Software solution for complex assembly systems

piaOptimum identifies bottlenecks in interlinked assembly plants, and allows for rapid, sustainable optimisation of production efficiency due to a high level of data transparency. The performance of both individual units and sections of the production line – or the entire plant – can be assessed.

piaOptimum can be flexibly connected to all types of automation systems – when new plants are set up or as a retrofit version for existing production lines. The application is said to stand out due to the detail of its data analysis. Along with cycle analyses for individual units, it can record and evaluate partial cycles for each individual movement or sub-movement.

All reports and errors are recorded, so process results can be evaluated in detail and sequences compared. With just a few clicks, piaOptimum shows which unit and partial movement has changed and affected overall output. The tool also offers many standard analyses.

Simple configuration of all required data points via the software’s web-based user interface means changes to the PLC programming are not required. piaOptimum allows flexible data connection using OPC-UA protocol. Access is also flexible: Data can be evaluated by service technicians on site or accessed remotely. The raw data is compressed so that it can be stored for long periods. 

The software offers extensive functionality and allows specific data and analyses to be made available to different target groups – for everything from production management and maintenance to system optimisation. A plant knowledge database is available for use in troubleshooting and process optimisation, which allows operating instructions for individual units to be saved along with internal notes. 

piaOptimum can be used with individual units, sections, the whole system, or an entire production location. For example, it could initially be used with problematic units for monitoring and optimisation. To achieve full transparency an identification of all OEE losses – meaning everything that reduces the overall effectiveness of the system – piaOptimum can be used with the entire assembly system.

PIA Automation offers a comprehensive service, from setting up the assembly line and the analysis software package to optimisation services (data-driven services) form the PIA analysis team.