Optimal process control

POS (Production Order System) is a software program for the organization and automation of processes in the foam processing sector in a modern line, from the long block to the finished product. In-line machines can thus be addressed from a higher level. POS makes it possible to link up several machines as well as intermediate systems (shuttles, conveyor belts etc.) on the basis of a central control system. 

From the warehouse to the finished cuts, the raw block covers a long distance until it leaves the factory as a contour cut, a mattress or as sheets.  

In classical production, each operation must be planned individually in each machine and performed manually: 

Work preparation:

  1. Inventory check of the blocks from long and short block storage
  2. Entry of customer orders for mattresses, sheets and contours
  3. Preparation of the programs for customer orders: nesting of the contours into corresponding sheets, collection of the various sheets to form a short block
  4. Transfer of the orders to the machine

Production:

  1. Requesting the block from the block storage
  2. Entering the block dimensions in the cut-off machine and cutting the blocks to size. Moving the blocks to the machine in question on the basis of the manual planning.
  3. Loading the cutting program and checking the options, or entering the number and thickness of the sheets, as well as the block height. Only then can the contour be cut
  4. Releasing the contour parts from the sheets or from the block
  5. Checking the number, quality and tolerances of the cut contour parts 
  6. Warehousing the contour parts correctly
  7. Marking the remaining blocks and warehousing them
  8. Booking the cut parts manually into the ERP System  

This means that an operator has to go through 12 operations. 

Disadvantages of the traditional working process:

This working process is labor-intensive, error-prone and time-consuming. A full-time worker is required for each machine. If the process is not optimally planned, this leads to pauses. The management of the remaining blocks is confusing, and the operators must be asked what the production status is. 

Optimum control and automation of the production process with POS 

Work preparation:

  1. The block bin status reports are already integrated in POS. The planner records only the customer orders for mattresses, sheets and contours. POS creates the mattress, sheet and contour programs fully automatically and passes these on to the respective machines.

Production:

  1. Requesting the block from the block storage. The long block order is then loaded. POS now processes the long block fully automatically as far as the final completion of the mattress, the sheets or the contour parts. At the same time the mattress and contour data are transferred automatically to the ERP.
  2. Releasing the contour parts from the sheets or from the block. With the optional software Quickselect, the operator can immediately see which parts belong to one order and which to another. This is visually represented in Quickselect.
  3. The cut contour parts only have to be examined for quality (foam defective)
  4. Warehousing the contour parts correctly
  5. Residual blocks can be automatically identified and are transferred to the warehouse 

Advantages

  • Order lists can be imported into POS from the individual work preparation system
  • POS sorts the orders to be cut according to quality and dimensions. These are assigned to the existing blocks. POS proposes residual blocks for processing
  • POS fully automatically transfers the orders to the controllers of the in-line machines and the preliminary units.
  • Order data are assigned unequivocally to the block and are passed on from one machine to the next with the material to be cut
  • When the long block is loaded into the storage rack, all of the data belonging to the block such as quality, color, block dimensions and storage location are stored in POS by means of an ID. When orders are received, it is then possible to check whether the required foam is in stock or whether foaming has to be initiated.
  • The entire block inventory in stock, including all decisive block data and updated storage locations, is stored in POS. When a production order is selected, POS determines the availability of the required block qualities and, depending on the order, picks these from the warehouse or, in the case of viscoelastic foam, directly from the curing rack.
  • In addition, POS gives you an overview: the status of the machine can be checked at any time by means of traffic light signals.
    • Green: the order is completed and the machines are ready for the next order
    • Amber: the order is being processed, the loading conveyor in front of the machine is free
    • Red: the order is being processed, the loading conveyor in front of the machine is occupied 

More efficient processes save time and money 

Through the use of POS you can save 50 % of the manual process steps, as these are fully automatic. You require less manpower and can thus reduce wage costs. Through automation, the waste rate improves. The throughput also increases within a shorter time. Machine investment thus pays off more quickly. No costly "just in time” storage, even for the smallest of order quantities. And that is not all …

  • Optimum utilization of material in conjunction with residual block management
  • Faster order intake and block selection
  • Bundling, selection and coordination of orders
  • Constant production status feedback
  • Efficient production flow and material throughput
  • Also control of third-party machines
  • Possibility of system-specific software adaptation

 

System requirements: WinCAP  

Optional: Mattress Nest, Bäumer Nest and Quickselect

Individual software training can be found here.

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About us

The Albrecht Bäumer GmbH & Co. KG has been a leading manufacturer of machines and equipment for the foam industry for 70 years. The company focus is on special machinery and equipment. In this area, we have grown as a medium-sized company from pioneer to world leader.