en Cosimir Factory Manual

COSIMIR® T
Factory
Operating Instructions
548588 EN
04/06
Order No.: 548588
Edition: 04/2006
Authors: Christine Löffler
Graphics: Doris Schwarzenberger
Layout: 20.04.2006, Beatrice Huber
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2006
Internet: www.festo-didactic.com
e-mail: did@de.festo.com
The copying, distribution and utilization of this document as well as the

communication of its contents to others without expressed
authorization is prohibited. Offenders will be held liable for the payment
of damages. All rights reserved, in particular the right to carry out
patent, utility model or ornamental design registration.
Contents
1. What information will you find in this manual?_____________ 5
2. How to install COSIMIR® Factory ________________________ 8

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2.1 System requirements _________________________________ 8

2.2 Installation of COSIMIR® Factory as a single
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workstation licence __________________________________ 9

2.3 Network installation of COSIMIR® Factory _______________ 15 T
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3. The COSIMIR® Factory system _________________________ 16

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3.1 Overview of COSIMIR® Factory ________________________ 16

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3.2 A production line in COSIMIR® Factory __________________ 23

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3.3 Production control in COSIMIR® Factory _________________ 25

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3.4 The structure of a project in COSIMIR® Factory ___________ 33 T

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3.5 The pre-assembled automation stations ________________ 44

3.6 The products_______________________________________ 52
3.7 The production database _____________________________ 60
4. The most important operator functions of

COSIMIR® Factory___________________________________ 63
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4.1 Modelling a new production line _______________________ 63

4.2 Modifying an existing production line ___________________ 75
4.3 Simulating a production line __________________________ 82
4.4 Modifying the view of a production line _________________ 83
4.5 Automatic generation of a production control system
for a production line_________________________________ 86
4.6 Simulating operation on a production line _______________ 93
4.7 Generating a production control system for
a modified production line___________________________ 112
4.8 Programming a production control system for
a production line using a process plan _________________ 125
4.9 Viewing and managing the production database _________ 145
4.10 Generating and modifying the order list for
a production line __________________________________ 176
© Festo Didactic GmbH & Co. KG • 548588 3

Contents
4.11 Executing and monitoring the order list for

4.12 Managing the automated warehouse for
4.13 Creating a new workpiece in the production database ____ 231
4.14 Creating and evaluating test data for a workpiece ________ 274
4.15 COSIMIR® Factory beenden __________________________ 297
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5. Material which you can teach using COSIMIR® Factory ____ 298
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5.1 Learning contents and learning objectives ______________ 298

5.2 Target group ______________________________________ 299
5.3 Previous knowledge required ________________________ 300
5.4 The learning concept of COSIMIR® Factory ______________ 300
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5.5 Learning scenarios for COSIMIR® Factory _______________ 303

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6. Example: Planning and simulating the

production of a product _____________________________ 305
6.1 Learning objectives ________________________________ 305
6.2 Methods _________________________________________ 306
6.3 Exercise: Planning, simulating and evaluating the
production of a baseplate ___________________________ 308
6.4 Exercise: Planning, simulation and evaluation of the
production of a deskset _____________________________ 327
4 © Festo Didactic GmbH & Co. KG • 548588

1. What information will you find in this manual?
What is COSIMIR® Factory?

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COSIMIR® Factory is a PC-based graphical 3D simulation system which

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offers an introduction to computer-integrated manufacturing.

You can use COSIMIR® Factory to
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• model production lines of differing degrees of complexity,

• automatically generate a production control system for a production
line or program parts of the production control system yourself
• simulate the operation of the production line and
• plan production on the basis of a production database.
The fact that you are working with a complete production process
means that you have a global perspective and can obtain a good
overview of computed-integrated manufacturing and a clear
understanding of the reciprocal effects and dependencies between the
individual elements of a production process.
It is equally possible to concentrate on individual aspects of CIM plants
and increase your depth of knowledge of these. Examples include robot
and CNC programming.
In this way, you can by using the COSIMIR® Factory simulation system
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acquire comprehensive knowledge and experience of CIM plants.
The simulated production lines are also available as real iCIM

installations. These allow you to apply the knowledge you have
acquired with virtual production lines to real installations and increase
the depth of this knowledge.
This procedure is supported by a COSIMIR® Factory expansion module
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The expansion module makes it possible to control corresponding real

production lines directly from COSIMIR® Factory.
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Target group This manual is aimed at

• trainers
The manual offers trainers ideas and suggestions for ways to use
COSIMIR® Factory for training purposes at various levels.
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• trainees
For this group, the most interesting part of the manual will be the
information and instructions on the operation of COSMIR® Factory.
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Structure of manual The manual is structured on the basis of the following thematic areas:
• Chapter 2 contains information and tips on the installation of
COSIMIR® Factory.
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• Chapters 3 and 4 describe the system and the main operator

functions of COSIMIR® Factory.
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• Chapter 5 deals with didactic matters. It lists the material taught by

COSIMIR® Factory and describes its learning concept and its
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possible uses in teaching.

• Chapter 6 describes concrete exercises using the taught materials,
methodology for finding solutions and ways to implement these in
COSIMIR® Factory.
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Conventions In order to allow you to find information more easily, certain notation is
used for text and for key combinations and sequences.
Notation Explanation
Bold Bold type is used for command names, menu

name, dialogue field names, folder names
and command options
Key 1 + key 2 A plus sign (+) between the key names means
that you must press the named keys at the
same time
Key 1 – key 2 A minus sign (-)between the key names

means that you must press the named keys
one after the other

Additional support Further information and support is available as on-line help. On-line
help consists of the following:
• COSIMIR® help for system operation
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• COSIMIR® Assistant.
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On-line help On-line help provides detailed information on the functions and
operation of COSIMIR® Factory. T
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The on-line help menu bar offers functions which will be familiar to you
from standard Internet browsers. These include forward and back keys,
a start-page button, the ability to print out selected subjects, the option
to view or hide the navigation bar, and the ability to define Internet
connection options.
You also have a facility via additional tabs such as Contents, Index,
Search and Favourites to navigate through the help information on
COSIMIR® Factory in a convenient way.
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COSIMIR® Assistant
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COSIMIR® Assistant provides detailed functional descriptions and

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technical documentation on the individual automation stations. Each

functional description includes a list of the macro process tasks which
each station can execute. The macro process tasks are a central part of
the control system for a production line.
Supplementary information on programming production control

systems in COSIMIR® Factory can be found in the COSIMIR® Control
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manual. COSIMIR® Assistant includes electronic versions of this manual

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and the COSIMIR® Factory manual.

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You need to have Adobe Acrobat Reader installed on your PC in order to

read PDF documents. The Adobe Acrobat Reader is available free of
charge and can be downloaded from the website www.adobe.de.
If you have any questions on the installation or operation of COSIMIR® T
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Factory, our telephone hot line is open to you at all times.

2. How to install COSIMIR® Factory T
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COSIMIR® Factory is supplied as a CD-ROM, a USB dongle, a copy of this

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instruction manual and a copy of a further manual with information on

network installation.
2.1 The following system requirements are specified for COSIMIR® Factory.
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System requirements
Minimum configuration of COSIMIR® Factory
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Processor Pentium IV 1 GHz processor or better
RAM 512 MB
Spare hard disk 800 MB

capacity
Operating system Windows 2000/XP; Microsoft Internet

Explorer from version 5.0
Graphics card Card with 3D booster and OpenGL

support, 64 MB RAM
Monitor 17“ with screen resolution 1024 x 768

pixels
Interfaces USB interface for dongle
Additionally Adobe Acrobat Reader version 6.0 or later

2. How to install COSIMIR® Factory
2.2 The instructions here apply for COSIMIR® Factory with a single
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Installation of COSIMIR®
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workstation licence, operated on precisely one PC, to which the dongle

Factory as a single is fitted.
workstation licence It is of course possible to install the COSIMIR® Factory software on
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various type of PC workstations.
This is how to install the software under a single workstation licence.
1. Switch on your PC and launch Microsoft Windows.

2. Insert your COSIMIR® Factory CD-ROM.
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3. Click on Run in the Start menu.

4. Enter d:Setup.exe in the input field which then opens.
Confirm your entry with OK.
5. The start screen for the installation program will then appear.
Choose the language in which you wish to install the software
package. Confirm your entry with OK.

6. Follow the instructions on the screen. Click on the Next button to

continue to installation.
7. Familiarise yourself with the Festo Didactic licence conditions. You

must accept these conditions in order to continue installation. Check
Accept and then click on the Next button.

8. Now define the directory in which COSIMIR® Factory is to be

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installed. The default setting is the sub-directory

C:\Programme\COSIMIR® Factory.T
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To install in another directory, click on the Browse button.

