. The digital operator guidance system weasl by the solution provider iSAX supports operators in their daily work routine. The use case illustrated below outlines the benefits for customers and how all integrated systems, such as ERP, MES, and operator guidance interact.
SCHOTT‘s digitalization strategy pushes a long-term, sustainable, and flexible solution architecture. Early on in their digitalization process, the company opted for the Manufacturing Integration Platform (MIP) to meet these requirements. Existing applications can be connected easily and new applications added in no time — no matter if mApps from MPDV or from third parties like those from iSAX are to be integrated. This way, SCHOTT can equip its staff with integrated solutions perfectly matching the requirements and at the same time pursue its superordinate digitalization goals.
“When we searched for the right operator guidance system, we wanted to find a standard solution that can be customized as needed and quickly integrated,” explains Heike Vocke, managing partner of iSAX GmbH & Co. KG. Further objectives were a completely paperless production and optimized processes to ensure product quality: “Our operator guidance system weasl meets all these requirements.” SCHOTT uses the software as manufacturing app together with the Manufacturing Execution System (MES) HYDRA on the MIP integration platform. Since the introduction of weasl, SCHOTT has managed to increase quality, productivity, and efficiency in production and to reduce costs.
Reasons for a digital operator guidance
weasl guides operators through their production processes and helps them perform specific tasks reliably without any errors. This becomes even more important as product diversity and complexity increase. Operator guidance systems support companies in their efforts to increase process and product quality and help them reproduce the same quality standards. The main objective still is to avoid rework and scrap.
In addition, the information generated during the work process is documented and passed on to other systems without the need for paper. Real-time data resulting from manual activities can be forwarded to production planning, for example. So, if a machine is down or material missing, you can easily and quickly trigger replanning. This also eases the strain on operators, which is a useful side effect.
Support with CNC processing
Consistent data integration makes sure you keep track of everything: “SAP provides production orders via the integration platform MIP. The process editor of weasl creates detailed work plans and specific work instructions that perfectly guide employees step by step,” Vocke explains. All data required to execute the production order is transferred to the machine’s shop floor terminals.
In SCHOTT’s pilot project, machine operators are supported particularly in CNC machining: “Our aim was to avoid printed Excel handouts and to enable our operators to directly interact with the system,” Vocke outlines and continues: “They now get all information they need to set up the machines. This also includes specific instructions on where special attention is required.” Since CNC machining usually takes quite a while, tests and measurements have to be carried out at regular intervals while processing an operation. The operator enters the measured values directly on the machine terminal. All data is centrally available and you can track how a part has been processed on a machine. weasl uploads the order and all related data to HYDRA or SAP via the MIP.
SCHOTT’s system architecture
The integration platform MIP provides the information on production orders, workplaces, and resources that is required for operator guidance. The weasl app supplies the required step-by-step work instructions.
SCHOTT has developed its user interface MIPS UI that integrates all mApps on a uniform UI. Consequently, operators are always provided with current information they need for their work steps. The user interface MIPS UI integrates weasl and the MES applications of HYDRA. According to Vocke, it was fascinating to see how quickly manufacturing apps like weasl have blended in the overall architecture. Integrating the operator guidance system with HYDRA via the MIP Connector was challenging, “but the teams have done a great job together,” Vocke says happily.
Further information
Overview of system architecture
- MIP is used as integration platform
- SAP is used as ERP and planning system
- HYDRA is used as MES
- weasl operator guidance as additional manufacturing app has been tested and implemented.
About the digital operator guidance system weasl
- Available as SaaS (cloud solution) or on premise
- Software can be rented (concurrent user license model)
- Can be used on stationary and mobile devices
- Machines and systems can be integrated via different interfaces
- Integrated security features for secure handling
- Can be extended by customized modules, third-party applications, and as required via open interfaces
- iSAX is an expert solution provider in the MIP ecosystem
About iSAX
iSAX has specialized in integrated Industry 4.0 solutions focusing on industrial IoT. More than 20 years of profound experience in process automation, data integration, system architecture, and implementation make the company, headquartered in Dresden, a strong partner in the discrete manufacturing and process industry. iSAX offers integral expertise from consulting (integrating all types of technologies) to operating customized applications.
About SCHOTT
Pioneering – responsibly – together. These attributes characterize SCHOTT, a manufacturer of high-tech materials for specialty glass. The founder Otto Schott is considered its inventor and became the pioneer of an entire industry. Always opening up new markets and applications with a pioneering spirit and passion — this is what has been driving the #glasslovers at SCHOTT for over 130 years. Represented in 34 countries, the company is a highly skilled partner for high-tech industries. With the best teams, supported by the best digital tools, the group intends to grow further.