For more than 25 years, ROTH has been successfully implementing manufacturing execution systems (MES) for production lines worldwide using its proprietary RPCS (Roth Process Control System) modular software framework.
RPCS plans, controls, and monitors the manufacturing processes of stand-alone machines or complete production lines. It also allows you to analyze your manufacturing processes and minimize downtime and production stoppages. In addition to numerous standard functions, our production control system offers customized, client-specific functions and solutions. These are defined in a joint workshop with our clients.
RPCS in the Automation Pyramid
Whether your goal is to optimize manufacturing through Industry 4.0, the Smart Factory, or digital production, RPCS provides the right tool to make it happen!
Like all manufacturing execution systems (MES), RPCS serves as the bidirectional link between a company’s enterprise management level (ERP system) and its production operations (automation technology). While the ERP system provides an overview of the entire company, the MES system focuses on individual production lines within a facility. Automation deals with the individual production steps and consists of a variety of control systems and equipment (portals, interlinked systems, machining and measuring machines, etc.).
RPCS is the overarching software package that integrates machines and manufacturing cells, thereby enabling the holistic organization and control of a manufacturing area. As materials flow along a production line, RPCS continuously collects all relevant operational data and makes it available to the overarching ERP system. This ensures seamless traceability of products, components, or batches. Furthermore, this operational data can be used to identify and capitalize on opportunities for optimization and process improvements.
At ROTH, we cover all aspects of software architecture for industrial manufacturing. We support and advise our customers on connecting machines and implementing all interfaces between machines and ERP systems.
RPCS at the management, production, and control levels
The central component of a manufacturing execution system (MES) is the server. Depending on the IT environment, our RPCS server software can run either on PC hardware supplied by us or in our customers’ virtual environments.
The RPCS server is complemented by powerful RPCS HMI/VISU clients. The functions, data, and content displayed can be individually configured on each VISU client according to the user’s tasks, permissions, and requirements.
In addition, RPCS Edge gateways in the field collect data from the control level and send it to the RPCS server, where it is stored in an MS-SQL database. Based on this data, production and business processes can be analyzed and optimized.
All machines and systems within the control level are connected to the RPCS network. Existing machines without a network interface that use older bus technology, such as MPI/PROFIBUS, can also be connected without any problems.
ROTH coordinates machine integration and helps achieve quick results.
RPCS System Architecture / IT Infrastructure
Our MES system, RPCS, can be easily integrated into any IT environment!
ROTH supplies a complete MES system control cabinet, including all components, a hardware diagram, and documentation. Our MES system includes all the hardware components necessary for fail-safe operation, user interface, maintenance, and data security.
If the appropriate IT environment is already in place, our MES software can be easily integrated. ROTH installs the MES software in the provided IT environment:
- virtual infrastructure (VMware on ESXi servers)
- Hardware Infrastructure
- Cloud Infrastructure (e.g., AWS)
In addition to our MES software for production lines, we also offer customized, customer- or machine-specific standalone software solutions tailored to your requirements, such as:
- Installation of RPCS software on the machine’s existing IPC; the ROTH visualization can be integrated into the machine’s HMI visualization
- Installation of RPCS software on an IPC supplied by ROTH in an existing control cabinet
System Overview / Part Tracking / History
How can production costs and lead times for production orders be reduced? By identifying unplanned machine downtime more quickly and shortening response times to malfunctions.
Our RPCS MES system provides a comprehensive overview of the status of the entire production line, including all machines and workpieces on it. This system overview not only identifies technical and logistical malfunctions in the machines but also locates machines that are not in production, as well as workpiece shortages at the input and workpiece backlogs at the output of the production line.
We boost productivity! Using the data from our MES system, we can evaluate and optimize the productivity of production lines based on data and facts. In addition to tracking and displaying the current location and status of all workpieces on the production line, our RPCS MES system creates a complete history for each workpiece.
Using part tracking, every workpiece movement and every machining process—including status (e.g., OK, Not OK)—can be analyzed retrospectively and without gaps, from the time the workpiece enters the production line until it exits. This ensures that any changes made to workpiece data can be traced and verified.
Customer System Integration
Our MES system is used to plan, control, and monitor production processes. Through a bidirectional, customized integration with an ERP system, the effort required for interfacing between the corporate management level (ERP system) and the production level (MES system) is significantly optimized. Through end-to-end planning, organization, and automation of manufacturing, the pervasive shortage of skilled workers can be significantly mitigated. The automated provision of information that was previously collected and processed manually directly increases workforce efficiency.
The foundation for planning, organizing, and managing your manufacturing operations is the necessary IT infrastructure, as well as the networking and integration of your machines. We provide consulting and support for networking and integrating your machinery, or we can carry out all necessary tasks ourselves. We integrate our MES system into an existing IT infrastructure or provide the necessary components and services from a single source.
This reduces the amount of value-added work employees have to do while simultaneously increasing staff productivity!
KPIs / OEE Calculation / Machine Cycle Times
A constant overview of production processes forms the basis for analyzing production performance.
Key performance indicators (KPIs) form the foundation for analyzing a company’s success and serve as the basis for business decisions. Achieving business objectives and sustainable process optimization are supported by professional systems for analyzing KPIs in production. This enables performance analysis and provides the necessary data foundation for improving production planning and execution—with production data collection and machine data collection being the most significant factors in this regard.
These results serve as a basis for decision-making for managers, foremen, and workers in their day-to-day work. This allows them to accurately assess complex situations and determine the availability and effectiveness of the company’s equipment and machinery.
These metrics help business owners assess the current state of affairs and shed light on existing improvements and their success. Processes and their progression can be monitored over time. Furthermore, it is possible to see exactly whether they have improved or deteriorated.
Make your company Industry 4.0-ready and let our IT experts advise you on the possibilities for analyzing your production KPIs.
Software Modular System / Customization
Our Production Line Control System (RPCS) is a comprehensive tool for increasing the productivity of your manufacturing operations. Our digitalization products are based on our RPCS modular software framework. This enables us to achieve a high degree of standardization and rapid deployment within our projects.
The modular design of our digitization products allows us to tailor them to meet a variety of requirements. In addition to the standard components from our modular system, we also offer components that are fully tailored to specific technical and functional requirements.
ROTH provides support ranging from consulting and design to the implementation of the necessary infrastructure. This includes connecting entire production lines (machines, automation, etc.) as well as customer systems (SAP and ERP systems).
