Software Products

Elite Flexible Assembly Configuration System (eFACS)

eFACS is a PC based software suite which is part of the larger FACS architecture.

 

  The following components are available for eFACS:


The FACS architecture is an industry supported controls architecture.  The upper level is eFACS.  The middle layer is vendor supported PLC hardware and standardized logic.  The lower level is equipment manufacturer supported hardware and PLC logic such as fastening systems, vision systems, etc.  Generally this is integrated with the conveyor by the machine tool builder.  Several machine tool builders already have successfully deployed assembly lines using the building blocks provided by Elite Engineering, the PLC manufacturer, and the equipment supplier.

FACS Enables Flexibility without Sacrificing Standards

In the past, Flexibility and Standards were at opposite ends of the spectrum.
Standardization was viewed as inflexible and controlling.
Flexibility was viewed as wide open custom solutions without regard to standards.
FACS combines the best attributes of Flexibility and Standardization.

FACS Makes Flexibility Manageable!

Key High Level Features:
  • Provides for fast line balance and process change.
  • Plug & Play system that leverages already developed Hardware & Software supported by Global Automation suppliers
  • Flexibility without sacrificing Standards
  • Full line of Error Proofing.
  • Facilitates standard processes and controls.
  • Re-Sequence your line in a fraction of the time it used to require.
  • Assembly tasks are easily added, deleted, moved and assigned to any station.
  • Configuration system does not need to be running in order for the line to run.
  • FACS has been installed and running in production since September 2007.
  • Minimal learning for new OEMs.
  • Automation Vender Neutral.
  • Continuously improve the process using the PDCA cycle.
  • Control all of your manufacturing sites with a true common standard which is supported by multiple OEM’s and equipment manufactures.
  • 80% of MWS programming and hardware design is provided
  • 45% of Auto station programming is provided
  • 30% lead time reduction
  • 50% Engineering savings (reduce assembly lines costs)
  • What took months, weeks & days now takes hours


There are several key concepts that enable the FACS architecture to be flexible, enforce standards, and reduce cost.
  • A PLC at each work station; whether it is an Automatic, Manual or Semi-Automatic station. This enables modularity and scalability of the product and process. A large high-volume assembly line and a small line use the same building blocks.
  • Standardized hardware and Logic in all the stations allow the interlocked devices to be enabled through the configuration tool. This enables rapid changes to the process simply through configuration changes.
  • A “task based” concept which is independent of the stations provides for a “database” like status tracking. This enables line changes (additions, deletions, and moves) without impacting downstream operations

How FACS Enables Flexibility:
  • Plug & Play Standardized hardware layout enables you to make changes to the process in a fraction of the time it used to, the constraint becomes the physical movement of the equipment!
  • Re-balance your line with market demands on the fly (downtime and cost reduction). Different line configurations can be saved and loaded on demand (“proven configurations”).
  • With this software you can share lessons learned with all of your installations. Configuration changes that are proven to improve the process can be shared with other facilities.

How FACS Enables Maintainability:
  • Packaged software and hardware supported by global automation suppliers.
  • Tier II suppliers have developed and maintained their own software interfaces .
  • One Set of prints for all manual work stations with a configuration sheet.
  • One program for all manual work stations.
  • Process and Industrial engineers can make changes to the process without the help of controls engineering (controls prepared the line to be configurable).
  • Reduce learning curve for new hires as well as existing electricians and process engineers.

How FACS Enables Lower Life Cycle Costs:

Up Front Costs:
  • Do not have to re-invent the controls system for each project.
  • OEMs are driven to your common controls and software architecture. In the past they have had their own flavor of controls system and software. Two different OEM’s that built projects to the customer’s specifications resulted in widely different solutions. This results in longer debug and commissioning time.
  • OEMs with limited knowledge of your standards will benefit from the common architecture. This reduces time and expense at every phase of the project, simultaneous engineering through the Start of Regular Production. (larger pool of potential OEM’s)

On-Going Costs:
  • Make changes to the processes in a fraction of the time it previously required.
  • Leverage lower labor rates while ensuring high quality standards. The built-in error proofing devices ensure the process is completed correctly.
  • The Process Improvement Tool allows plants to compare processes and adopt the best practices. The flexible assembly architecture enables the changes to be easily implemented.
  • Common architecture across various plants enables successfully implemented improvements to be shared with other plants.

How FACS Enables Lean Manufacturing:
  • The flexibility of FACS allows you to continuously tune your line by applying “lean tools”.
  • Flexibility, data analysis and transparent metrics empower all employees to understand current performance and make     suggestions which can be quickly implemented for improvement.
  • Most operators just need to be better informed and empowered to try new ideas and realize their impact. In addition, if the operator knows that his suggestion will become a standard for the organization they will become more engaged.
  • The standard PLC logic available at every station enables every station to do any task. This allows the line to be rebalanced to adjust to market demand.

Process Improvement Tool (PIT):


The eFACS computer system collects data on the process as it is running. The data can be analyzed using the Process Improvement Tool to find deficiencies in the process. The flexibility offered by the FACS architecture allows changes to be made to the process to improve the process and the data collected can determine if the process change had the desired effect. The tools available in the Process Improvement Tool provide quantitative, qualitative and statistical analysis of the part including build status and cycle time.


Sample Report Output

Shift in Mean Chart

Individuals Controls Chart

Non-Conforming Pareto Chart
Process Engineering Tool (PET):
  • Allows for Process or Industrial Engineers to balance an assembly line or sub-system (“Configuration” instead of “Programming”)
  • Calculates process efficiency, operator loading, expected cycle time, considers maximum fastening loading, etc
  • Allows for attachment of files to operations such as job instructions, process charts, process validation videos, etc.
  • Makes use of a standard database with standard element times which can be modified and added to.
  • Rapid Estimating and Methods Improvements analysis

 For more information on eFACS contact us at eFACS@eliteengineering.com