When you have completed your settings, click on the Next button.
Note Be sure to choose a directory for installation which does not contain any
other version of COSIMIR®.
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9. Enter the program group in which the COSIMIR® Factory symbols are
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to be stored. The default setting for the program group is COSIMIR®

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Factory. You can of course change this if you wish. Confirm your
choice by clicking on the Next button.

10. COSIMIR® Factory is now ready for installation. Click on Next to start
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the installation.
11. The COSIMIR® Factory software package will now be installed,

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including a run-time version of Microsoft Access 2003.

The various programme components will be installed
simultaneously in some cases. This is made apparent by the
multiple entries in the start bar.

12. The installation of COSIMIR® Factory is now complete. Click the

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Finish button. As soon as the dongle has been plugged into the USB
interface, you can launch COSIMIR® Factory. T
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Note Proceed as follows in order to uninstall COSIMIR® Factory: T

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• Activate the Control Panel in the start menu under Settings.

• Double click Software.
• Click COSIMIR® Factory. Then click the change/remove button in
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order to uninstall the COSIMIR® Factory programme.

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• The COSIMIR® Professional and COSIMIR® Factory-Control

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programmes can be uninstalled in the same way.

2.3 The term “network installation” relates above all to the software
Network installation of licence. In the case of network installations, software access is provided
COSIMIR® Factory
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via a network and a central licence server.
Licences are issued dynamically and can be requested from any desired
workstations within a network up to the maximum number of licences
ordered. The licence server is a computer within the network which
issues licences. A dongle must be in place on the USB port of the
computer concerned at all times when COSIMIR® Factory is running to
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allow network users to access dongle data.
Information and instructions on network installation can be found in the

document Network Installation.pdf in the Network directory on the
installation CD for COSIMIR® Factory.
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The network licence files can also be found in the Network directory on
the installation CD for COSIMIR® Factory.
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3. The COSIMIR® Factory system T
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The COSIMIR® Factory system includes:

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• COSIMIR® Factory simulation software

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• A production database as a Microsoft Access application

• A runtime version of Microsoft Access
• An on-line COSIMIR® help system T
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• An on-line COSIMIR® Assistant T

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• A dongle for a USB interface

• A manual.
3.1 COSIMIR® Factory is a PC-based graphical 3D simulation system which

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Overview of COSIMIR® T
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offers an introduction to computer-integrated manufacturing. You can

Factory use COSIMIR® Factory to plan, program and simulate production lines.
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Example of a production line

3. The COSIMIR® Factory system
Production lines consist of one or more production cells. Within

COSIMIR® Factory, production cells are also referred to as automation
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stations. Production cells are made up of several automation devices.

Typical automation devices are processing stations such as industrial
robots or CNC machines. Additional devices such as peripheral devices
and conveyor systems are also used. The most important feature of
production cells is that they work together to process various products
within the production process. The processing sequence is programmed
in the production control system.
Production lines are also called production cells in COSIMIR® Factory

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software, and are administrated as such.
When you carry out production planning for production cells or

production lines, you are working on the Enterprise Resource Planning
(ERP) level within a factory automation hierarchy.
The actual control process for production lines runs on the

Manufacturing Execution System (MES) level.
The Controls (or “Shopfloor”) level is the lowest level within the factory
hierarchy. On this level you will find real or virtual production lines and
automation components.

Factory levels
COSIMIR® Factory offers an introduction to computer-integrated

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manufacturing. It covers the CONTROLS and MES levels completely and

also parts of the ERP level.
For the CONTROLS level, COSIMIR® Factory offers the function:

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• Creation of a production line.
For the MES level, COSIMIR® Factory offers the following functions:
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• Creation of relevant project for production control system

• Automatic creation of production control system for production line
• Optional: Programming of production control system using process
plan
• Simulation of production line operation

For the ERP level, COSIMIR® Factory offers the function;

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• Planning of production on the basis of a production database
The functions of COSIMIR® Factory are implemented in three program

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sections:
• Factory Production Manager
• Factory Simulation
• Factory Control
Factory Production Manager

Planning
Factory Simulation Factory Control

Production Project for
line production control
Visualisation
The COSIMIR® Factory system

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Factory Simulation The plant editor within the Factory Simulation program section allows
modelling of production lines on the basis of ready-made automation
stations. The automation-station data is stored in a library. As soon as
you begin to simulate a production line, working from Factory Control,
you can use Factory Simulation to follow events on the production line
in a highly realistic way.
Editing mode Simulation view
Factory Simulation program section
The library offers a variety of automation stations and devices. These

include:
• Various robots
• Various CNC machine tools
• Equipment for quality testing and inspection
• Automated warehouse with automatic infeed and outfeed of
workpieces
Factory Control The Factory Control program section allows you to create a project for a
production control system for a production line. Data on the type and
composition of the production plant is automatically exchanged
between the Factory Simulation and Factory Control program sections. A
production control program can be created automatically. Alternatively,
it is possible to expand this program, optimise it or program parts of the
production control system using process plan.

The following central tasks are carried out on production lines or in

production cells:
• Workpieces are taken from the stores and transported to the
machine tools.
• Robots pick workpieces from a conveyor belt and set these down at
defined positions within a station.
• CNC machines process workpieces.
• Assembly machines fit two or more workpieces together to form an
end product.
• Special stations check the quality of the workpieces produced.
When the operation of a production line is simulated, a visualisation

with simple operator functions is automatically created at the same
time. Data on stock levels and facilities for operator intervention are
also available in the Production mode.
Process plan
Stock administration
Visualisation
Factory Control program section

Factory Production Factory Production Manager allows you to carry out simple functions of
Manager a production planning system. These include:
• Creation of new workpieces by entering an order number and an
assembly instructions number on the production database.
• Setting up a production process for new workpieces on the
production database and describe this.
• Compilation and execution of a task table on the basis of a pre-
defined production database.
• Display of the latest data on the stage reached in the processing of
the task table.
• Management of an automated warehouse.
...
Production
data
...
Stock
contents
Factory Production Manager program section

3.2 A production line in COSIMIR® Factory consists of the following

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A production line in elements:

COSIMIR® Factory
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• Conveyor belt
• Automated warehouse
• Processing and assembly stations
• Optional: Quality station
• Production control with visualisation
• Production database
Station Station
stock assembly
Station transport system
Station Station
processing quality
Schematic representation of a production line
Materials flow on a The tasks of a materials flow system are:

COSIMIR® Factory
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• Transport of workpieces between automation stations

production line • Transport of workpieces within an automation station
Example:
Laying a workpiece on a conveyor belt, taking a workpiece from a
station magazine.
Workpieces are generally transported between the various automation

stations by means of a conveyor belt. Conveyor-belt pallet carriers are
used to bring pallets of workpieces to the desired automation station. A
robot is responsible for the transport of workpieces within the station.

When a robot accepts a pallet with a workpiece from a conveyor belt, it

will typically set this down at a buffer station. From this point, the robot
will feed the workpiece to a processing or assembly process. After the
desired process has been carried out, the robot will replace the
workpiece on the pallet and then feed the pallet with the processed
workpiece onto a pallet carrier on the conveyor belt.
Stock management on a An automated warehouse is used as the main storage point for a
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production line. Each warehouse compartment accepts one workpiece

production line on a pallet. The workpieces are fed from this point to the individual
stations.
In addition to this main storage point, there are also local storage points
for the stations. These storage points are allocated to individual
stations and managed by these. This allows stations to operate
independently of the main storage point.
Typical storage points within stations take the form of magazines and
belt systems.
Executable programs Each automation station carries out certain tasks. The execution of
these tasks is defined in programs. These programs – which include
PLC, CNC and robot programs – are an integral part of the automation
station in question.

3.3 The production control system used in COSIMIR® Factory has a

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Production control in hierarchical and easily adaptable structure.

COSIMIR® Factory
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Example Here is an example to explain the mode of operation of the production

control system:
The task for the production line is as follows:

The product aluminium desk set with aluminium pen holder and
thermometer is to be produced.
Ask yourself: What tasks does the production control system need to
carry out? What data does this system need? What conditions must be
fulfilled?
The table below summarises the most important steps in the production
of the desk set.
No. Process steps Execution of steps
1 What is the part All the workpieces required for production have their own part
number of the desired number and are described on the production database by a number
product? of features.
By accessing the production database, we find:
The desired product has the part number 52368.
2 Issue of order to Order is added to production table:

production line. Produce part no. 52368.
START.
3 What workpieces are Data on the workpieces which make up a particular product is stored
required for the on the production database.
product? By accessing the production database, we find:
The desk set consists of a baseplate (part number 42140) and a pen
holder (part number 42102). These workpieces are supplied from
the warehouse.
Also present in the assembly station are stocks of the thermometer
(part number 30000) and the pen (part number 30100).

