OEE Toolkit RC Revised ManualUS

RemoteCollect
Manual
5.4
12th of September 2007

FullFact bv
info@fullfact.com
www.fullfact.com
© 2007 FullFact
X RemoteCollect Manual
RemoteCollect Manual OEE Toolkit 5.4 FullFact – Your Partner in Productivity • 2-49
X.0 Introduction and table of contents
Introduction RemoteCollect is a system for collecting OEE data in an efficient and

accurate way. This manual contains information regarding different areas of
application, electrical diagrams, configuration and the daily use of
RemoteCollect. The information regarding the electrical diagrams and the
configuration has been written for a public with a technical background.
X RemoteCollect Manual 2
X.0 Introduction and table of contents................................................................... ..............3
X.1 Before starting.................................................................................... ..........................4
X.2 Technical specifications.................................................................... ............................6
X.3 Connecting the I/O module..................................................................... ......................7
X.4 Installation and configuration.............................................................. ........................14
X.5 Using RemoteCollect............................................................................... ...................31
X.7 RemoteCollect Functions................................................................................... .........37
X.8 Appendix 1...................................................................................................... ............44
X.1 Before starting
RemoteCollect RemoteCollect has been developed to make OEE data collection easier
and more accurate. RemoteCollect can be used on all production
processes, whether discrete production or continuous processes.
In the RemoteCollect software various different types of measurement
have been defined.
Where to The measuring point must be installed as close to the location where value is
measure added as possible .
Kinds of Signal RemoteCollect can manage 3 kinds of signal: “Output counter”, “Machine
status” and “Heartbeat”. These 3 signals are described below.
The reasons for stops are standardized by the users in a predefined table. If
RemoteCollect detects a stop it is then possible to choose the reason for this
stop from the table.
Output counter The 'Output counter' uses 1 input signal. This signal is linked to the product.
The pulse provides information about the number of products produced.
RemoteCollect detects that the machine is in production because there is
output of products.
Production times; with a bottle filler for example, it is usually possible to count
the number of products when the line is producing. Counting the bottles (1
pulse = 1 product). RemoteCollect has the capability to factor this signal.
For example, if 6 bottles are filled at the same time the product factor is 6.
Machine status 'Machine status' uses 1 input signal. This signal is linked to the status of the
machine. RemoteCollect only detects whether the machine is producing or
not. Stops can be defined and their lengths configured for each machine. The
pulses are not related to the number of products. The pulse is continuous
when using 'Machine status'.
For example, if a milling machine produces 1 product during 5 hours, when
the milling machine is running the machine signal (RemoteCollect input
signal) is continuous. In this way RemoteCollect detects that a machine is
producing. If the signal changes to 0 RemoteCollect has detected a stop.
Heartbeat The 'Heartbeat' signal is very similar to the 'Machine status' signal. There is
one difference. In the heartbeat mode RemoteCollect gets a pulsing signal
instead of a continuous signal. However, these pulses are not related to
products. The data processing is the same as the 'Machine status' signal.
Sensor Decide whether RemoteCollect needs to detect an external signal.
RemoteCollect needs a signal to determine if the machine is producing or has

stopped. This can be done by counting products coming out of the machine.
If there is a sensor, then a relais signal or a PLC signal containing this
information can be used. No other external sensor is necessary. The electrical
diagrams are included in this manual.
Computer Location of the operator panel (computer).

The operator panel has 3 functions:
1. Manual input of the reasons for stops.
2. Dislay of real time OEE graphs updated every second.
3. Connection of the machine signal (sensor).
The operator panel should be located in a place where it is easy for the
operator to process the data. If it is dirty and wet an IP 65 touchscreen could
be a solution.
Remote- Before configuring RemoteCollect certain issues should be dealt with. The
Collect checklist below can be used as a guide during the configuration.
configuration
Remote- Utilities Execution Who When

