Proposed to

Process Industries

PMS
Process Monitoring System
Systems; Configuration & Operation

101 Gulshan Trade Center, GSM +92 341 391 4871 support@GNoorPCtronics.com
Rashid Minhas Rd., Karachi SMS +92 333 213 2780 www.GNoorPCtronics.com
PMS Introduction
Process Monitoring System
An automated system is suggested to any industry who process raw materials to produce a finished
product. The system is strictly based on (a) Physical Properties and (b) Material Identification. This
automated system is referred as PMS, Process Monitoring System.

System Overview
PMS is composed of three units;
(a) Back-Office Data Center
(b) Factory Floor Units
(c) Inter-Connectivity between [a] & [b]

Back-Office Data Center

The back-office data center is composed of Intel based computer running Microsoft Windows with
Internet Information Services along with Microsoft ODBC compliant database that connects Microsoft
Access Database.

Factory Floor Units

The “Factory Floor Units” collects data from weigh scale and reel identification code from barcode
scanner. Following equipment forms a single “Factory Floor Unit”;

(a) IOTA (Internet of thing for Android)

(b) Thermal Printer, Barcode Scanner, Weigh Scale
(c) Operator Console (Android 4.4 tablet)

IOTA is a “Publisher” that connects (a) Weigh scale and (b) Barcode Scanner to collects data from
equipment and publishes it to “Broker” after re-forming the incoming data to more generalized form
suitable for PMS system.

Operator Console; is an Android application acting as a “Broker” for PMS that manage incoming data
from “Publisher” and provides the same to “Subscriber”, in PMS the subscriber is “Server Side
Application” running on Intel computers under Microsoft Windows & IIS with Database.

Inter-Connectivity between Back-Office Data Center & Factory Floor Units

Three types of inter-connectivity is in operation for PMS; (a) Ethernet WiFi between Operator Console
& IOTA (b) Ethernet between Operator Console and Back-Office Data Center and (c) RS232C between
IOTA and weigh scale, barcode scanner and thermal printer.
PMS Introduction
Systems Overview
Following illustration shows composition of PMS.

General Description for Data Flow

IOTA is connected to weigh scale and barcode scanner via RS232C. Weight information collected by
IOTA from weigh scale is published to “Operator Console”. Resources identification codes are
collected by IOTA using connected barcode scanner. Operator console display weight and
identification codes, it communicates with back-office data center to get the associated information
and post weight data to database for further processing. The thermal printer connected with IOTA
produces labels and stickers. Refer to technical details of weigh scale and barcode scanner for
compatibility with PMS.

PMS Geography

There are three basic geographical areas in PMS. Each area identified as “Processing Zone”. Following
are planned areas for PMS.

(a) Warehouse
(b) Material Mixing, Blending & Processing
(c) Semi-Finished & Finished Product Area
(d) Dispatch Area
PMS Description
Systems Pre-Requisites (Part-1)
PMS needs following resources to manipulate data from one point to another point. These resources
are mandatory to form an operational PMS. The required resources shall be provided in the vicinity of
IOTA, not far beyond 10 feet.

(a) Electrical Power Sockets

(b) Ethernet (RJ45) Cable
(c) A WiFi Router
(d) Barcode Scanner (see technical specification for detail)
(e) Weigh Scale (see technical specification for detail)
(f) Thermal printer loaded with label & ribbon
(g) RS232C Cable connected with barcode scanner
(h) RS232C Cable connected with weigh scale
(i) RS232C Cable connected with thermal printer

Systems Pre-Requisites (Part-2)

PMS needs following resources to manipulate data from one point to another point. These resources
are mandatory to form an operational PMS.

(a) Four valid IP in the same domain for each site (e.g. 192.168.5.?)
(b) Back-Office Data Center IP (e.g. 192.168.5.3)
(c) A valid SSID & Key (should be same for each site)
(d) Ethernet wired connectivity between IOTA and Back-Office Data Center
(e) Microsoft Windows Server
(f) Microsoft Internet Information Services
(g) Microsoft Access Driver (ODBC Compliant)
(h) Microsoft ASP Classic 3.0 & ASP.Net
(i) Host Name for Internet Information Services
(j) Android 4.4 Tablet

Notes:
1. SSID should not contain white spaces
2. Back-Office Data Server should not be on VMWare
3. Portal should be accessible via web browser using “host name” instead of IP
4. Internet Information Services should be accessible from remote web browser
5. WiFi signal strength should be better than -57dBm in the vicinity of IOTA & Operator Console
6. FSTP cables are recommended to avoid signal losses in communication
7. Electrical “Earth” connection is recommended for safety & port latches
PMS Description
Systems Inter-Connectivity
Connectivity between IOTA and Weigh Scale is RS232C, using DB9 Connector. Cable length should
not be larger than fifteen feet. The configuration of RS232C cable depends on type of weigh scale
and should be provided by manufacturer.

