Real-Time Process and Inventory Tracking Software

Customizable solutions for real-time process and inventory tracking.

  • Control and view production status
  • Produce process certifications
  • Real-time Process Statistical Control (SPC)
  • Spare parts and inventory management
  • Record maintenance schedules and activities

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Product Details

Main Functions

Total Trac is a set of PC based software components made specifically to track production processes, in real time, using the barcode equipment. Total Trac is the state-of the-art product that can be used in many different production applications, where production processes have to be closely monitored and guaranteed (or certified), such as in the heat treating, forging, and foundry industries.

Total Trac continuously collects production data allowing users to view the full production history of each lot of parts. The production tracking can be achieved with minimal effort on the production personnel. Total Trac makes it possible to repeatedly produce products of consistent quality. If the problem occurs, the plant personnel can use Total Trac to easily pinpoint where in the process the problem has occurred and which lots of parts are affected.

With Total Trac you can have a real-time Statistical Process Control (SPC). Since all the data are collected in real time, you can instantaneously analyze the data using the X-bar and R charts, histograms, etc.

Through its unique Process Definition capability, this product can help you to become ISO-9000, and CQI-9 certified.

Figure 1: General Work Flow

Figure 1: General Work Flow

Total Trac software handles all the data entry and processing requirements for your site, from receiving parts, producing work orders, defining processes to be performed, tracking production processes, capturing all the data during production– in real time using barcode scanners, assisting in quality control using Statistical Process Control (SPC), finally shipping and invoicing. All data is stored in the SQL database, and can be easily retrieved whenever needed. Since the system is fully integrated you do not have to re-enter any data.

The barcode network makes it is easy to enter information directly from the plant floor and keep up with the production status in real time. Each person can easily view on their computers what is happening on the floor.

Figure 2: Tracking Using Barcode

Figure 2: Tracking Using Barcode

If the plant has the electronically attached scales, you can record the weight data associated with the work order, by simply reading the barcode label.

Usually the operator scans a barcode label in front of each furnace (station), providing the Total Trac with a record of Trac Units processed by the furnace (station).

You can also use the barcode readers to enter the test data into the system and associate this data with the scanned work order. One can view on the PC monitor all data that have been scanned so far.

Physical Configuration

Figure 3: Typical Total Trac Configuration

Figure 3: Typical Total Trac Configuration

The TracMaster consists of the following components:

  1. TTSServer – a software component that provides the data collection services. This component is responsible for communicating with the controllers, PLCs, barcode terminals, and electronically attached scales and testers. This component runs in the background serving other client components: OfficeTrac and DataTrac. Multiple TTSServers can be used on the site, each running on different computer.
  2. OfficeTrac – a client software component that supports office functions, such as receiving, shipping, certifications, scheduling, and allows users to create parts, customer, and process definitions records. It allows the users to view the status of the production work even while in process or any past records.
  3. DataTrac – a client software component that presents the real time data, such as temperatures, flows, digital i/o and analog i/o data. An optional component of the DataTrac is the Recipe Programmer function that allows users to create recipes and execute recipes.
  4. SQL Database – while not included in the Total Trac software, the Total Trac must have an access to an SQL database. Total Trac can generally attach to any JDBC compliant database.
  5. ConfigTrac – a software that enables the customer to configure your site, defining data collection computers, stations, barcode networks, I/O controllers with which the computers will interface, and various operating policies.
  6. BarcodeDraw – a software to help you create a barcode labels
  7. MaintenanceTrac – application that supports the maintenance activities on your site,

Each component can reside on different computers, as shown in Figure 3 Typical Total Trac Configuration, or on a single computer.

Barcode Network Function

The barcode network allows you to attach the barcode scanners, scales and electronic testers to the Total Trac. It provides a simple and inexpensive way for the operators to interface with the Total Trac system, without requiring PC terminals to be present on the plant floor..

Total Trac also support attachment of the Barcode printers. Currently only the Intermec printers are supported, but additional drivers can be provided in the future. Bar code printers may be used to print cards that accompany a batch of parts for processing.

Total Trac allows you to track all the activity associated with production of the batch parts. When you use the barcode scanners, the Total Trac shows you graphically the process steps that have been completed. You can also visually see which SPC measurements were already collected regardless whether they are entered via the barcode scanners or manually.

Figure 4: Process History

Figure 4: Process History

Statistical Process Control and Certifications

The Statistical Process Control function allows you to view the collected SPC data in the format that helps you control your process. You can display X-bar and R charts, P charts, or histogram on any collection for parts defined in one or more work orders.

You can also print the certifications. As you create certifications, you can identify a person whose name will be provided in the signature section of the document. You can also customize information that you want to provide on the printed document.

You can also use Auto-Generate certification capability to automatically create certifications for all the completed work.

Figure 5: SPC Histogram Charts

Figure 5: SPC Histogram Charts

Data Collection and Graphs

The Total Trac can communicate with a variety of controllers and PLCs for the purpose of collecting the data such as temperatures, gas flows, and digital signals used in production. The data are stored on the hard disk where they are available indefinitely. Total Trac eliminates the need for chart recorders. No longer do you need to save the charts in file cabinets where it is difficult to find information when you need it.

You can view graphs for any selected day desired. The data collected will instantly display. You can print graphs.

Figure 6: Station Graphs

Figure 6: Station Graphs

Maintenance Support

The Maintenance Support allows you to records all your maintenance activities where they can be easily audited as required by ISO-9000, CQI-9 specifications. The Maintenance Support provides the following functions:

  • Keeps maintenance schedules for your equipment. It is color coded to allow you to easily spot when maintenance actions are due.
  • Keeps calibration schedules for your testing equipment. It is also color coded to allow you to easily spot when calibrations are due.
  • Allows you to record all your maintenance and calibration actions
  • Keeps inventory of all your spare parts, and sensors
  • Keeps a list of all your part suppliers together with prices and lead times and tracks your current orders

Recipe Programmer

Figure 7: Monitoring Execution of Recipe

Figure 7: Monitoring Execution of Recipe

The Recipe Programmer is optional software that allows the user to create recipes needed to control an entire furnace via the loop controllers.

A recipe represents a sequence of simple instructions that allow you to control furnaces, such as SETPOINT, RAMP, SOAK, INQUIRE, etc. The execution of a recipe can be monitored from your desktop computer, as shown above.

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