MES-PLC Work Instructions for Real-Time Abnormal Response
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Solution Overview
Problem
Existing production processes face inefficiencies and accidents due to the inability to promptly address abnormal situations using traditional technical instruction manuals, leading to reduced productivity and potential hazards.
Innovation Solution
A system and method for real-time communication and data processing between Manufacturing Execution System (MES), Programmable Logic Controllers (PLCs), and host computers to provide immediate technical instructions to workstations through display devices, ensuring timely handling of abnormal situations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional technical instruction manuals are used, then device complexity is reduced, but response time to abnormal situations increases and production efficiency decreases
Solution Approach 1:
The system pre-establishes a database of abnormal situations and corresponding technical instructions in the MES. When an abnormality occurs, the system has already prepared the relevant instructions, eliminating the need for manual searching and enabling immediate retrieval and display of appropriate technical guidance.
Solution Approach 2:
The patent introduces an MES as an intermediary system between the PLC and the technical instruction database. The MES receives abnormal situation data from the PLC, queries the instruction database, and returns the appropriate technical instructions, thereby automating the information retrieval process and reducing response time without requiring direct complex connections between all system components.
2Productivity
If real-time communication systems are implemented, then production efficiency improves, but device complexity increases
Solution Approach 1:
The MES serves multiple functions: it monitors production status from the PLC, queries the technical instruction database, manages the display of instructions on workstations, and handles data storage. By making the MES multi-functional, the system achieves real-time responsive capabilities without adding separate dedicated components for each function, thereby improving productivity while controlling overall system complexity.
3Measurement precision
If manual inspection processes are used, then ease of operation is maintained, but accuracy of technical instruction delivery decreases
Solution Approach 1:
The system enables self-service by automatically detecting abnormal situations through the PLC, querying the appropriate technical instructions from the MES database, and displaying them directly at the workstation. This eliminates the need for manual inspection and retrieval processes, ensuring accurate delivery of the correct technical instructions while maintaining ease of operation through automated workflows.
Solution Approach 2:
The system implements feedback mechanisms where the PLC continuously monitors production status and automatically triggers queries to the MES when abnormalities are detected. The MES then provides feedback by returning the appropriate technical instructions, creating a closed-loop system that ensures accurate and timely delivery of technical guidance without manual intervention.
Data Source
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AI summary
Provided are a working instruction method and a production control system. The method includes: obtaining (S110), by a first PLC (203), a first working instruction request including a working instruction identification requested by a target workstation from a second PLC (204); sending (S120), by the first PLC (203), a second working instruction request including the working instruction identification to a MES (202) based on the first working instruction request; receiving (S130), by the first PLC (203), a working instruction response including working instruction type information returned by the MES (202) based on the working instruction identification; and sending (S140), by the first PLC (203), the working instruction type information to a host computer (201), searching, in the host computer (201), working instruction contents based on the working instruction type information and sending the working instruction contents to a display device connected to the target workstation.