1. ROCKWARE® IMM Intelligent Manufacturing Machine™
Automated Software for Injection Molding and other Manufacturing Machines
Functionality Overview
Copyright © 2019 Rockware Corp.

2. The ROCKWARE® IMM Platform
Intelligent Manufacturing Machine™ (“IMM”) collects machine cycles automatically and combines with configuration data and personnel input to provide valuable real-time and historical information.
IMM is scalable across multiple plants and global operations.
Key Performance Indicator (“KPI”) summary calculations are customizable to match Corporate specifications.
IMM interfaces and reports can be customized to match Corporate standardized reporting.
IMM can be configured to work with all types of equipment and production environments including facility equipment such as dryers and silos.
IMM can be integrated with ERP or third party software systems.
IMM provides a plant-wide and/or a corporate-wide application to centralize information from multiple IMM systems.
Industrial Internet of Things (“IIoT”) add-on modules are available to provide notifications and information to personnel on smart phones or outside of the plant.
IMM can operate from either a local server or cloud-based server based on customer’s preference.
IMM tracks cycles and scrap at the cavity granularity.
IMM provides fully integrated Manufacturing Execution System (“MES”) modules for scheduling, quality, materials inventory, labor, and process parameter/recipe management.

3. Real-Time Scoreboards
A default Home Scoreboard is configured specific for each customer.
Customers determine what style of Scoreboards they want along with what calculations, color coding, and values they want displayed.
Users will be able to choose from several different Scoreboard styles to display as the Home Scoreboard on their computers.
Home Scoreboards provide buttons and hyperlinks to get to all other system interfaces and reports.
A Legend is available explaining color codes, displayed values, and calculations.
Custom interfaces can be developed for Plant TV applications.
Scoreboards can be created for applicable work centers, departments, areas or for single machines.

4. BoxScore™
The BoxScore™ format was the format used in the original Rockware® Injection Molding system from 2006.
Machines are laid out as they are positioned on plant floor or in order by name/number.
The BoxScore™ format works well with phone displays organizing machines in order by name in 2 columns.
Example Single Machine
Example BoxScore™ Scoreboard viewed from Computer
Example viewed from Phone

5. LEGEND
Example of a Legend explaining BoxScore™ values, calculations, and colors

6. Example Table Scoreboard viewed from Computer
The Table format is another option for real-time display.
Example Table Scoreboard viewed from Computer

7. Example Hourly OEE Scoreboard viewed from Computer
The Hourly OEE Scoreboard allows you to view OEE calculations for each hour of the shift. It also provides a weekly contest between shifts awarding Gold, Silver, and Bronze distinction based on weekly OEE.
Example Hourly OEE Scoreboard viewed from Computer

8. ELECTRONIC Whiteboard
The eWBD™ displays a single machine’s hourly production, machine status in 5 minute intervals, and shift summary. Designed to replace dry erase boards commonly found on plant floors.
Example Electronic Whiteboard Interface from Computer

9. Example Hourly Count Graph from Computer
The Hourly Count Graph displays Target, Parts, and Scrap over the 24 hour business day for a selected date.
Example Hourly Count Graph from Computer

10. Shift Recap™ Reporting
The Shift Recap™ Reporting module is a tool built for supervisors to report on shift production, scrap, downtime and overall performance.
Automated data, operator input, and supervisor input are combined to provide a full report on shift activity that can be manually or automatically ed to all applicable recipients.
This report is very informative for shift and daily production meetings. It has all production numbers, performance numbers, downtime with downtime codes, all scrap with scrap codes, along with supervisor comments to provide all details.
Scrap entry and downtime code entry can be reconciled by the Supervisor from this interface.

11. Shift Recap™ User Interface
Comments, Scrap and Downtime (DT) can be entered and/or reconciled for selected shift from this interface. Downtime events with no code entered (No Code) to assist Supervisor in ensuring all DT is coded.
Example of Shift Recap™ User Interface from Computer

12. Shift Recap™ REPORT
Example of Shift Recap™ Report which can be ed, Exported to PDF, or Printed

13. DATA logs and Reporting
Data logs provide a repository and filtering tool for historical, real-time, and any other applicable data set.
Predefined graphs and reports for each individual log allows filtered data to be displayed in a multitude of formats.
There are many predefined graphs and reports to choose from but additional graphs and reports can be added upon request.
Graphs and reports can be exported to PDF, ed, or printed.
All logs allow exporting of filtered data to Excel
Custom Excel exports derived from the underlying filtered data can be created upon request.
The Quick Click Reporting™ (“QCR”) module provides Paynter charts, multi-shift trend charts, and quick access to key Data Logs and Data Log Reports linked to Production Constraints.