No. Process steps Execution of steps
4 What resources (in Data on the required resources is also stored on the production
this case machines) database.
are required for the By accessing the production database, we find:
production process? We required an automated warehouse, a circulating belt system, a
lathe and a milling machine.
5 Does the production A check as to whether the required resources are available is made
line contain the by evaluating the project. This contains a list of all production line
required machines? devices.
By evaluating the project, we find:
In COSIMIR® Factory,
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The required resources are available.

machines are also
referred to as
automation stations.
6 What steps need to be The actual production sequence is formulated in a special

executed during the programming language:
production of the Command to belt: Position pallet carrier in front of stores.
products? Command to stores: Set down workpiece on pallet carrier.
Command to belt: Transport pallet carrier to NC machine.
....
7 What is the criterion The production control system supplies status and error messages
for the end of the to the production process.
production process? The production order is complete: END

If we evaluate the production process, we come to the following

conclusions:
• The production line and production control system has a hierarchical
structure.
• In order to be able to address the individual devices, the production
control system must possess data on the structure and devices of
the production line.
• The sequence for the production control system is written in a
special programming language. In COSIMIR® Factory, the
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programming language “process plan” is used.

• In order to allow automatic production, all data on the workpieces
and production process must be stored on a database. The
production control system then accesses this database.
Process plans
Production Production
database control
Station
Station ...
transport
stock system
Structure of production line

Hierarchical structure of The production control system for production lines has a hierarchical
production control system structure. Each hierarchical level has defined tasks and defined
interfaces to the adjacent levels.
Factory Control
PC production
controller
Layer control
of production
Program for
production line
in process plan
...
Handshake Handshake Layer

process plan process plan network
Driver Driver
Layer
drivers
Process tasks Process tasks
Device Device
Layer
devices
Programs Programs
Hierarchical structure of production control system

The production line control system includes:

• Executable device programs:
Production lines consist of automation stations. Automation
stations in turn consist of various devices such as robots, a PLC or a
CNC machine. Devices, including automation stations, carry out
certain tasks. The individual tasks are stored as programs. These
programs are called up selectively by the production control system.
Example:
Robot programs for the Festo Assembly Station or PLC programs for
the Festo Stock Station.
• Process tasks of devices:
The individual tasks of a device are referred to as process tasks.
Each device has certain process tasks.
In the interests of simplicity and user-friendliness, automation
stations operate with so-called macro process tasks. Macro process
tasks describe the major tasks of a station. Macro process tasks are
made up of the process tasks for the individual devices.
Example:
The Festo Assembly Station has macro process tasks such as
AsmDeskSet (Assembly Desk Set), MovFromTrans (Move From
Transport) and MovToTrans (Move To Transport).
• PC-based production control system:
The process tasks are called up by the master production control
system. In certain cases, further data will also need to be transferred
to the process task in the form of parameters.
After a device has completed a process task, it sends a feedback
signal confirming this to the calling production control system.
Example:
Macro process task DeskSet (TargetPartNumber, OrderNumber).
The macro process task AsmDeskSet includes the
parametersTargetPartNumber and OrderNumber. TargetPartNumber
indicates the part number of the product which is to be assembled,
while OrderNumber is the number of the production order.

• Networking
The production control system and the devices must be networked
to allow them to exchange data.
Example:
Networking via Ethernet using the TCP/IP protocol or an RS 232
serial interface in the case of a real production line, networking via
PARSIFAL in the case of a simulated production line.
• Drivers:
The process tasks or macro process tasks of a device are contained
in a driver and its associated handshake process plan. The driver is a
program which addresses a device directly. The driver
communicates on one side with the production control system via
the appropriate network and on the other side with the device. The
communication with the device also follows certain rules. The driver
thus links the production control system and the device. The driver
and the associated handshake process plan convert the process
tasks into a form in which it can be executed by the device.
Example:
The driver $PARSIFAL communicates with all the devices on the
simulated production line, including the Robot Assembly1Robot1
devices of the Festo Assembly Station. For example, the driver
converts the process tasks ExecProg(“MP”,15, 3, 0) in such a way
that the robot program with the specified name MP is executed. In
this robot program, the robot picks a pallet from the circulating
conveyor belt and sets this down at buffer station 3 of the Festo
Assembly Station.

The production control system is programmed using a special high-level

language, process plan. This language provides many system functions
such as arithmetic or character string functions. Character string
functions, for example, can be used to create messages for machine
operators. System functions are required for, among other things, the
initialisation and de-initialisation of drivers and devices. In addition to
basic functions, there are also commands for process tasks and macro
process tasks.
Flexibility of production The hierarchical structure ensures that the production control system is
control system highly flexible. This flexibility is achieved through the use of device-
specific drivers and their associated handshake process plan.
• The device drivers are programmable. They can thus be modified at
any time for new tasks.
• If a different or new automation device is installed, it is only
necessary to create a new driver and a new handshake process plan
for this device and load it into the system. The existing parts of the
production control system will not be affected by this change.
Drivers and handshake process plans can be programmed by skilled
users or by the system manufacturer.
• Any changes to the robot or PLC programs will not affect the
production control system.
• Changes to the production process can be made easily by the user.
It is only necessary for the user to modify the process plan
appropriately.
• The use of device-specific drivers makes it possible to use the
production control system with heterogeneous cell structures.

Factory Control
Production control
...
OPC TCP/IP SERIAL PARSIFAL ...
Ethernet Ethernet Serial port PARSIFAL

TCP/IP TCP/IP RS 232
Robot CNC Factory ...

PLC
controller controller Sim
Real production line Virtual production line
Example of production lines
Process plans for The product-specific production process in the production cell is defined
production control system for each product by a separate process plan.
The following applies to process plans:

• A process plan is executed by the production control system as an
applications program.
• A process plan contains all the process steps for an individual
product.
• A process plan can be programmed freely by users. The COSIMIR® T
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Factory system provides support for the programming of process

plans.

Modes of operation of A production control system offers various modes of operation:

production control system • In the set-up mode, you can create a program for the production
control system. During this time, the production line is at a
standstill.
• In the Production mode, the production control system program will
be executed and the production line will operate.
3.4 COSIMIR® Factory allows the user to create production lines with their
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The structure of a project associated production control systems. The production lines are
in COSIMIR® Factory
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managed as a project.
A COSIMIR® Factory project thus contains data on:
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• The configuration – in other words, the structure and composition –-

of the production line and
• The production line control system.
Data on the project is supplied by various project elements.
Element Description
Devices A production line is made up of various automation stations. The automation

stations in turn consist of devices.
Process plans Process plans describe the sequence of the production process on the
production line. They form part of the production control system.
Drivers Drivers are assigned to individual devices. The drivers, together with the
handshake process plans, cover the possible process tasks of an individual
device. They convert the process tasks in such a way that they can be
executed by the devices. Drivers also form part of the production control
system.
Libraries Individual project elements to control the production line can be linked in
from libraries. Libraries thus also form part of the production control system.

Element Description
Processes Processes are not static project elements. They are created during the
operation of the production control system (Production mode) as
manifestations of the execution of process plans.
Process tasks Processes are not static project elements. They are created during the
operation of the production control system (Production mode) when
individual process tasks are started in devices.
Elements of a COSIMIR® Factory project

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In Factory Control, the program section for the production control

system, all the data on a project is displayed in the Project window.
The project window in Factory Control
When you open the lower hierarchical levels for the individual data
entries, additional data on the relevant project element will be
displayed.

Devices A production line is made up of various automation stations. The

automation stations in turn consist of devices. The project element
Devices shows both the stations and the subordinate devices.
You can model the production line in Factory Simulation. In order to

ensure that the production line control system can be created
automatically in Factory Control, Factory Control must have data on the
production plant structure. The necessary data is available in an XML
file.
The production control system transmits process tasks to the

production line devices. This is carried out using a driver. All the process
tasks of a device are grouped together in the driver and associated
handshake process plan. Drivers are therefore always allocated to
precisely one device.

In the Project window the following additional data is shown for each
device:
• The allocated drivers with the name prefix $ and
• The process tasks.

Process plans Process plans are an important element of a production control system.
Process plans are used to program the process sequences for a
production line. They define the sequence in which the individual
process steps are to be executed and also permit the creation of parallel
branches.
Process plans have a line-oriented structure. Each line is made up of

these fields:
• Line number
• Condition
• Device
• Process task
• Next line
• Comment (optional)

In the Project window, the following process plans are displayed:

• The automatically generated process plans and
• The process plans generated by the user and stored in the User
folder.