Connectivity between IOTA and Barcode Scanner is RS232C, using DB9 Connector. Cable length
should not be larger than fifteen feet. The configuration of RS232C cable depends on type of barcode
scanner used and should be provided by manufacturer.

Connectivity between IOTA and Thermal Printer is RS232C, using DB9 Connector. Cable length
should not be larger than fifteen feet. The configuration of RS232C cable depends on type of thermal
printer used and should be provided by manufacturer.

Connectivity between IOTA and Operator Console is wireless Ethernet (WiFi). The IOTA and Operator
Console (Android 4.4 tablet) should be on same network. Data from weigh scale & barcode scanner
are continuously published to operator console.

Connectivity between “Operator Console” and Back-Office Data Center is wireless Ethernet (WiFi). The
Operator Console (Android 4.4 tablet) and Back-Office Data Center should be on same network.

Server Side Application

The application used by back-office is written in ASP. It is ported on Internet Information Services.
ODBC DSN connectivity is required between ASP application and Microsoft Access database. The
application is accessible from any remote computer using standard web browser. The client
computer should use proxy server to access the portal

The URI is http://pms.com

Client Side Application

An application written for Android 4.4 can be installed on any compatible Android tablet. The best
result would be on Kit Kat 4.4 with 7” display.

Middleware
Middleware designed for Microchip based microcontroller in MPASM. Data parser for various weigh
scale and barcode scanner is built on this layer to post data to PMS.
Systems Configuration
Server Side Configuration, IIS
Internet Information Services, required to run PMS. IT department shall install IIS on Microsoft
Windows Server. The Back-Office Data Center; should use static IP as explained above under
“Systems Pre-Requisites Part-2). The IIS configuration for PMS must use “Host Name” instead of static
IP. This will be easier for end-user to access the portal using this name. Application pool should be
selected for “Classic .NET”.

The URI is http://pms.com

It is explained
above under “PMS
Description, Server
Side Application”
heading. Screen
shot shows the
current setup on
IIS.

Server Side Configuration, Database

PMS is using Microsoft Access. However,
any ODBC compliant database can be
used for PMS. The database should be
compatible with Microsoft SQL
Statement. ODBC name should be
“dbRMS”.
Systems Configuration
WiFi Router Configuration
Any standard WiFi router can be used
to connect IOTA, weigh scale,
barcode scanner, printer and back-
end data server. Uplink to data server
from this router should not be linked
via WAN. The IP to this WiFi router
should be assigned by central LAN
router. Refer to following screen shot
for setting up WiFi required at each
area.

Console Operator Configuration

“Console Operator” is running on Android tablet. Any tablet can be used. Android OS 4.4 gives the
best performance. However,
Marshmallow, Nougats and Oreo can
also be used with minor compromise
on security and UI appearances. APK
should be installed on Android
device. The WiFi must be configured
to get connected with weigh scale,
barcode scanner, and printer and
back-end data server. Following
screen shot shows the configuration
panel for setting WiFi on Android
tablet. The SSID should be “PMS” with
“rms778165221” as Key for the WiFi
access point.
Systems Operations: Back-Office Portal
Back-Office Systems Operation
Portal running on Internet Information Services at back-end data server performs all basic data
management limited to PMS requirement. Following pages gives a quick overview on each section of
the portal. The portal can be access using following URL from any client computer on the same
domain or any other domain if it is configured to access over cross network.

http://pms.com

Following pages describe four basic operation required to collect and review the material
information. The four basic operation supported by PMS is given below;