14. Example of a Trend Pareto Painter (TPP) report for this log
Data logs - How To USE
Data can be filtered and viewed in predefined reports or exported to Excel
View predefined reports developed for this log or export filtered data to Excel.
Use filtering list boxes to select desired data set.
Click on Selected Report
Example of a Trend Pareto Painter (TPP) report for this log

15. data LOGS
Rockware® IMM™ has a powerful relational database that combines advanced configuration data, manually entered shift data, and automated shift data to provide elaborate summarized performance information to aid in making mission critical decisions and allocating resources.
Cycle Log (Automated Input Data)
Downtime Log (Automated Input Data)
Scrap Log (Manual Input Data)
Machine Shift Recap Log (Summarized Information)

16. Example Data Log Report for Production By Machine
DATA LOG Reports
Example Data Log Report for Production By Machine

17. Graphical Reports
Example Graphical Report displaying multiple graphs to dissect Change Overs

18. Graphical Reports
Example Graphical Report displaying each point of test performed on floor and where it resides in relation to limits

19. Graphical Reports
Example Graphical Report displaying Cycle Time of chronological cycles versus the standard cycle time

20. Graphical Reports
Example Graphical Report displaying individual cavity peak pressure cycles over several weeks

21. Trend-Pareto-Paynter
Example Trend-Pareto-Paynter Report displaying Utilization by week. These types of reports are available by hour, shift, week, and month.

22. Trend-Pareto-Paynter
Example Trend-Pareto-Paynter Report displaying Scrap Count by Hour

23. Custom Reports
Example Year/Month Paynter Chart for TRS which is similar to OEE based on a specific Corporate Report Format

24. Quick Click Reporting™
The Quick Click Reporting™ (“QCR”) module provides instant access to predefined graphs and reports. The QCR interface is opened by clicking hyperlinks on a Scoreboard. Most data filters are automatically set based on what machine or area was clicked.
Use data range and filtering combo boxes to fine tune or quickly vary what data to view
Click applicable buttons to view resident Paynter Charts, predefined reports, or prefiltered data logs.
Machine Shift Recap Log (Summarized Information)

25. Quick click reporting™
Example of a report opened by clicking 3 Shift OEE button

26. MACHINE SCHEDULING
There are multiple types of machine scheduling modules available with Rockware® IMM.
A machine scheduling module will be chosen for each customer system based on production environment and will be customized as needed to fit the needs of the customer.
Historical Build To Schedule (“BTS”) data is available with most modules.
Automatic notifications can be linked to Scoreboards, text messages, or .

27. Example of reporting displays for Job Order Sequence scheduling

28. Example of display for Kanban Scheduling
KANBAN SCHEDULE
Example of display for Kanban Scheduling

29. Tool PM Rate Real-Time Scoreboard
PM Tracker™
The PM Tracker is a fully integrated module that allows tools to be monitored by cycle for Molds/Tools and by run hours for machines. The PM history is stored indefinitely.
Tool PM Rate Real-Time Scoreboard

30. Automated Data Collection
Rockware® IMM is extremely flexible and supports all applicable automated data collection.
A review will be done with each customer system to understand the type of equipment and the network typography is present to determine feasible options. The customer will ultimately choose.
Rockware Corp. has multiple middle-ware applications for interfacing with OPC, RJG’s eDart™ Active X Object, or other communications protocols such as RS-232 that are field proven and extremely reliable.
The Rockbox X™ appliance is an option for equipment without OPC compliant controllers like most injection molding machines. Discrete electrical signals from machine controllers are connected to relays in box.
Ethernet IO is an option for equipment without OPC compliant controllers for facilities with a Controls/PLC Network or VLAN. This option also requires discrete electrical signals from machine be connected to a remote I/O block. This method supports I/O link and allows the integration of items like RFID readers to identify molds or analog values such as temperatures, pressures, levels, and positions from sensors with I/O link.
RJG eDart™
Rockbox X™

31. Manual Data ENTRY
Rockware® IMM provides a multitude of interface options to allow data to be entered for supervisors, operators, and other personnel.
Applications for operator entry are available in both windows based and web based formats. Web based interfaces can be ran on low-priced Android tablets, thin-clients with touchscreens or thick clients with touchscreen.
Downtime is calculated automatically but downtime codes need to be entered manually. Down Time codes can be entered from Scoreboard hyperlinks, Shift Recap™ user interface, or from line side devices running IMM Cash Register™ or more advanced, add-on application, Operator Entry Interface (“OEI™”).
Scrap can be entered after shift from Scoreboard hyperlinks or Shift Recap™ user interface or entered real-time from line side devices running IMM Cash Register™ or more advanced, add-on application, OEI™.
Changing Jobs/Mold during a changeover can be performed from Scoreboard hyperlinks or from hyperlinks provide by lines side devices with IMM Cash Register™ or OEI™.
Other items commonly entered are comments, call initiate/answer, RFID badge, barcode, alarm answer, checklists, process changes, document review, quality alert checks, and part gauging.