Collect Computer near machine Touchscreen, normal PC
checklist Remote I/O module COM, USB
Machine signal External sensor
Connecting hardware to Remote I/O and signal
PC
OEE Awareness Management
OEE Awareness Operations team
OEE Toolkit knowledge Managing OEE Toolkit
OEE Toolkit knowledge Processing data
OEE Toolkit knowledge Analyses
X.2 Technical specifications
Operating PC with Windows 2000 or Windows XP

system
Processor CPU 600 Mhz

Internal memory 512 MB
Hard disk 50 MB
Screen Touchscreen or screen with 1024 x 768 resolution
Network LAN 100Mb
Remote I/O Connection of the PC to the I/O module is possible in 2 ways, RS232 or USB)
modules Signal to other modules RS 485
Maximum length between the modules: 3000 meters
Input of I/O Connections on Remote I/O module

Input signals activitated with “0”
Output relais max 1 A, 220 V
PNP (1 per module) and NPN sensors can be connected.
Touchscreen* IP 65 Fanless stainless steel casing

17 Inch screen
Integrated PC
* RemoteCollect is developed for Touchscreen but functionates also with a normal PC.
X.3 Connecting the I/O module
Before This chapter includes the electrical diagrams for RemoteCollect. Some
starting technical knowledge is recommended.
Types of RemoteCollect usually works with 2 types of Remote I/O modules depending
Remote I/O on the connection to the PC. There is one for the serial port (COM, RS 232)
modules and one for an USB port (pictures below).
COM type USB type
Connecting The connection of the remote I/O modules is explained in the electrical
the remote I/O diagrams and in writing. The electrical diagrams for both COM and USB
module connections are followed by explanatory texts.
Connecting The connection of the sensor is explained after the instructions for the COM
the sensor and USB connections.
COM The electrical diagram below shows the COM type module. The diagram has
Electrical 4 drawings.
Diagram
COM (RS232) Network adapter – 24V AC

Components Adapter to COM connection EX 9520
RS 232 cable
Remote I/O module EX 9065 D
COM (RS232)
COM (RS232)
(continued)
USB Electrical The electrical diagram below shows the USB type module. The diagram has 4
Diagram drawings.
Attention: install the USB driver, C:\Program Files\OEE Toolkit 5\Drivers
USB Network adapter – 24V AC

Components Adapter to USB connections EX 9530
Remote I/O module EX 9065 D
USB
USB
(continued)
Explanatory Below are the explanatory texts for both COM and USB connections.
text for
Remote I/O
Connection
COM (RS232) Connection of the EX 9520 Connection of the EX 9065D

Connection Serial cable to COM Port
(B)GND 10 0V (B)GND 10 0V
(R)+Vs 24V (R)+Vs 24V
Data+ Data+(EX 9065D) (G)Data- Data - (EX 9520)
Data- Data-(EX 9065D) (Y)Data+ Data+ (EX 9520)
IN 1 * (B)GND 10 (gives
pulse)
IN COM * (R)+24V
* Use the information under the heading “Connecting sensor" if an external sensor
will be used instead of a contact for the signal.
USB Connection of the EX 9530 Connection of the EX 9065D

Connection USB cable to USB Port
(F)GND 10 0V (B)GND 10 0V
TX+/D+ (Y) Data+(EX 9065D) (R)+Vs 24V
TX-/D- (G) Data- (EX 9065D) (G) Data- TX-/D- (EX 9530)
(Y) Data+ TX+/D+ (EX 9530)
IN 1* (F)GND 10 (gives pulse)
IN COM * (R)+24V
Attention: install the USB driver, C:/program files/OEE toolkit 5/drivers

* Use the information under the heading “Connecting sensor" if an external sensor
will be used instead of a contact for the signal.
Connecting Standard PNP (sourcing) type sensors have a voltage pulse if they detect
Sensor something. Connect this sensor as follows.
IN 1 (B)GND 10 (gives pulse)

IN COM Black sensor cable (pulse)
Brown sensor cable 24V
Blue sensor cable 0V
Standard NPN (sinking) type sensors have a voltage drop if they detect
something. It is possible to connect more NPN sensors to one EX 9065D
module. Connect this sensor as follows.
IN 1 Black sensor cable (gives pulse)