Drivers Drivers are programs which, together with the handshake process
plans, contain the process tasks of a device. Drivers thus form the
interface between the production control system and a device. In behalf
of the production control system, a driver start the process task of a
device. Once this process task has been completed, the driver is
supplied with the process result and relays this to the production
control system.
A driver is allocated to each device. Drivers are suppliers by the device

manufacturers.

A list of connected devices is also displayed as additional information in

the Project window.

Libraries Libraries are projects from which project elements can be copied or
linked into the current project.
The following elements are displayed for each library in the Project
window:
• Process plans
• Devices
• Drivers

Processes Processes are not static project elements. They are created in the
Production mode as manifestations of the execution of process plans.
The associated variables are displayed for each process in the Project
window.

Process tasks Process tasks are also not static project elements. They are created
during the operation of the production control system (Production
mode) when individual process tasks are started in devices.
The associated process is displayed for process tasks in the Project

window.

3.5 The models of pre-assembled automation stations are authentic

The pre-assembled representations of real existing iCIM stations.
automation stations
Each station model includes
• a graphical representation of the station and
• the robot and PLC programs for the associated devices.
The robot and PLC programs are called up by the production control
system. The programs cannot be modified.
You can use these automation stations to model production lines with
different functionality.
Automation stations Description
FMF-G 3x1 4P
Transport System 4
Transport system as circulating belt system with 4

stopper positions and 6 pallet carriers. The
stopper positions are located both on the long
sides and ends of the transport system.
FMF-G 4x1 6P
Transport System 6


FMF-G 6x1 6PV1

Transport System 6V1

stopper positions are located on the ends of the
transport system only.
FMF-G 6x1 6PV2

Transport System 6V2

FMF-G 6x1 8P
Transport System 8

Single Stock Station
Single automated warehouse with 5 x 8 storage

locations.

Double Stock Station
Double automated warehouse with 11 x 8 storage

locations. There are 40 storage bins in the front
row of the automated warehouse, and 48 in the
back row.
QH 200
Handling & Quality Station
Handling & quality station for checking of milled

workpieces.
FAC-405
Assembly Station RH-5A55
Robot assembly station with SCARA robot, vision

system and magazines as local storage locations.

FAC-601
Assembly Station RV-1A
Robot assembly station with RV-1A robot, vision

system and chutes.
FAC-602
Assembly Station RV-2A
Robot assembly station with RV-2A robot, vision

system and chutes.

FAC-603
Assembly Station RV-3SB
Robot assembly station with RV-3SB robot, vision

system and magazines which serve as local
storage locations.
FCT 56
Turn Station 55
Robot station RV-1A with EMCO Turn 55 CNC

lathe.

FCT 166
Turn Station 155
Robot station RV-2A with EMCO Turn 155 CNC

lathe.
FCM 56
Mill Station 55
Robot station RV-1A with EMCO Mill 55 CNC

milling machine.

FCM 166
Mill Station 155
Robot station RV-2A with EMCO Mill 155 CNC

milling machine.
FCMT 56
Mill & Turn Station RV-1A
Robot RV-1A station on linear axis with EMCO Mill

55 CNC milling machine and EMCO Turn 55 CNC
lathe.
FCMT 166
Mill & Turn Station RV-2A
Robot RV-2A station on linear axis with EMCO Mill

155 CNC milling machine and EMCO Turn 155 CNC
lathe.

FCMT 176
Mill & Turn Station RV-3SB
Robot station RV-3SB on linear axis with CNC

milling machine EMCO Mill 155 and CNC lathe
EMCO Turn 155.

3.6 With COSIMIR® Factory, you can produce:

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The products • Desk sets in a number of variants

• Intermediate products for desk sets
Example of product
The desk set has three drilled holes:

• One hole is intended for a pen holder
• Two are intended as instrument holders

Base plate
You can produce the desk set in numerous variants. The variants are
created by selecting different component variants.
The details are as follows:
• The aluminium base plate can be produced in 5 variants. These are
of different designs.
• There is a choice of aluminium or brass as the material for the pen
holder.
• 5 variants are possible for the aluminium or brass pen holder. These
are of different design.
• The pen holder can be equipped with a ballpoint pen or left empty.
• Each instrument holder position can be equipped with a
thermometer or hygrometer or left empty.

Base plate variants, untested Description
Base plate type 1, untested
Base plate for desk set, aluminium type 1: Basic

version
The base plate is untested
Part no.: 42 140
Base plate for desk set, aluminium type 2:

with small chamfer
Part no.: 42 141

with large chamfer
Part no.: 42 142

with small rounding
Part no.: 42 143

with large rounding
Part no.: 42 144

Base plate variants, tested Description
Base plate type 1
Base plate for desk set, aluminium type 1: Basic

version
The base plate is tested
Part no.: 46 140
Base plate type 2

with small chamfer
Part no.: 46 141
Base plate type 3

with large chamfer
Part no.: 46 142
Base plate type 4

with small rounding
Part no.: 46 143
Base plate type 5

with large rounding
Part no.: 46 144

Variants of aluminium penholder Description
Penholder type 1
Penholder, aluminium
Type 1, 1 slot
Part no.: 42 100
Penholder type 2
Type 2, 2 slots
Part no.: 42 101
Penholder type 3
Type 3, 3 slots
Part no.: 42 102
Penholder type 4
Type 4, 4 slots
Part no.: 42 103
Penholder type 5
Type 5, 5 slots
Part no.: 42 104

Variants of brass penholder Description
Penholder type 1
Penholder, brass
Type 1, 1 slot
Part no.: 42 120
Penholder type 2
Penholder, brass
Type 2, 2 slots
Part no.: 42 121
Penholder type 3
Penholder, brass
Type 3, 3 slots
Part no.: 42 122
Penholder type 4
Penholder, brass
Type 4, 4 slots
Part no.: 42 123
Penholder type 5
Penholder, brass
Type 5, 5 slots
Part no.: 42 124

Components for fitting Description
Thermometer
Thermometer
Part no.: 30 000
Hygrometer
Hygrometer
Part no.: 30 001
Ballpoint pen
Ballpoint pen
Part no.: 30 100

Blanks Description
Aluminium blank
Blank for penholder, aluminium

Diameter: 30 mm
Length: 58 mm
Part no.: 42 000
Blank Brass
Blank for penholder, brass

Diameter: 30 mm
Length: 58 mm
Part no.: 42 001
Baseplate blank
Blank for baseplate, aluminium

Part no.: 42 010

3.7 The production database manages all the data associated with a
The production database computer-integrated production process. During the production
process, this data is available to all the machines and personnel
involved in the process.
The data is structured and compiled into tables. The totality of all the
tables form the production database.
Workpieces Production process Customer ...

table table table table
Part no. Part no. Customer no. ...
Designation Machine Address ...
Type Machine program Order no. ...

number
Design Type of production ... ...

process
... ... ... ...
Production database
The production database contains data on:

• Stock management
• Products, intermediate products and blanks
• Production process resources, including, for example, transport
devices and machine tools
• The quality of the produced workpieces
• Customers and their orders

As delivered, the COSIMIR® Factory production database contains data

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on a number of workpieces.
These are:
• Blanks
• Intermediate products
• End products
You can use these blanks and intermediate products to define new end
products and store their data on the database.
There are various database masks to allow you to input data.
A workpiece on the production database, for example, is characterised

by the following data:
• Part no.
• Product designation
• Workpiece type: Produced in-house or outsourced
• Geometrical structure of workpiece
• Pallet
• Costs
• Sales price
A definition of the production process used for the workpiece needs the
following data:
• The machine used to produce the workpiece
• The processing task which the machine needs to carry out
• The program used for this
• An indication as to whether the workpiece is processed or
assembled from several parts
• An indication as to whether test data is to be generated for the
produced workpiece
• The action to be taken with “bad” workpieces

Customer data such as the following:

• Address
• Customer number
• Order number
is also managed on the production database.
You need to define the stock level at the start of production. This level
will then be automatically updated and adapted during the production
process.

