At ITMA 2015 in Milan the Oerlikon Manmade Fibers Segment presents the next development stage of its modular Plant Operation Center (POC). The software and Internet based control system now captures the complete manufacturing process and is said to represent Industrie 4.0, the fourth industrial revolution.

The extended process and production control system can now capture and digitise all the steps of yarn production and processing including plant technology from third party suppliers. In addition, it can be linked to ERP systems such as SAP. The networking of several plants via cloud computing is likewise possible, opening the door for manufacturers to highest process efficiency and transparency at Industrie 4.0 level. 

The production technology is linked via computer and Internet technologies, production and machine data are available in real time, as well as over the entire value chain. This is said to allow for extremely fast reaction, creating maximum traceability and planning reliability, and thereby continual improvement of processes and competitiveness.

Control in real time

Using this job and product tracking system, authorised personnel can track at all times, which product is being produced at which position and in which quality, whether machine performance and production quality are currently correct and whether production is on schedule. 

As a result, the POC is becoming increasingly mobile and besides the desktop and web-based workstations available from the very beginning, also supports smartphones and tablets. This is true particularly in the case of tools to control and improve operating performance and task management. 

Tools for greater operating efficiency

Operators can also view critical operating conditions and urgent tasks on mobile devices. The appropriate tools provide a clear overview of the processing priorities using a colour code, the company reports. Thereby operating efficiency can be considerably increased and maintenance and servicing better planned and carried out just in time.

Authorised management personnel can also access the current Key Performance Indicators (KPI), which were previously stored on the POC server or on the Intranet of the customer, per smartphone, anytime and anywhere. The current status of the machines and installations can be recognised immediately in regard to target values, via the traffic light colour scheme on the display.

Modular and adaptable

In a POC network, information can be exchanged between production sites in a safe and controlled manner. Cloud computing enables the provision of data, KPIs and recipes. This smoothens the way for best practice processes in the global production network, according to the manufacturer.

"With our extended POC our customers receive all information at an early stage to steer course for efficiency and thus success in production. Shift management, personnel deployment and centralised reporting are made easier, and time and resources saved. At the same time, we adapt the POC precisely to the requirements of each individual customer,” explained Reinhard Muehlenmeister, Head of Software Solutions.

According to company information, there are approximately 100 POCs currently installed at customers of Oerlikon Manmade Fibers around the world. "Quality and traceability are playing an ever greater role in business. There is also demand for highest efficiency, planning reliability and data integration. That's why we are working on the POC of tomorrow – today,” added Muehlenmeister.

www.oerlikon.com/manmade-fibers