IN COM 24V
Brown sensor cable 24V
Blue sensor cable 0V
X.4 Installation and configuration
Installation Installation of OEE Toolkit and RemoteCollect is quite simple. Both programs
are installed by the OEE Toolkit setup.
Choose the 'standard installation' option during installation.
Sequence OEE Toolkit and RemoteCollect use the same database. The masterdata
must be completely configured in the OEE Toolkit before using it with
RemoteCollect. Information about this configuration can be found in the OEE
Toolkit manual. Also check the licence code because RemoteCollect must be
activated using this code. Contact FullFact or your retailer for this code.
It is important for RemoteCollect that the following definitions are added to the
OEE Toolkit masterdatabase:
In activities:
• Minor stops, a name for a category of stops which are too short to
justify a reason. This kind of minor stop must be configured in the 'Idle'
category.
• Undefined stops, a name for a category of stops which are not justified
when RemoteCollect is closed. This kind of undefined standstill must
also be configured in the 'Idle' category.
• Hardware failure, a name for a category which accounts for the
duration of a problem with the remote I/O module. This kind of
standstill must be configured in the 'Failure' category.
In products
• Undefined products, if products which have been produced are not
justified.
Open the Machine-Time-Product table in the OEE Toolkit masterdata and link
the newly defined names of stops and products to the related machines.
Configuration The configuration of RemoteCollect is executed by a wizard. The wizard has

two parts. In the first part the general settings of the computer are configured.
In the second part the specific settings of a machine are configured.
Computer Configuration of the computer which deals with the machine signals.
settings
The first time RemoteCollect is used the wizard will open.
Activating the To reconfigure the settings again the wizard can be activated by modifying the
Wizard shortcut.
Click with the right mouse button on the shortcut to modify the properties.
Attention: the extension /init must be inserted after “the” with a space
between.
Close this window and start RemoteCollect.
Don't forget to delete /init after reconfiguration of the settings.
RemoteCollect Verify that the hardware is connected to the computer before proceeding.
Configuration
COM port The Baudrate, databits, Parity and Stopbits settings are already OK.
Configuration Click 'Detect Hardware'. The scan will detect which port the Remote I/O
module is connected to.
Double click on this port to save this setting.
COM port Double click on this port to save this setting.

Configuration Click ‘Next’.
(continued) Attention: If theRemote I/O module is connected via USB then the USB
driver must be installed. See C:/program files/OEE Toolkit 5/drivers.
Computer Local user settings/preferences of the computer connected to RemoteCollect
Settings can be configured here.
Configuration Configuration of the user rights can be modified if there are any preferences.
of user rights These settings can be modified later for each machine.
Adding Click on 'Add..'
Machines Choose the machine(s) which will use RemoteCollect.
Click ‘Next>’
Connecting If there is a connection between the I/O module and the computer then the !
Machines 019065D text will be displayed.
If this is not the case, click ‘back’ and refer to appendix 1.
Once the connection is made, the machine settings can be configured.
Click ‘<Prior’.
Configuring Select the machine which needs to be configured.
Machines Click 'Edit...'
Repeat this procedure for the other machines if more than one machine is
connected to one computer.
Machine Configuration of the machines connected to the computer.
settings
Hardware 1. “Sensor-style” setting:

Sheet • “Output counter” if output is counted in products.
• “Machine status” if the status of the machine is monitored.
• ”Heartbeat” if the machine gives pulse signals when it is running.
2. Address: the default setting of 1 is OK. Modify this setting only if more I/O
modules are connected.
3. Product Sensor port: the default setting is 1. Modify this if there is another
I/O module input, e.g. more than one machine.
4. # undefined activities allowed: this setting defines the maximum number
of activities which can be undefined.
5. Signal-output: if the allowed undefined activities number is reached then
an output signal will be activated. This output port number can activate an
audiovisual signal (lamp or horn).
6. Sample size: this setting defines the frequency at which the velocity is
measured. The velocity of the machine is shown in real time on the
machine screen.
Refresh every: refresh period of the machine velocity.
Unresolved It is possible to define reasons to minor stops, which are not justified and/or
Activities when RemoteCollect itself has a hardware problem, automatically. In this way
Sheet those time periods can be analyzed.
It is also possible to select a default product category for production runs
without a defined product.
Attention: these stops must be configured in the OEE Toolkit before including
them in the 'Unresolved Activities' setup.
Threshold Configuration of minor stops and stopcode.
time Sheet:
Rule: the time between 'Minor stop 5 Sec.' and 'Stopcode 10 Sec'. will be
automatically counted as minor stops.
If there is a stop of more than 10 seconds then the operator should justify this
stop by choosing a reason.
If there is a stop shorter than 5 seconds, then this stop will be counted as
production time.
Product- Configuration of Product-multipliers.
multipliers Attention: if the number of decimal places is configured at 0 then it is not
Sheet possible to set the factor to 0.5 for example. Go back to the beginning of the
wizard and adjust the number of decimal places.
Example: the sensor counts the number of machine strokes. Every stroke is 2
products. In this case adjust to 'Default multiplier 2'.
Exceptions can be configured in the 'Default multiplier' table below.
Activity Activities can be configured in groups to improve visualization.
Grouping Every group may include a maximum of 14 activities.
Sheet Click on the activity (or stopcode) on the right-hand side, then click on 'Add
Activity' to move the activity to the group on the left-hand side.
The default categories are based on: idle, line restraint, failure and
unscheduled.
Activity By clicking on a group with the right mouse button, the colour and edit options
Grouping appear. It is possible to edit the display name and the colour.
Sheet Attention: Only activities defined in the OEE Toolkit are available. Activities
(continued) should first be added in the OEE Toolkit.
Out of Specs Out of specs. output can be configured in groups to improve visualization.
Grouping Every group may include a maximum of 14 scrap or rework reasons.
Sheet Click on the scrap or rework reason on the right-hand side, then click on 'add
Out of Spec' to move this reason to the group on the left-hand side.
By clicking on a group with the right mouse button, the color and edit options
appear. It is possible to edit the display name and the colour.
User rights If there are different user rights as the default settings for a certain machine
Sheet for then these settings can be modified.
each machine Click ‘OK’.
More than one One machine has been configured.

machine Repeat the procedure if there are more machines connected to the computer.
X.5 Using RemoteCollect
Starting Modify the shift and/or team after starting or after a shift change by clicking
RemoteCollect on the button below on the left-hand side of the screen.
Justifying A stop only needs to be justified if it takes more than the minimum time period
stops configured for the machine.
1. Click on the machine.
1.
Justifying 2. Select the category or group to which the stop is related.

stops
2.
Justifying 3. Select the reason for the stop.
stops
Justifying 4. It is also possible to justify the stop at a later time. Click on the
stops 'undefined' button in the screen below to justify the stop. Every button
in the screen below is related to a stop or production time.
4.
What is a 5. A minor stop is a stop which takes longer than the minor stop time
minor stop? setting configured but shorter than the time setting configured for a
stopcode.
6. This time period will automatically be counted as 'minor stops' without
interference of the operator.
5.
6.
Selecting It is possible to select products after the start of a production run.
Products 7. The purple color and the “Select Product” text indicate that the current
product should still be selected. Click on the machine.
7.
Selecting 8. Select the product.

Products These are the basic functions of RemoteCollect. An explanation of these
functions can be found in Chapter 6.
8.
X.6
X.7 RemoteCollect Functions
RemoteCollect Starting RemoteCollect

Functions 1. Initializing hardware. RemoteCollect hasn’t defined a production,
minor stop or real stop status yet. This situation will change if a
something is produced or a timespan is exceeded.
2. Production? Will there be production?
1.
2.
RemoteCollect Starting RemoteCollect:
Functions 3. Minor stop? The production timespan has been exceeded. If the
sensor detects a product then this time period will be counted as a
'minor stop'.
3.
RemoteCollect Starting RemoteCollect

Functions 4. Select the activity. The timespan of a minor stop has been exceeded.
The reason for the stop has to be selected.
4.
Main screen, signal lights:
5. Background color of the button shows the reason for the stop.
6. Yellow light; there are stops which are not defined.
7. Red light; there are more undefined stops then the maximum
configured.
5. 6. 5. 7.
8. Selecting the reason for a stop:

