Production Automation System

7/29/2019 Production Automation System

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1.1 ORGANIZATIONAL PROFILE

The system study entitled "Production Packaging System" is developed for

"Thangam Plastic Industries". It was established in the year 1961 in Salem.

This company is managed by Mr.K.C.Palanisamy, Chairman and Managing

Director and Mr.K.C.P.Shivaraman Joint Managing Director. This company is having

capacity for manufacturing best quality of packaging bags to export to various

countries such as U.S.A, U.K, and to many European countries. This company was

developed with the great effort.

Jumbo Bag, Circular Bag, U-Panel Bag, Baffle Bag, Tunnel Bag, Asbestos

Bag. The main objective of the project is to computerize the manual work done in

production. Now a days mostly all the business oriented concerns use computers.

Each and every thing in the production division must be kept up-to-date to carry over

the business successfully and efficiently. This system fabric cutting monitoring

system makes the production to be so as computerized and keep track of entire

function of the production division in a well organized manner.

The system concentrates on all the department of the entire production, their

functions, and the material details, manufacturing details. The system monitors the

production function and keeps track of entire things, which make the work to be look

easy and carry them with less error and mostly all the works are finished in time

efficiently by reducing the material wastage.

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1.3 SOFTWARE FEATURES

Windows XP

WindowsXP has a new user system completely different from Windows98.This new system has been inherited from Windows NT/2000.

Now various users with independent profiles can be defined. This means that

each user can have different permissions that will allow him to carry out certain tasks.

Each user will have a different start menu and it's own My documents folder that will

be able to be protected by password. There also is a folder to which all the users have

access where the documents that want to be shared with other users can be placed.

For example, a Father user type that has access to all Internet and a Son user

type that is not allowed to certain violent or sexual webpages, can be defined.

To jump from one user's account to another is not necessary to turn off the

computer nor that a user closes what he was doing, one must simply initiate a new

session with another user and later it's possible to go back to the other session which

will remain in the same state it was left. The system handles the different active users

without interferences.

This way Microsoft intents to reduce illegal copying because a program can

only be used in one computer. This arises some questions that are difficult to answer:

What happens if a user updates his computer with a new processor or with a new hard

disk.

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Visual Basic dot net

Visual Basic (VB) is a programming language based on the original DOS

language called BASIC (Beginners' All-purpose Symbolic Instruction Code).

VB.NET 2005, an offshoot of Visual Basic, is an object-oriented programming

language based on VB that is implemented using the Microsoft .NET framework. The

basic syntax of the Visual Basic language remains unchanged in VB.NET 2005, but

includes additional features such as structured exception handling and short circuited

expressions to enhance the infrastructure of the programming language. Developers

have found VB.NET to be controversial as some of the software and developmental

changes clash with the original language within VB and have caused compatibility

issues. Visual Studio .NET is the predominant integrated development environment

(IDE) that VB.NET developers employ.

The visual Basic is a widely used scripting language and a subset of the Visual

Basic language. The investment you make in learning Visual Basic will carry over to

these other areas. In developing applications with Visual Basic programming is about

new keywords and functions. I choose the topics that felt every programmer should

learn in order to master the language.

The Visual Basic programming language is not unique to Visual Basic. The

Visual Basic programming system, application edition included in Microsoft excel,

Microsoft access, Microsoft SQL server and many other windows applications use the

same language. There is nothing new in Visual Basic dot net in this area, but graphics

are such an important part of the language that the related techniques had to be

explained in detail.

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2. SYSTEM STUDY

2.1 EXISTING SYSTEM

The system study manufactured Jumbo bags which are exported to countries

such as U.K, U.S.A and to many European countries. They are getting order from

various countries and process through the commercial department. This order comes

to execute after Confirmation. The Fabric cutting is the main part of the production.

They are done through manual calculation. This causes many waste sheets and lacks

in analysis of the report.

To update of the existing system we computerized the Fabric cutting section

using MS Visual basic dot net 2005 and SQL server 2005.Through this application we

can easily enter data, take a particular report, and can avoid wastage.

Another important existing system is time factor. It will not help the

management to solve the problem in time. The management could not act on any

issue; purchase or production unless getting the reports in time controls cannot be

used. The above said reasons are to overcome through this application.

The modules are

Jumbo Bag

Circular Bag

U-Panel Bag

Baffle Bag

Tunnel Bag

Asbestos Bag

MS-SQL server is a powerful multi-user RDBMS developed by Microsoft

Corporation. It can store and manipulate large amount of information and repetitive

tasks such as maintaining the roll slip no, fabric cutting roll no etc., Data can be

processed and meaningful reports can be generated easily.

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2.2 SYSTEM DESIGN

System design centers the software engineering and applied science

regardless of the software process model that is used. Once the software

requirements have been analyzed and specified, tests that are in the building

and verifying the software is done. Each activity transforms information in a

number that ultimately results in validated computer software.

There are mainly three characteristics that serve as guide for evaluation

of good design,

The design must implement all of explicit requirements contained in theanalysis model, and it must accommodate all of the implicit

requirements desired by the customer.

