¶ 1. Introduction to PlantStar 4.0
¶ 1.1 Overview
The primary benefit of PlantStar 4.0 is the ability to schedule and manage every aspect of every production or manufacturing Job. Using all the available Configuration Managers (e.g., Machines, Tools, Materials, etc.) allows administrators and plant managers to have real-time data at their fingertips and avoid interruptions to product out the door.
Some of the Managers are optional; for example, you don’t have to enter Tool or Materials data to use the Job Manager and generate productivity reports. But the more data you enter and allow the system to use for analysis, the closer you will be to your OEE and production goals and to maximizing the productivity of each of your machines.
Data is power. Our software gives YOU the power to take control of your production schedules and maximize the assets in your plant by using the data you input to analyze what’s happening on your plant floor. The more data you collect, the more you’ll know, and the more efficient you can be. .
Please don’t hesitate to contact us (574.232.3900) if you need help with your initial data input or configuration. We have the personnel and the resources to get you up and running, fast.
¶ 1.2 System Architecture Overview
There are three components essential to every PlantStar System:
- One or more Data Collection Modules (DCMs) to gather raw data from manufacturing machines on the plant floor.
- An Application Processing Unit (APU) to collect and process the raw data that was gathered by the DCMs and provide HTML-based interfaces for users to interact with the PlantStar system.
- One or more Client Machines to interact with the pages served by the APU. This can be any computer(s) on your network with a web browser.
¶ 1.3 Application Process Unit (APU)
The main PlantStar 4.0 computer is referred to as the Application Processing Unit (APU). The APU is a powerful Debian Linux server that contains the PlantStar database, PlantStar software and all necessary configuration files. SYSCON provides the APU to the customer, with all software already installed and pre-configured
The APU has three primary responsibilities within the system:
- Gathering data from the DCMs
- Maintaining the PlantStar database
- Providing a web server to facilitate all user interactions with PlantStar.
All data collection modules (DCMs) connect to the APU computer. If DCMs are enabled (connected to the APU), then all data from the DCMs is automatically stored on the APU and can be viewed from other computers in real-time.
Primarily, the APU will be accessed by system administrators with proper credentials.
SYSCON International may retain APU access via a Virtual Private Network (VPN) for purposes of trouble shooting and system monitoring. Control-level access rights will be agreed upon between the customer and SYSCON.
Note: The PostgreSQL-11 database comes with the Debian installation and cannot be changed. Customers will not be able to write directly to this database but will be able to read from the database if needed.
¶ 1.4 Data Collection Module (DCM)
A Data Collection Module or DCM is an industrial-grade device that resides on the factory floor. It is responsible for three tasks:
- Maintaining hard-wired interfaces with manufacturing machines,
- Gathering the data sent out by those machines and storing it internally,
- Sending that data to the APU when requested by the APU.
A single DCM can interact with as many as 16 machines via digital connections and 24 via analog connections. Depending on the number of machines and physical layout, a plant may utilize as few as one or as many as dozens of DCMs.
Each DCM can be set to run in either of two modes:
- When Display Mode is used, a touchscreen monitor and keyboard are directly attached to the DCM. This allows a DCM to double as a PlantStar client, available to operators on the factory floor. This allows operators to view data about the current machine processes and to input relevant information (e.g., force the machine into down status).
- A DCM in Blind Mode can be put in any location in the vicinity of your manufacturing equipment, then accessed remotely via any client computer on your network.
Note: In earlier version of PlantStar, each DCM ran its own web server to provide an interface to machine operators. As of version 4.2, This function has been moved to APU. This simplifies the connection between the APU and the DCM and vastly improves speed and efficiency.
¶ 1.5 PlantStar Clients
The PlantStar 4.0 is user interface is a browser-based system. This means that the software runs on the APU, which interacts, via built-in web server software, with any client device you choose.
Any device on your network that is browser-enabled can be used as a PlantStar client. These could be desktop computers, laptops, tablets, etc. No special software is necessary to access the PlantStar system. You just need to direct your web browser to the IP address of your APU or any DCM.
With a client interface (and appropriate user rights) you can configure your system, schedule jobs, view machine statuses in real-time, create reports, etc. The number of clients is dependent on customer need and preference.
¶ 1.6 Human-Machine Interface (HMI)
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A Human-Machine Interface (HMI) is an industrial strength computer, specifically designed and built by SYSCON to work as a shop floor client. HMIs feature a 15-inch touchscreen monitor and four external USB ports for connecting devices such as keyboards, printers, and code scanners. An optional external HDMI port is available for displaying your production data on a large screen monitor. Using an HMI (shown here with an optional pedestal), operators and shop floor personnel can quickly perform a variety of important tasks, including:
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