ORCA MES Work Completion Counting with Photoelectric Sensors
Separate Completion Checks Replaced by ORCA Sensor Counting
Automate work completion counting with a counting photoelectric sensor module.
Work completion counts in the cosmetics manufacturing site had to be checked separately. ORCA MES connects counting photoelectric sensors with BOM and BOP routing-based manufacturing MES management for orders and production plans.
- Automate work completion counting with a counting photoelectric sensor module.
- Install and test the ORCA sensor digital module package on site.
- Manage related orders and production plans in ORCA MES based on BOM and BOP routing.
Challenges in the Previous Workflow
Previously, work completion counts had to be checked separately. It took time to confirm completed quantities against the shop-floor workflow and align production plans with actual completion status.
Repeated checks were also needed when linking orders and production plans to the shop-floor workflow. The site needed to organize related production management work while automating work completion counting.
What Changed with ORCA
The main scope was work completion counting automation using a counting photoelectric sensor module. The ORCA sensor digital module package was installed and tested on site, so counting could use sensor recognition.
Orders and production plans were organized as related MES management areas. ORCA BOM and BOP routing support product structure and process flow management, alongside sensor-based shop-floor counting.
- Counting automation: A counting photoelectric sensor module processes work completion counts automatically.
- Site setup and testing: The ORCA sensor digital module package was installed and tested on the shop floor.
- MES management scope: ORCA MES manages related orders and production plans based on ORCA BOM and BOP routing.
Sensor Module Configuration and Installation
This shows the internal setup of the ORCA sensor digital module package.
This shows the ORCA sensor digital module package installed on site.
This shows installation and testing of the ORCA sensor digital module package.
Video Frames of Container Sensor Recognition
The three images below are frames from a video where the sensor recognizes a container. After container recognition, the sensor light changes to red.
ORCA MES Screen for Automatic Production Quantity Counting by Sensor Recognition
This is the Korean ORCA MES work completion screen for checking production quantity of a sensor-linked item. Linked to the container recognition frames above, the item quantity is counted automatically and reflected on screen when the sensor recognizes a container.
Before / After
| Before | After |
|---|---|
| Work completion counts had to be checked separately. | The counting photoelectric sensor module processes work completion counts automatically. |
| It was difficult to connect equipment flow with production management data. | The ORCA sensor digital module package is installed on site to connect the counting flow. |
| Orders and production plans had to be checked repeatedly against the shop-floor workflow. | Related orders and production plans are managed in ORCA MES based on BOM and BOP routing. |
Frequently Asked Questions
- What workflow was automated in this implementation?
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It was work completion counting at a cosmetics manufacturing site. A counting photoelectric sensor module was applied for automated processing.
- What devices were applied on site?
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A counting photoelectric sensor module and the ORCA sensor digital module package were applied. The provided images show internal setup, installation, and testing.
- What role do ORCA BOM and BOP play?
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They provide the MES management basis related to work completion counting automation. They support order and production plan management based on product structure and process flow.