4.
The most important operator functions of COSIMIR® Factory T
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This chapter describes the most important operator functions of

COSIMIR® Factory. Microsoft Windows programs offer various facilities
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for activating commands. In this description, commands are triggered

by entries in the menu line. You can of course also use the symbol bar,
appropriate key combinations or the context-sensitive menu available
via the right-hand mouse button.
Detailed information on the use of all the facilities offered by COSIMIR®T

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Factory can be found in the on-line help within this software package.
Note The library which contains automation stations for models and
production lines is expanded at regular intervals, making it possible for
you to create a wide variety of different production lines. For example,
the new software version now includes a double stock station in
addition to the single stock station. As a result of library expansion, the
screenshots used in the handbook might not always correspond to the
current software revision level.
4.1 You can create production lines in the Factory Simulation program
Modelling a new section.
production line
Models for the creation of a production line are available in a library.
The models can be positioned and aligned to form a production line very
easily using predefined coupling points on the models. In this process,
the station models are aligned to the model of the transport system and
connected to this. The connection or coupling points correspond to the
stopper positions of the transport system.
Use only the New production line command in the File menu in order to
create a new production line. A system editor is linked to this command
which provides you with extensive assistance in modelling the
production line. For example, the objects you’ll use to set up the
production line have preset sizes and views. The newly created
production line is saved as a production cell in factory simulation.

4. The most important operator functions of COSIMIR® Factory
Note New production lines cannot be created with the New button in the
toolbar.
The modelling of a production line will be explained by means of an

example. This example of a production line is to consist of a transport
system, a stores, an assembly station and a CNC milling station.
Modelling a production line in Factory Simulation
1. Start Factory Simulation. To do this, execute the COSIMIR® Factory

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Simulation link in the COSIMIR® Factory program group in the

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Microsoft Windows start menu.

2. In the File menu, activate the command New production line.
The window Create new production line will open.
3. Choose, for example, the Projects directory as the storage location
for the new production line. Projects is created as standard by
COSIMIR® Factory Control as a sub-directory.
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You can, however, also choose any other sub-directory as the

storage location for your production line.
Enter a file name. Select COSIMIR® workcells (*.mod) as the file
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type. Finally, click on the Save button.

4. A model of an empty production line will open. When a new

production line is created, a number of settings are made
automatically:
– The program switches to the Edit mode
– Top view is selected as the view
– The Model libraries window is opened.
5. If the model library Festo FMS is not open, click on the + symbol of
Festo FMS.
Information on the models, such as functional descriptions, is
available via the on-line help system in the chapter COSIMIR®T
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Factory. A short description of the model will be displayed if you

click on the More button in the Model libraries window.

6. First add the Transport System 6 model. To do this, click on the

entry Transport System 6. The model will be displayed in a preview.
Now click on the Add button.
Alternatively, add a model by clicking on the appropriate model
entry.
The production line now contains only the Transport System 6
model. The transport system is displayed in green as it is still
highlighted.

7. Add the Stock Station model in the same way. The term Single
Stock Station is included in newer libraries instead of Stock Station.
If this is the case, select Single Stock Station.
8. The two models are now next to each other but are not as yet
connected. To ensure that working and transition points match up
during production line operation, the models must be aligned and
connected up in an appropriate way.

9. Now align the Stock Station model to the Transport System 6

model.
To do this, click on the red coupling point of the Stock Station. Hold
down the left-hand mouse button and drag the coupling point to the
upper left-hand coupling point of the Transport System 6 model.
The Stock Station is now connected to the Transport System 6. The
position and orientation of the Stock Station model have been
changed automatically.

10. Now add the Assembly Station RV-1A model.

11. Connect the Assembly Station RV-1A model to the lower left-hand
coupling point of the Transport System 6 model.
To do this, click on the red coupling point of the Assembly Station
RV-1A. Hold down the left-hand mouse button and drag the coupling
point to the upper left-hand coupling point of the Transport System
6 model.
As soon as you click on a point outside the station, the highlighting
of the station will disappear.

12. Finally, add the Mill 55 Station. Connect the Mill 55 Station to the
lower right-hand coupling point of the Transport System 6 model.
As soon as your production line has been created, exit from the Edit
mode. Change to the View mode in order to obtain a realistic 3D view of
the productionline.

Changing to the view mode
1. Deactivate the command Edit mode in the menu Execute. To do this,

click on the command Edit mode. The tick next to the entry Edit
mode will then disappear.
2. You will obtain a 3D view of your production line. The display will
also included a top view.

3. In order to obtain a perspective view of the 3D model, select, for

example, the command Standard/Default Settings in the View
menu. With the commands under View, you can move, rotate and
zoom the appropriate view of your production line.
Before you create a project for a production line control system and
simulate production, you must save the new production line.

Saving a production line
1. Activate the command Create Plant in the menu Execute.

This command causes the model of the production line to be saved
as a *.MOD file. These files are also referred to as production cells.
At the same time, a data interchange file is created with data on the
production line. This data interchange file requires the Factory
Control program section in order to be able to generate a project for
the production control system automatically.
2. The window Save plant file will now open.
Switch to the directory in which the production line model is to be
saved. The sub-directory Projects of COSIMIR® Factory/ Control is
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provided for this purpose and set as the default.

You can, however, also select any other sub-directory. Please note
that the MOD file and the associated XML file should be saved in the
same sub-directory.
Accept the file name which is offered and click on the Save button.
Note If you wish to save the production line model only as an MOD file,
without simultaneously generating a data interchange file *.XML,
activate the Save command in the File menu.

4.2 You can modify a production line model, for example by adding further
Modifying an existing stations.
production line
Modifying a previously-created production line
1. Start Factory Simulation. To dot his, execute the link COSIMIR®

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Factory Simulation in the program group COSIMIR® Factory in the

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Start menu of Microsoft Windows.

2. Load the desired production line by activating the Open command in
the File menu.
3. The Open file window will open. Switch to the directory in which the
production line model has been saved. The standard choice is the
Projects sub-directory of COSIMIR® Factory\Control.
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Select the desired file and click on the Open button.
4. The standard setting is the View mode. In order to modify the

production line, switch to the Edit mode by activating the Edit mode
command in the Execute menu.

5. If you want to see a display of data on the individual production line

stations, highlight the station concerned by clicking on it with your
mouse.

6. Open the context-sensitive menu with the right-hand mouse button.

Activate the Properties command.
The Properties for work station window will open. You can see from
the station name that the highlighted station is of the type Assembly
RV1A.
Once you have obtained the information you require, close the
window.
7. If you wish to add a further station to the production line, change

the view to a top view and activate the Standard/top view command
in the View menu.

8. Select an appropriate view of the production line by zooming,

moving or rotating the production line.
Note
The editing mode is exited when commands are executed from the
view menu. Make sure that the editing mode is restarted before
adding new models.
9. Now open the model library and activate the Model libraries
command in the Execute menu.

10. Make the desired modifications to the production line, for example
by adding a CNC lathe. Double-click in the library on the entry Turn
55 Station.
The desired station will now be added.
11. Close the model library in order to view the complete production
line.

12. Connect the new Turn 55 Station model to the right-hand coupling
point of the
Transport System 6 model.
To do this, click on the red coupling point of the Turn 55 Station
which you have added. Hold down the right-hand mouse button and
drag the coupling point to the right-hand coupling point of the
Transport System 6.
13. If you wish to delete one of the production line stations, highlight
the station concerned. Open the context-sensitive menu with the
right-hand mouse button. Activate the Delete command. The
highlighted station will be deleted.

14. When you have completed your modifications to the production line,
exit from the Edit mode. Switch to the View mode and deactivate the
Edit mode in the Execute menu.
15. The production line will be displayed as a 3D view. Select an
appropriate view of the production line.
16. Save the modified version of the production line.

Click Save in the File menu to this end, if you want to retain the
existing filename. If you want to save the system using a new
filename, click Save as.
17. In order to prepare the project for Factory Control, activate the
Create plant command in the Execute menu. An XML-formatted data
interchange file will be generated.

Note When you make modifications to the modelling of a production line, the
functionality of the production line will also change in most cases. If this
is the case, you must adapt the production control system
appropriately. If you are working with an automatically generated
production control system, you must generate the entire project for the
production control system again in Factory Control.
4.3 The operation of the production line is started and controlled by Factory
Simulating a production Control. Only here are operator functions available in a visualisation
line window. The buttons and switches on the control panels for the
individual stations within the production line are disabled during
system simulation. The task of Factory Simulation is to display the
behaviour of the production line during simulated operation.
A simulation of production line operation can be started in Factory

Simulation independently of Factory Control. The station robot and PLC
programs will then be executed to the maximum degree possible
without the presence of workpieces.
Switching the simulation function of Factory Simulation on and off
1. Activate the Restart command in the Execute menu. Simulation will

now be active. You can see that the simulation mode is operative by
the entry Running in the status line.
Alternatively, you can activate simulation by the entry Start, Start
Cycle in the status line or via the Stopped button.
2. You can stop the simulation by clicking on the entry Stop in the
Execute menu.
Alternatively, you can click on the entry Running in the status line.