32. Cash register™ Scrap Entry Down Time Entry
1. Select Cavity for New Scrap Entry. Selected will Turn Green.
2. Select Scrap Code for New Scrap Entry. Selected will turn Green.
3.Touch “Enter” button once a Cavity and Scrap Code is selected.
4. Edit Job of Previously Entered Scrap.
5. Edit Cavity of Previously Entered Scrap.
6. Edit Scrap Code of Previously Entered Scrap.
7. Edit Scrap Count of Previously Entered Scrap with a Number Pad.
8. Add Scrap Count to Previously Entered Scrap
9. Subtract Scrap Count to Previously Entered Scrap.
11. Delete Previously Entered Scrap.
11. Scroll Up and Down through Scrap Log if Multiple Pages.
12. View Electronic White Board Interface for Respective Machine.
13. Add Comments to Shift Recap Report for Respective Machine.
14. Manually Modify Current Job.
15. Initiate Calls.
16. Answer Open Calls.
17. Pop Up Action Entry Menu for Checklists, Alerts, and Quality Checks.
18. View Alarms Such as No Login and Scrap Threshold.
19. Modify what Machine is being Displayed.
20. Modify what Date and Shift is being Displayed.
21..Toggle Auto Update On and Off to Allow Previous Shifts to be Viewed.
22. Toggle Between Viewing SCRAP ENTRY or DOWNTIME CODE ENTRY. Button is RED when there is Open Downtime with a NO CODE.
23. View Department Boxscore Dashboard.
24. Login for Trainee.
25. Login for Operator(s)
26. Exit Application.
27. Split Downtime Instance into Multiple Entries so Different Codes Can Be Used If Needed.
28. Button Allows Split Entries to Be Deleted.
29. Select Downtime Code. See Downtime Code Entry Below for Instructions.
30. Enter a Single Downtime Code for Multiple Downtime Instances.
31. Scroll Up and Down through Downtime Log if Multiple Pages.
Scrap Entry
Down Time Entry

33. OPERATOR ENTRY INTERFACE OEI™
OEI™ is a an add-on or stand-alone product that utilizes part pictures to determine zone based defects and provides an interactive web-based reporting module.
Example of OEI web-based line side user interface

34. Example IMM Network
Example of Network diagram for a Rockware® IMM System showing many potential options

35. Industrial internet of things
Rockware Corp. provides several IIOT products including items below to provide data and immediate notification to personnel in or outside of the plant.
AWD™ (Any-Where-Data Internet Cloud Service) Provides a lighter version of the in-plant real-time dashboard to provide machine status and machine performance KPIs on any device and where including outside of the plant. This service is hosted on a Rockware® Corp. Cloud Server to allow access from any device with an internet connection.
eMsg™ (Automated Text Message/ Notification Service) Provides Alerts for Alarms, KPI Threshold Violations, Production Scheduling Sequence Events, Calls, and Custom Events. Allows setting up a Hierarchy of subscribers so Escalation procedures can be implemented.
eRpt™ (Automated Report ing/Text Message Service) Provides the delivery of custom reports, sent as attachments, by hour, by shift, by day, by week, or by month to a specific distribution list or a list of subscribers

36. Auxiliary Items
Rockware Corp. provides auxiliary systems for dryers, regrind grinders, silos, compressors, cooling towers and other facility equipment that integrate with production systems.
Rockware® Calls can be integrated with applicable overhead paging system.
Rockware Corp. provides barcode creation, barcode printing and barcode reading applications.
RFID personnel badge readers and mold identifiers can be integrated into IMM.
TV displays can be configured to scroll through different interfaces for specific intervals of time for.
Engineering Shift Recap, Action Plan List, Machine/Mold Process Parameter are example of custom modules that are integrated with IMM.

37. If You are Interested in This Product
or Any Other of Our Products and Services Please Contact Us
Rockware Corp.
1814 River Road Huron, Ohio Office Fax
Copyright © 2019 Rockware Corp.