The design must be readable, understandable guide for those who

generate code and for those who test and subsequently support the

software.

The design should provide a complete picture of software, addressing

the data, its functional and behavioral domains from the implementation

perspective.

System design is a process of planning a new system or to the complement

of the existing system. The design based on the limitation of the existing

system. The requirements specification gathered in the phase of system

analysis.

Logical design

Physical design

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2.2.1 Logical Design

Logical Design of the system is performed where is features are described,

procedures tat met the system requirements are formed and a detailed specification of

the new system is provided.

Context Analysis Diagram

Data Flow Diagram

Entity Relationship Diagram

2.2.1.1 Context Analysis Diagram

A Context Diagram confines project scope to an agreed limit by obtaining

agreement from the customer on the data flows that are included in the scope of a

project. The Context Diagram focuses on relationships with external entities and

identifies the information that is exchanged between these external entities and the

business system under review. The external entities themselves are outside the scope

of the project but the data flows between the entities and the business system are

within the project scope.

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Figure 1

Looming

Details

Validated

Fabric

Cutting

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2.2.1.2 Data Flow Diagram (DFD)

Data flow diagram is modeling tools that allow picturing a system as a

network of functional process to one another by data. They are also widely used for

representation of external and internal design specification.

Data Flow diagram is a graphical representation of the "flow" of data through

in information system. DFD's can also be used for the visulalization of data

processing. on a DFD's data items flow from an external data source or an internal

data store to an internal data store or an external data sink, via an internal process. a

DFD' provides no information about the timings of process, or about whether

processes will operate in sequence or in parallel. it is therefore quite different from a

flowchart which shows the flow of control through an algorithm, allowing to

determine what operation will be performed, in what order, and under what

circumstances but nt what kinds of data it be input to and output from the system over

where the data will come from and go to, where the data will be stoud. This is the

graphical representation of the data processes and used in the support of an

information system they describe system as collections of data that are manipulated

by functions. Data can be organised in several way. The basic elements are

Bubbles

Arrows

Open boxes

Input/output boxes

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DFD FOR FABRIC ROLL CUTTING

LEVEL 0

Figure 1

DFD FOR REPORTS

Figure 2

DFD FOR ROLL SLIP REPORT

Figure 3

DFD FOR RECOVERY REPORT

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Figure 4

DFD FOR PRODUCT ORDER WISE REPORT

Figure 5

DFD FABRICROLL CUTTING

LEVEL 1

Figure 6

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2.2.1.3 Entity Relationship Diagram

The Entity-Relation(ER) model is a conceptual data model that views

the real world as entities and relationships. A basic component of the model is

the Entity-Relationship diagram, which is used to visually represent data

objects. The model has been expended and today it is commonly used for

database design.

Features of ER Model are

It maps well to relational model.

It is simple and easy to understand with the minimum of training.

Therefore, database designer to communicate to the end user can

use the model.

In addition, the model can be used as a design plan by the

database to implement a data model in specific database management

software.

ER diagram is a model that describes the store layout of a system at high level

abstraction. The diagram is based on the three primitive concepts entities, relations

and attributes. E-R diagram enables to examine and highlight the data structure and

relationship between the data stores in data flow diagram based on the information

provided by the E-R diagram, the kind of keys or indexes needed to access the data

base can be determined. E-R diagram can express the overall logical structure of a

database graphically .E-R diagrams are simple and clear qualities that may well

account in large part for the widespread use of the E-R model. Such a diagram

consists of the following major components.

Rectangles which represent entity sets

Ellipses which represent attributes

Diamonds which represent relationship sets

Lines which link attributes to entity sets and entity sets to relationship sets

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ENTITY_RELATIONSHIP DIAGRAM

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1 : M - One to many

M :M - Many to many

M

M

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2.2.2. Physical Design

2.2.2.1. Database Design

The goal of database design is to generate a set if relations that allows storinginformation easily. The database is designed in relational model in which the data are

organized into entries and relation between them.

In our data flow diagrams, we have given names to data flows, process and

data stores. Although the names are descriptive of the data, they do not give details.

So the following DFD gives the details of the fields used. A data dictionary has many

advantages in improving analyst of user communication by establishing consistent

definitions of terms elements and procedures.

Types of Data Constraints

There are two types of dara constraints that can be applied to data being

inserted into a database table. One type of constraint is called an I/O constraint. The

other type of constraint is called a business rule constraint.

I/O Constraints

The input/output data constraint is further divided into two distinctly different

constraints.

The Primary Key Constraint

Here the data constraint attached to a column ensures:

That the data entered in the table column is unique across the entire

coloumn.

That none of the cells belonging to the table column are left empty.

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pw float PercentageofWaste

achieved float AchievedPieces

diff float Difference

recovery varchar(50) Recovery

rpcs float RecoveryPieces

rpc Float RecoveryCutLength

rfrom varchar(50) RecoveryFrom

rto varchar (50) RecoveryTo

recmtr float RecoveryMeter

ap float ActualPieces

wwm float Waste WeightMeter

wwp float Waste WeightPercentage

type varchar(50) Type

spondate float SPOndate

spupdate float SPUdate

awon varchar(5G) AnotherWorkOrderNo

Table 2

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Table Name : Loop cutting table

Primary Key : tokenno

Description : This table contains details about loop cutting.