4.4 Within Factory Simulation, you have a free choice of perspective view of
Modifying the view of a the production line. Using just a few central commands, you can move,
production line rotate or zoom the production line display.
The perspective view is defined by the coordinates of the viewer (=

standpoint) and a reference point on the production line (= mid-point).
Reference point
Turn Angle
Z
Defining the perspective view

Moving the production line

1. Activate the Move command in the View menu.
The mouse cursor will change into a small coordinates system. This
indicates the direction in which the standpoint and reference point
can be moved. A dotted arrow indicates that moving in the direction
concerned is not possible.
2. Hold the left-hand mouse button down.
3. Move the mouse cursor in the Z or X direction.
4. Release the mouse button again.
The view will then change as desired.
You can also activate the Move command by holding down the Shift key
and then pressing the left-hand mouse button.
Rotating the production line

1. Activate the Rotate command in the View menu.
The mouse cursor will change into a small coordinates system. This
indicates the direction in which the standpoint and reference point
can be rotated. A dotted arrow indicates that rotating in the
direction concerned is not possible.
2. Hold the left-hand mouse button down.
3. Move the mouse cursor in the Z or X direction.
4. Release the mouse button again.
The view will then change as desired.
You can also activate the Rotate command by holding down the Control
key and then pressing the left-hand mouse button.

Zooming the view in and out

1. Activate the Zoom command in the View menu.
The mouse cursor will change into two rectangles..
2. If you wish to make the view larger, hold down the left-hand mouse
button and move the mouse cursor in the direction of the arrow.
3. If you wish to make the view smaller, hold down the left-hand mouse
button and move the mouse cursor in the opposite direction to the
arrow.
You can also activate the Zoom command by holding down the Shift and
Control keys and then pressing the left-hand mouse button.
Zooming a certain selection

1. Position the mouse cursor on a corner of the selection.
2. Hold down the Shift + Control keys.
3. Press the right-hand mouse button and move the mouse. A frame
will appear.
4. Move the mouse to position the frame around the selection which
you wish to enlarge.
5. Release the right-hand mouse button. The selection will then be
enlarged.
Enlarging the view

Activate the Zoom-In command in the View menu. The view will enlarge
to 125%.
Reducing the size of the view

Activate the Zoom-Out command in the View menu. The view will
reduce to 80%.

4.5 You have created a project in Factory Control for a production control
Automatic generation of a system for a production line. The production line has been modelled
production control system with the Plant Editor of Factory Simulation.
for a production line
The project which forms the framework for the production control
system also requires and manages data for the creation and assembly
of the production line. Factory Control receives the necessary data from
Factory Simulation via an XML-format interchange file.
As soon as data is available on the production line devices, a production

control system program for a simple production line operating sequence
can be generated automatically.
In order to make working with Factory Control as simple as possible,

work within a predefined project with the name Proj.

Creating a project for the production control system of a production

line
1. Start Factory Control in the ProjectStudio mode. To do this, execute
the COSIMIR® Factory Control ProjectStudio link in the COSIMIR®
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Factory program group in the Microsoft Windows start menu.

2. You will see an empty project for a production control system with
the name Proj.lpj.
The predefined project is stored as standard in the Projects\Default
sub-directory of COSIMIR® Factory\Control.
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If you click on the individual elements in the Project window, you

will see that as yet no devices have been entered for the production
line.

3. Activate the command Import COSIMIR® project in the

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Extras/ProjectStudio menu in order to read in data for the assembly

of the previously created production line.
4. In the Open window you can select the XML file previously
generated by Factory Simulation. This XML file contains the data
required for the assembly of the production line. The XML-format
interchange file and the model file with the file extension mod are
stored in the same sub-directory.

5. After the COSIMIR® Factory project has been opened, a 2D view of

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the production line will be displayed. If you click on an object in the

2D display, information will appear on the object in question under
the Properties tab in the ProjectStudio window.
The Elements navigation tree in the Project window includes the
stations and the production line devices within these.

Note After you have executed the command Import COSIMIR® project, you
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must not execute the Save command. Otherwise the empty predefined
production control project with the name Proj.lpj would be overwritten.
This would means that the project Proj.lpj would no longer be empty but
would contain the plant configuration which had just been generated.
Save the production control system project only after you have
automatically generated the production control system program.
The production control system project at present includes only the

devices for the production line. There are as yet no programs for the
production control system. You can see this by the navigation tree for
the Project in the Project window. For example, the Process plans
folder is still empty.
In order to simulate production line operation, a program must be

available for the production control system. Factory Control offers you
comprehensive support for this, allowing you to automatically generate
a program for a simple production line sequence. You can, however,
also program parts of the production control system yourself using
process plan.
Note: Always use the Setup mode to make changes to the production
control system project.
Generating a production control system program for the production

line automatically
1. Ensure that COSIMIR® Factory ProjectStudio is open with the
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necessary production line data.

2. Activate the Setup mode. To do this, select the Setup command in
the Project menu.
You can generate and modify project elements only when the Setup
mode is active. This also applies to the generation of program for
the production control system.
3. In order to generate the production control system automatically,
active the Generate project in the Extras/ProjectStudio menu.

4. The production control system for the production line has now been
generated. You can see this by the new entries in the project tree in
the Project window. You can ignore the message “Control elements
are not yet defined” in the Messages window. It has no meaning in
this context.
5. The individual project elements in the Project window are also

identified by a symbol.

Symbol Meaning
Process plan
Component
Driver
Library
Process
Process task
The folders for Processes and Process tasks are still empty, since these
Note
project elements are not the static type. They originate in the
Production mode as manifestations of the execution of process plans or
when a process tasks is started on a component.
Storage location for the The project with production control is saved to the default directory,
project with production namely My files.
control Make sure that the production control project (*.lpj) and the production
line (*.mod) are saved to different directories.

4.6 As soon as a production control system has been generated for a

Simulating operation on a production line, you can simulate production line operation.
production line Start production line operation and control it from Factory Control. Only
here are operator functions for the process available in a visualisation
window. The buttons and switches on the control panels for the
individual stations are disabled during factory simulation.
The prerequisites for production simulation are that Factory Simulation

must have been started and the relevant production line must have
been loaded. Factory Simulation works with a virtual production line.
This virtual production line executes the control commands of the
production control system and supplies appropriate feedback signals to
the production control system.
Predefined production orders are available for use in production

simulation. You can also generate and execute your own production
orders.
You can also execute the production of a product using a sequence
which you have defined yourself.

Predefined production orders are available for the following:

• A penholder (Penholder button)
• A baseplate (Baseplate button)
• A complete deskset (Deskset button)
To initiate a production order, simply click on the appropriate button.
If you are producing a deskset, the production control system takes into
account whether your system includes a handling & quality station or
not. If this station is present, it will be used to test the baseplate. If no
station is present, the testing will be omitted.
The buttons Listed Orders and Timed Orders can be used to initiate
production orders which you have previously generated yourself.

The orders in Listed Orders will be executed in succession, one after the
other, provided that the necessary machines are available.
The Timed Orders list comprises orders which must be carried out at a
certain time.
You can generate these lists with the production database manager
function. You can activate this function by clicking on the Database
button.
Once you have programmed the production line sequence in a separate

process plan and saved this under one of the default names
Prod_User1, Prod_User2 or Prod_User3, you can execute this sequence
here by clicking on the appropriate button User 1, User 2 or User 3.
After you have activated an order by clicking on the appropriate button,

the button will be surrounded by a blue frame for the period in which
the order is being executed.
We are currently working on a facility to link COSIMIR® Factory to an

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external production planning system. The MRP (Material Resource

Planning) button has been provided for this purpose.

Simulating production with predefined production orders

1. Ensure that Factory Simulation has been started and the desired
production line has been loaded in Factory Simulation. The
production line must be in its initial position. You can achieve this by
executing the command Workcell initial position in the Processing
menu.
2. Start Factory Control ProjectStudio and load the project for the
production control system of the desired production line.
To load the project, click on the Open command in the File menu.
COSIMIR® Control Project (*.lpj) must be set as the file type. Select
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the desired file. Then click on the Open button.

3. The desired project is loaded.
4. Start the Production mode by selecting the Production command in

the Project menu.
When the production mode is activated, the production control
project is tested, and the necessary drivers and components are
installed.
Initialisation may take a while. The Start production window is open
during initialisation, and displays the statuses of the components
and drivers.

5. After the Production mode has been initialised, the visualisation

window for operator control and display of the process will
automatically open.

6. As soon as you click on the Deskset button, the production of a

deskset will be initiated.
The Deskset button will be highlighted in blue for the period in
which the order is being executed.
You can track the production operation in the visualisation window.
A display will provide you with information such as the process
tasks currently being carried out or the positions of the individual
pallet carrier.
Since the current plant configuration does not include the handling
& quality station, a deskset will be produced with an untested
baseplate.