(a) Production List

(b) Production Department
(c) Customer
(d) Job Card
Systems Operations: Back-Office Portal
Portal Operation; Production List
Click on “Production List” to get the following screen. All processed JCN (Job Card Number) is listed
on this page. A user can get details on processed job. To get details of each reel being processed by
any processing area are listed chronologically with weight and reel identification number.
Systems Operations: Back-Office Portal
Portal Operation; Production Department
Click on “Production Department” to get the following screen. Each processing area is designated as
“Department” as explained in “PMS Description, PMS Geography”. All possible department types are
predefined in PMS. Following screen shots gives detail on each step to create a department. Each
department contains processing are named as “Station” as illustrated below.
Systems Operations: Back-Office Portal
Portal Operation; Customer
Click on “Customer” to get the following screen. A customer basic profile is required to be created
before processing any reel. A Customer ID is generated by PMS itself when a user creates a new
customer. A reference number can be provided to keep trace with any existing customer base.
Attribute “Active” must be checked to make a customer active in the system. The “Ref Number” must
be unique, it cannot be repeated for several customer.
Systems Operations: Back-Office Portal
Portal Operation; Job Card
Click on “Job Card” to get the following screen. A job card is mandatory to be generated before
processing any reel. Each reel produced at any stage must be connected with any job card. A Job
Card Number (JCN) is generated by PMS itself when a user creates a new job card. A reference
number can be provided to keep trace with any existing customer base. Attribute “Active” must be
checked to make a job card available for processing area. The same JCN would appear to “Console
Operator” so reel data can be collected and stored in PMS. The reference number must be unique.
User can define profile for job & reel as well. The important element is “Total Weight & Length”
required for a job is defined under the section “Job Card Assignment”. The weight is appeared on
“Console Operator”, this helps a processing are to watch the quantity of reel produced.
Systems Operations: Console Operator
Console Operator, application is designed for collecting “UN-EDITED” weight information of a reel
produced. This section explains quick operational activities required to collect data from any IOTA
installed at each processing area.
Console Operator
Following snap shows UI of the Console Operator. There are gadgets on screen to perform various
tasks. The system statuses are visible on top of the screen including live real time weight information
at the bottom. The “Status” of PMS is visible on top of the screen. There are things to note on this
screen as explained below;
(a) The “28” on top right corner shows the stability of connection between “Console Operator”
and weight scale. If it starts falling from 28 to 27, 26 and so on; than it indicates break in
communication between weigh scale and console operator. Application restarts once it
reaches ZERO. End-User must watch this value and should not perform any task if it is not
static to either 28 or 29.
(b) The”-82%” in status shows the battery level of the tablet. The “-“sign indicates charger is not
connected. It show “+82%” when charger is connected.
(c) The letter 4D05A8C0 is the IP assigned by WiFi router to this “Console Operator”.
(d) The 7C:8B:CA:82:9D:02 is the MAC address of the “Console Operator”.
(e) The -56dBm” is RSSI of communication channel.
(f) The “RMS” & “Good” shows the SSID and WiFi signal strength. It should be “Good” and “Fair”.
(g) The “SAM” on bottom panel is used for “Systems Administration”.
(h) The “56.5kg” show live, real-time weight information collected from weighs scale.
(i) Next to the weigh data; barcode is displayed.
(j) The “PRO” on bottom panel is used to process any job card and/or reel. A popup screen
would appear when a user taps on “PRO”.
(k) The “PIN” on bottom right corner is used to get inside RMS portal. A valid pin code must be
entered before performing any operation.
Systems Operations: Console Operator
Console Operator: Login
A valid pin code is required to get access on “Console Portal”.

Console Operator: Job Card

Active job cards are displayed relevant to the department being logged in. The JCN and “Product
Title” is highlighted. A user can tap on “Product Title” to activate its processing, OR can tap on JCN to
record various parameters for a reel.
Systems Operations: Console Operator
Console Operator: Job Card (navigation)
There are navigation taps at the bottom of the list. In this example we will be using product
“Blueberries” as show in following screen.

Console Operator: Activating Job Card to Initiate Production

The “Product Title” is tapped to get this screen, where a user can select “YES” to initiate a reel
processing. It also display details of the production requirement.
Systems Operations: Console Operator
Console Operator: Job Card Activated for Processing
Once a job is activated in previous screen will display the following screen.