Field Name Data Type Description

won varchar(50) WorkOrderNo

compname varchar(50) ComponentName

size numeric(18, 0) Size

gsm float Unlamination.

colour varchar(50) Lamination

cut float CutLength

target float Target

datel varchar(50) Date

shift varchar(50) Shift

rwkgs float RollWeight Kgs

awm float AverageWeight

ondate numeric(18, 0) Ondate

udate numeric(18, 0) Update

bal float Balance

cbw float CutBitWeight

wwkgs float WasteWeightKgs

wp float WastePercentage

tokenno varchar(50) TokenNo

oname varchar(50) OperatorName

actual float ActualPieces

diff float Difference

Table 3

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Table Name : Master Table

Primary Key : token

Description : This table contains details about master.

Field Name Data Type Description

token varefaar(50) TokenNo

OName varchar(50) OperatorName

Table 4

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2.2.2.2 Input Design

The input design is the process of entering data to the system. The input

design goal is to enter to the computer as accurate as possible. Here inputs are

designed effectively so that errors made by the operations are minimized. The inputs

are to the system have been designed in such a way that manual forms and the inputs

are coordinated where the data elements are common to the source document and to

the input. The input is acceptable and understandable by the users who are using it.

The quality of the system input determines the quality for system output. Input

specification describes the manner in which data entered the system processing.

Input design is the process of converting user-originated inputs to a computer

based format input data are collected and organized into group of similar data. Once

identified, appropriate input media are selected for processing.

The input design also determines the user to interact efficiently with the

system. Input design is a part of overall system design that requires special attention

because it is the common source for data processing error. The goal of designing input

data is to make entry easy and free from errors.

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FORM DESIGN

Form Name : Fabric roll details

Description : This form contains details about Fabric roll.

Form 1

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Form Name : Fabric Cutting Details

Description : This form contains details about fabric cutting.

Form 2

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2.2.2.3. Output Design

The output design was done so that results of processing could be

communicated to the users. The various outputs have been designed in such a way

that they represent the same format that the office and management used to.

Computer output is the most important and direct source of information to the

user. Efficient, intelligible output design should improve the systems relationships

with the user and help in decision making. A major form of output is the hard copy

from the printer.

Output requirements are designed during system analysis. A good starting

point for the output design is the Data Flow Diagram (DFD).Human factors educe

issues for design involves addressing internal controls to ensure readability.

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REPORT DESIGN

Report Name : Fabric Roll and Cutting Details

Description : This report contains details about Fabric Roll andCutting.

Report 1

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Report Name : Loop Cutting Details

Description : This report contains details about Loop Cutting.

Report 2

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Report Name : Component Wise Report

Description : This Report contains details about component wise.

Report 3

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Report Name : Work Order Report

Description : This Report contains details about Work Order.

Report 4

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3. CONCLUSION

The world of computers is not static. It is always subject to change. The

technology today will become outdated the very next day. To keep abstract of the

technological improvements the system need refinements, so it is concluded, it will be

improved for further enhancements, whenever the user needs an additional feature

into it.

The system study title "Production Packaging System" has mostly all the

modules. It generates reports such as fabric roll component wise report, report based

on work order etc., will be very useful in analyzing the wastage of material where it

occurs and that can be recovered which will be useful in saving the material that leadsto more profit.

The system satisfies the all the requirements of the company and the

application is developed by advanced software Visual Basic dot net which is widely

used in all applications.

The system has been developed in Visual Basic dot net 2005 to reduce the

response time and ensure flexibility. The system also gives opportunity for further

development and enhancement of the existing system.

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4. BIBLIOGRAPHY

1. Rogger S.Pressman,"SOFTWARE ENGINEERING A

PRACTITIONER'S APPROACH", Tata McGraw Hill, 3rd Edition, 1996.

2. Julia Case Bradley, Anita C.Millspaugh, "PROGRAMMING IN

VISUAL BASIC", 2nd Edition, 1997.

3. James A.Senn,"ANALYSIS AND DESIGN OF INFORMATION

SYSTEM", Tata McGraw Hill, 2nd Edition, 1993.

4. John Connel, "BEGINNING VISUAL BASIC 6.0 DATABASE

PROGRAMMING", Wrox publication, 1998.

5. Joyce Cox And Polly Urban - "Quick Course In Microsoft Office".

6. Gray Cornell - "Visual Basics 6.0", TATA McGraw-Hill publication.

Websites

1. www.sazele.org

2. http://www.google .//concepts of databases//.com

3. http://www.yahoo.eom //learning software engineering on line//.com

4. http://www.w3schools .//online examples for visual basic//.com

5. www.msdn.microsoft.com

6. www.vbcity.com

7. wwvv.vbdotnetheaven.com

8. vyww.codeguru.com

Production Automation System

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