7. In the program section Factory Simulation, you can observe a

realistic representation of the production of the current order – in
this case the production of a deskset – and evaluate this.
Note
The buttons and switches on the control panels are disabled during
production. Intervention in the process is only possible via the
visualisation window.
8. Once the deskset production order is completed, you can initiate the
production of a further deskset. In addition to the production order
for a deskset, other predefined production orders are available.
These are an order for the production of a penholder and an order
for the production of a baseplate. To access these, just click on the
appropriate button.
9. If you wish to cease production operation, deactivate the Production
mode. To do this, click on the Production entry in the Project menu.
The tick next to the Production entry will then disappear.

Simulating production with newly-generated production orders
production line must be in its intial position. You can achieve this by
menu.
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3. The desired project will be loaded.

4. Start the Production mode. To do this, select the Production

command in the Project menu.
5. After you have initialised the Production mode, the visualisation
window will open for operator control and display of the process.

6. As soon as you click on the Orders Listed or Orders Timed buttons,

the associated production list will be activated. The button will be
highlighted in blue for as long as the order is being executed.
Ensure that adequate stocks of workpieces are present. You can
manage the current stock level on the production database with the
aid of the Stock Contents mask.
You can track production operation in the visualisation window. This
displays information such as the process tasks currently being
executed or the positions of individual pallet carriers.

7. In the program section Factory Simulation, you can observe and

assess a highly realistic representation of the production of the
current order
Note
8. If you wish to terminate production once the order table has been
processed, deactivate the Production mode. To do this, click on the
Production entry in the Project menu. The tick next to the entry
Production will disappear.

Starting production with a process plan you have generated yourself
production line must be in its initial position. To achieve this,
execute the command Workcell Initial Position in the Edit menu.
2. Start Factory Control ProjectStudio and load the projectwith the
production control system for the desired production line.
To load the project, click on the Open menu in the File menu.
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window will open for operator control and display of the process.

6. As soon as you click on one of the buttons User 1, User 2 or User 3,

the associated process plan will be activated. The associated button
will be highlighted in blue for as long as the order is being executed.

7. In the program section Factory Simulation, you can observe and

assess a highly realistic representation of the production of the
current order.
Note
8. If you wish to terminate production once the order has been


Notes regarding the The production mode must be activated if you want to simulate
production and setup production at a given production line.
modes
The setup mode can be activated at the same time. This provides you
with the opportunity of executing certain setup tasks within the
production line. These include, for example, manual initialisation and
disabling of components and drivers. This makes it possible for you to
remove defective (real) components from the production process during
operation, correct the defects, and reintegrate the components into the
production process. The scope of possible setup tasks depends upon
the status of the affected part of the project. Manual setup tasks should
only be executed by experienced users during production.

4.7 You have modified the model of production line, for example by adding
Generating a production a further automation station. To allow you to simulate the production
control system for a operation of the modified production line, you must adapt the
modified production line associated project with the production control system in COSIMIR® T
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Factory.
The way in which you will need to adapt the project will depend on the
parameters of the production control system. The decisive factor is that
you can import data on a production line to Factory Control and
generate a production control system only if no project with the same
name has already been created in Factory Control.
Case 1 You are working in COSIMIR® Factory with an automatically generated

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production control system. You have made no changes to the

production control system, for example by adding your own process
plans or by expanding the production database.
In this case, delete the previous project with the production control
system. You will find this project as standard in the directory COSIMIR® T
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Factory\Control\Projects as a separate subdirectory. Next, import the

modified system configuration into Factory Control and generate the
standard production control system provided. By using this procedure,
you can retain the existing project name.
If you save the modified production line in Factory Simulation under a
new name and also generate the associated interchange file under this
name, you can import the modified system configuration into Factory
Control under this name. Next, generate the standard production
control system provided. As soon as the production control system is
ready, you can simulate theoperation of the production line.

Case 2 You are working in COSIMIR® Factory with an automatically generated

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production control system. You have, for example, made modifications

to the process plans or the production database.
In this case, save the modified production line in Factory Simulation
under a new name. Then import the modified system configuration and
generate the standard production control system provided. Now copy
the program parts of the automatically generated production control
system which you are taking over from the previous project and wish to
use. User-defined process plans can, for example, be copied with the
aid of the library function of Factory Control.
This procedure ensures that an existing production control system

cannot be overwritten at the press of a button and that user-defined
program parts cannot be deleted.
A project for a production control system can therefore be generated
automatically only if no project with this name already existing.

Generating a new project for the production control system using

existing process plans

the link COSIMIR® Factory Control ProjectStudio in the program
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group COSIMIR® Factory in the Start menu of Microsoft Windows.

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2. You will see an empty project with the name Proj.lpj.
3. Ensure that the data on the modified configuration of the production

line is available in the associated XML-format interchange file. You
can generate this file by activating the command Create plant in
Factory Simulation in the menu Execute.Note: The modified file
should have a different name.

4. Activate the command Import COSIMIR® project in the menu

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Extras/ProjectStudio in order to read in the data on the

configuration of the modified production line.
5. In the Open window, select the XML interchange file previously
generated by Factory Simulation. The XML file interchange file and
the model file with the file extension mod are stored in the same
sub-directory.

6. After you have opened the COSIMIR® Factory project, a 2D view of

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the modified production line will be displayed.
7. Now activate the Setup mode. To do this, select the command Setup
in the Project menu.
You can generate a production control system for the production
line automatically only when the Setup mode is active.
8. In order to generate a project with a production control system
automatically, activate the command Generate project in the menu
Extras/ProjectStudio.

9. The project with a production control system for the production line
has now been generated. You can recognise this by the new entries
in the project tree in the Project window.

10. Copy the user-generated process plan from your earlier project into
the new project with the aid of the library functions. To do this, open
the Libraries directory in the project tree.
11. Then add the project which contains the user-defined process plan
to the Libraries directory. Select the desired project and click on the
Open button.

12. Project 1 is now present as a library element within the current

project.

13. Select the desired process plan, here Prod_User1, in the sub-
directory Process plans. Activate the context sensitive menu with
the right-hand mouse button. Select the Copy command. The
selected object will be copied onto the clipboard.

14. Now highlight the directory in the project tree into which you wish to
copy the user-defined process plan. This is the sub-directory User in
the directory Local Project\Process plans. Activate the context-
sensitive menu with the right-hand mouse button. Select the
command Paste.

15. The new process plan has now been copied into the sub-directory
User under the name Prod_User11.
16. Now delete the file Prod_User1 in the sub-directory User. To do this,
select the file, activate the context-sensitive menu using the right-
hand mouse button and activate the Delete command.

17. You must now rename the file Prod_User11 as Prod_User1. Only
user- defined process plans with the names Prod_User1,
Prod_User2 or Prod_User3 can be started automatically via the
18. If you wish to simulate the production operation of the modified

production line, ensure that Factory Simulation has been started
and that the modified production line has been loaded within this.

20. After the initialisation of the Production mode, the visualisation

window with operator functions and a display of the process will
open automatically.

4.8 In the program section Factory Control ProjectStudio, you can program
Programming a parts of the production control system yourself. These include a
production control system production line sequence. This sequence describes the order in which
for a production line using the individual production steps are to be executed.
a process plan
You can generate the sequence in a separate process plan by using pre-
defined macro process tasks. You will be offered macro process tasks
for every station.
Programming is carried out on the basis of the 2D display of the

production line. You are able to select an appropriate process task, and
Factory Control will enter this automatically into the table for the
process plan.
Detailed descriptions of the process tasks and their parameters can be

obtained from the COSIMIR® Factory Online Assistant.
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Prerequisite for the generation of users’ own process plans:

The automatically-generated program for the production control system
must be available. This program also forms the framework for the
execution of user- defined process plans. This framework provides, for
example, drivers, handshake process plans and process plans for error
handling.
The generation of a process plan will be explained by means of a simple

example:
Let us assume that we wish to generate a process plan which will

transport the blank for a baseplate from the automated warehouse to
the CNC milling machine and transfer it to this machine. The blank has
the part number 42010.
As soon as the process plan is ready, you can initiate and track its
execution in the Production mode.

Generating a process plan with macro process tasks
1. Ensure that Factory Control ProjectStudio has been started.

2. Load the desired project. To do this, activate the Open command in
the File menu. Enter the project name.

3. Check that the production line includes a CNC milling machine.

The data on the stations and devices in the 2D layout show that a
Mill55 stations is included in the production as a milling station.

4. Ensure that the automatically-generated program for the production

control system is present. To do this, activate the Project index entry
in the Project window. You will see that the project tree is filled with
process plans, devices, drivers, etc. The production control system
for the production line is therefore present.