Console Operator: Processing the selected Job

Once a job is activated. User should tap on JCN to process the reel, as in the following screen.
Systems Operations: Console Operator
Console Operator: Step 1 “Deploying Core”
Before recording a processed reel, user should deploy an empty core on production line. Place a core
on weigh scale. The weight 11kg is displayed on Console Operator.
Systems Operations: Console Operator
Console Operator: Step 2 “Deploying Core”
Tap on “PRO” will display the following screen. User should tap on POL to select correct “Point-of-
Load”, where the core is being deployed for producing a reel. Thereafter, tap on “Install Core” will
deploy the core on selected POL.
Systems Operations: Console Operator
Console Operator: Step 3 “Unloading a Reel”
To unload a finished reel from production line, a user should tap on PRO. Following screen appears.
Before doing this, the finished reel should be placed on weigh scale. Assuming a 53.5kg reel is
produced in our example. This screen shows the weight is 53.5kg, while the core weight is 8kg and
the resultant actual reel weight is 45.5kg Once the data displayed on screen is stabilized, user should
tap on “PRO” again to record the reel weight against the selected reel under a job after confirming to
record it.
Systems Operations: Console Operator
Console Operator: Recording Waste/Other
Waste and Other production can be record into PMS against any job & reel. Following screen shows
waste recording.
Systems Operations: Console Operator
Console Operator: Recording Tags
Tags are used to indicate any fault in produced reel. The number of tags can be recorded into system
using following screen.
Systems Operations: Console Operator
Console Operator: Adding Inputs to a Production
PET, Lamination Foils and other materials are fed into a system using this screen. Other than
extrusion all other departments uses inputs to produce a reel. In our example, we uses “Rewind”
department to illustrate the “Feed”.
Systems Operations: Console Operator
Console Operator: Return (Leftover)
All materials fed into a process to produce a reel can be return to store. Even if a feed is completely
utilized, it should return an empty core to record the material return.
Systems Operations: Console Operator
Console Operator: SAM
Tap on “SAM” to get the panel for managing “Resources” used for processing a reel at any stage. A
PET Reel not produced by company should be recorded here. Core, Lifters and all other materials that
can be used as “Feed” into a reel production can be recorded using “SAM”.
Technical Support
We rely on your feedback to let us know if we are reaching our goal. If you cannot find the
solution to your particular problem, or, if for any reason you need additional technical
assistance, you can call +00923413914871 during 0900 and 1800 PST Monday to Saturday
excluding public holidays. “Technical Support” required by end-user needs to launch a
complaint via email, providing the following information so it can be rectify easily,
without such information it is difficult to provide technical support.

(a) What “Operation” a user is performing on system. The same operation will be
simulated at our lab to understand the complaint.
(b) Environment info: is Electrical Status OK as expected? Yes/No
(c) Environment info: is all parts connected to LAN/WLAN?
(d) Environment info: is printer connected to IOTA via RS232?
(e) Environment info: is weigh scale connected to IOTA via RS232?
(f) Environment info: is barcode scanner connected to IOTA via RS232?
(g) Environment info: is printer, weigh scale, barcode powered ON?
(h) Environment info: is printer, weigh scale, barcode working OK?
(i) Environment info: is Console Operator connected with LAN/WLAN?
(j) Environment info: is Console Operator can login to data server?
(k) Environment info: is WLAN signal strength is sufficient?
(l) What message is displayed on Console Operator when launching this complaint?
(m) What message is displayed on portal when launching this complaint?
(n) Who is performing the task on system at the time of complaint launched?
(o) Is electrical status checked by electrical maintenance department?
(p) Is networking, database & data server checked by IT department?

Warranty
The product is warranted free from defects in materials and workmanship for the period of
eleven months after first operational installation on site. This warranty is limited to
repairing or replacing defected parts at actual cost of manufacturing that may change in
future, any defective component, circuit board, or module contained within the product only
when it is returned to GNoor PCtronics. In all cases, the customer is responsible for
shipping charges to and from GNoor PCtronics. The time-required to repair the defective
parts are determined after inspection of the defective parts. Electrical parts and
Electronic Components used in this product are available in spare for six months,
thereafter compatible parts & components will be available to support the defective parts
at price determined by manufacturer at the time of repairing.

Life Support Policy

As a general policy, GNoor PCtronics does not recommend the use of any of its products in
life support applications where failure or malfunction of the product can be reasonably
expected to cause failure of the life supporting devices or to significantly affect its
safety or effectiveness. GNoor PCtronics does not recommend the use of any of its products
in direct patient care. GNoor PCtronics will not knowingly sell its products for use in
such applications unless it receives in writing assurances satisfactory to GNoor PCtronics
that (a) the risks of injury or damage have been minimized, (b) the customer assumes all
such risks, and (c) the liability of GNoor PCtronics is adequately protected under the
circumstances.

E&OE
DOCUMENT REV 1.0
DATE: 2018-12-23
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