The stop can be selected on this screen. The reasons buttons are one level
below the current activity buttons. See picture below.
8.
Selecting the reason for a stop:
9. Select the reason for a stop by clicking on the button.
10. Click on the first button to go up one level.
10. 9.
Selecting the reason for a stop:

11. Start time of the stop.
12. Duration of the stop.
13. Total time the machine has stopped for this reason.
12. 13.
11.
General buttons.
14. Back to main screen (the dashboard).
15. Show real time activity graph.
16. Show all undefined stops and production issues.
14.
15.
16.
Registered stops.
17. Current stop.
18. Last activity before the current stop. Click on this 'production' button to
justify the products. See also item 20.
19. Stop in the past. Click on the button to modify.
17.
19.
18.
Selecting products:
20. It is possible to select products during or after production.
Extra options for registered stops:
21. Possibility to modify stops which were already justified.
22. Possibility to split the current stop. This could be the case if for
example the stop turns into a failure or waiting for material.
23. Number of operators.
21. 22.
23. 24.
Extra options for registered stops:

24. Possibility to type notes in the logbook.
X.8 Appendix 1
Problems The USB port simulates the COM port and this could introduce some
with USB problems. Follow the procedure below to solve the problem.
Is the USB driver installed? (c:\program files\oee toolkit5\driver)

Is the hardware connected correctly?
Is the correct COM port selected?
If these three steps do not solve the problem then select COM 4 for the USB
port which is connected to the hardware.
Forcing COM Windows sometimes doesn't make the COM ports available.
configuration Follow the procedure below to force the COM ports.
Open the configuration menu in Windows.

Open 'System'.
Select the 'Hardware' sheet and click on ‘Device Manager'.
Click on 'Ports´.
Select the port named 'Prolific-to-Serial Comm Port'.
If this port is not available then the hardware is not connected correctly or the
driver is not installed.
Double click on 'Prolific-to-Serial Comm Port'.
Select the 'Port Settings' sheet.
Select the ’Advanced…’ option
Open the scroll down menu where the COM port number can be selected.
Select COM 4 in the scroll down menu.
Start RemoteCollect and also select COM 4 in RemoteCollect.

Continue following the configuration wizard for RemoteCollect.
If there are still any problems, contact the FullFact B.V. helpdesk.
support@fullfact.com

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RemoteCollect

12th of September 2007

Introduction RemoteCollect is a system for collecting OEE data in an efficient and

RemoteCollect needs a signal to determine if the machine is producing or has

Computer Location of the operator panel (computer).

Remote- Utilities Execution Who When

Operating PC with Windows 2000 or Windows XP

Processor CPU 600 Mhz

Screen Touchscreen or screen with 1024 x 768 resolution

Network LAN 100Mb

Input of I/O Connections on Remote I/O module

Touchscreen* IP 65 Fanless stainless steel casing

COM type USB type

COM (RS232) Network adapter – 24V AC

USB Network adapter – 24V AC

COM (RS232) Connection of the EX 9520 Connection of the EX 9065D

USB Connection of the EX 9530 Connection of the EX 9065D

Attention: install the USB driver, C:/program files/OEE toolkit 5/drivers

IN 1 (B)GND 10 (gives pulse)

IN 1 Black sensor cable (gives pulse)

Configuration The configuration of RemoteCollect is executed by a wizard. The wizard has

The first time RemoteCollect is used the wizard will open.

Don't forget to delete /init after reconfiguration of the settings.

COM port Double click on this port to save this setting.

Hardware 1. “Sensor-style” setting:

More than one One machine has been configured.

Justifying 2. Select the category or group to which the stop is related.

Selecting 8. Select the product.

RemoteCollect Starting RemoteCollect

RemoteCollect Starting RemoteCollect

8. Selecting the reason for a stop:

Selecting the reason for a stop:

Extra options for registered stops:

Is the USB driver installed? (c:\program files\oee toolkit5\driver)

Open the configuration menu in Windows.

Double click on 'Prolific-to-Serial Comm Port'.

Start RemoteCollect and also select COM 4 in RemoteCollect.

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