5. Open the sub-directory User in the directory Process plans. This

contains three process plans ready-prepared for the user,
Prod_User1 to Prod_User3. If you generate process plans yourself,
you should save these under one of the names Prod_User1 to
Prod_User3.

6. In order to generate a process plan simply and with comprehensive

support from Factory Control ProjectStudio, activate the tab section
Process plan in the window ProjectStudio. A window will open with
an empty process plan.

7. Highlight the Stock station. Activate the context-sensitive menu with

the right-hand mouse button. Under the entry Process task a list will
be displayed of the macro process tasks of the Stock station.
8. You have access at this point via the Help command to Online
Assistant. This contains detailed descriptions and examples of the
use of macro process tasks.

9. Select the entry REQUIRE from the macro process tasks. The effect
of theprocess task REQUIRE is to request an empty pallet carrier.
The dialog Process Task Parameters will then open to allow entry of
the necessary parameters. The only parameter necessary is
Parameter 2: CarrierID, where the number of the pallet carrier
should be entered (1). Make this entry by clicking on the Ok button.

10. When you close the dialogue window Process Tasks Parameters by
pressing Ok, the selected process tasks will be transferred into the
empty process plan.The process plan now contains a command line.

11. Activate the context-sensitive menu using the right-hand mouse

button and select the macro process task MovToTrans. The effect of
this process task is to transfer a workpiece from the stores to a
transport system pallet carrier.
Enter the number of the part under Parameter 1: PartNumber which
is to be set down on the pallet carrier. In our case, this is part
number 42010. Close the window by clicking on Ok.

12. When you close the dialogue window Process Task Parameters with
Ok, the selected process task will be transferred to the process plan.

13. Now highlight the station Mill55. Activate the context-sensitive

menu using the right-hand mouse button and select the entry
Process Task. A display will appear of the macro process tasks for
the station Mill55.

14. Select the macro process task to_Mill55 for the station Mill55. The
effect of this process task is that the pallet carrier with the specified
number is moved to the station Mill55.
Enter the number of the pallet carrier under Parameter 1: CarrierID.
In this case, you can accept the preset value 1. Close the dialogue
window with Ok.


16. Activate the context-sensitive menu again using the right-hand

mouse button and select the macro process task MovFromTrans.
The effect of this process is to transfer the workpiece from the pallet
carrier to the milling station.
Enter the part number of the workpiece under Parameter 1:
PartNumber which is to be set down on the pallet carrier. In this
example, this is the part number 42010. Close the window with Ok.

18. Ensure that the Setup mode is active. To do this, activate the Setup
command in the Project menu. You can save the process plan only if
this mode is active.
In order to save the process plan, activate the command Process
plan in the Extras menu under the entry ProjectStudio.

19. The window Generate process plan will open. Accept the preset file
name Prod_User1 and confirm with Ok.
20. The macro process plan generated by you is now saved under the
name Prod_User1 in the directory Process plans\User. Double-click
on Prod_User1 to display the process plan.

21. In order to execute the process plan Prod_User1, activate the

Production mode. To do this, click on the Production command in
the Project menu.
window will automatically appear with process operator functions
and a display.

23. As soon as you click on the button User 1, the process plan
Prod_User1 will be executed. You can track production operation in
the visualisation window. This displays data such as the process
tasks currently being executed or the positions of the individual
pallet carriers.

24. In the program section Factory Simulation,you can observe and

assessa highly realistic representation of the production of the
current order.
25. If you wish to terminate production once the order table has been

4.9 The production database is used to store all the data required for
Viewing and managing automated computer-aided production. The production database is
the production database project-specific.
The data is stored in various tables.
Access to the production database is available from the program section

Factory Control. The prerequisites are:
• The Production mode is active for the selected production control
system for a production line,
• The visualisation window for the production line is open.

As soon as you have activated the production database, the first screen
iCIM Production Manager – Main Menu will appear.
This includes buttons to call up the individual database masks.
You can use these masks to modify or delete individual data records.
You can also generate new data records.

The following central functions are available:

– Orders Listed List of production orders
– Orders Timed List of production orders with a defined start
point
– Resources List of machines
– Production Data List of data for production process
– Products List of products/workpieces
– Pallets List of pallets
– Stock Contents Current stock levels
– Stock Init Standard preset for stock levels
– User Stock User-defined preset for stock levels
– Customers List of customers
Access authorisation There are various levels of access authorisation for the production
database.
Every user has read authorisation, while write authorisation is reserved
for a defined list of persons. Only these persons are allowed to modify
the production database.
Authorisation is obtained by logging-in on the production database,

using the Login button.
Provision is made for two groups:
• User group, with the password Festo
• Instructor group, with the password didactic

The passwords of the User and Instructor groups can be changed as

desired. Both passwords are managed by the Instructor.
As soon as you have completed any desired modifications to the

production database, log out again. To do this, click on the Logout
button.
Please note: It is not necessary to log in to obtain read authorisation.
Note The production database and the associated database masks are
displayed in English only.

Accessing the production database during production operation
1. Ensure that the project with the production control system for the
desired production line has been loaded in Factory Control and that
the Production mode has been activated.
2. Click on the Database button in the production visualisation
window..

3. The initial screen of the production database iCIM Production

Manager – Main Menu will open.
From this window, you can access all central database masks to
display and enter the desired data.
4. In order to close the production database, click on the Quit button.

You will then be returned to the Factory Control visualisation
window.

Obtaining write authorisation in order to make modifications to the

production database
1. Ensure that the initial screen of the production database iCIM

Production Manager – Main Menu is open.
2. Click on the Login button.

3. A login dialogue will appear.

Select the Usertype entry.
Then enter the password in the appropriate field. If you have not
changed the password since you installed COSIMIR® Factory, the
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default password will still be valid.

Enter under Password: Festo
Please note the use of a capital and lower case letters.
Confirm your entry with Login.

4. Your login will be processed. You can recognise this by the fact that
a Logout button is now visible in iCIM Production Manager.
5. Carry out the desired modifications to the production database.

As a User, you can as standard make modifications to the following
lists: Listed Orders, Timed Orders, Stock Contents, User Stock and
Customers.
As soon as you have completed your modifications, logout from the
production database again by clicking on the Logout button.

Changing your password as an Instructor
1. Ensure that the intial screen iCIM Production Manager – Main Menu
of the production database is open.
2. Click on the Login button.
3. Log in as an Instructor.
To do this, select the entry Instructor under Usertype.
Then enter the password in the appropriate field. If you have not
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Enter under Password: didactic
Please note the use of lower case letters only.
4. Your login will be processed. You can recognise this by the Logout
and Settings buttons.

5. If you wish to change the password of a group, click on the Settings

button. A dialog will open to change the password and assign the
authorisation rights associated with this password.
Select under Current User the group whose password and
authorisation you wish to modify.
In the tab section Password, enter the old and new passwords. The
tab section Options allows you to define which database sections
can be modified by the user group in question.
Confirm the changes you have made by clicking on the Modify
button.

6. The User group normally has restricted write authorisation. The

dialogue shown below shows the standard settings. As an Instructor
you can change these settings at any time.
7. The Instructor has write authorisation for all database contents.

Managing the list of production orders
1. Ensure that the initial screen iCIM Production Manager – Main

Menu of the production database is open.
2. Click on the Orders listed button.
3. The database mask iCIM Production Manager - Orders listed will
open.
You will see a list of production orders. If the execution of the list is
started from the production visualisation window, the orders will be
executed in the sequence in which they appear in the list. Orders
can also be executed in parallel if machines are available. You can
view, expand or delete the list of production orders by using the
following buttons:
Add Adds a new order
Clear Clears the data of the order currently being edited
Modify Saves the changes made to the currently selected
order
Delete current Deletes the currently selected order
Clean up Deletes all completed orders
Report Prints out the desired orders
Home Returns to the initial screen of the production
database.


Managing the list of timed production orders

2. Click on the Orders timed button.
3. The database mask iCIM Production Manager - Orders listed will
open.
You will see a list of production orders. If the execution of the list is
started from the production visualisation window, the orders will be
executed at the time defined in the production order in the columns
Start Date and Start Time, provided that machines are available.
You can view, expand or delete the list of production orders by using
the following buttons:
Add Adds a new order
Clear Clears the data of the order currently being
edited
Modify Saves the changes made to the currently selected
order
Delete current Deletes the currently selected order
Clean up Deletes all completed orders
Fullscreen View Displays the list of orders as a full screen
Report Prints out the desired orders
database.


Managing the list of workpieces

2. Click on the Products button.
3. The database mask iCIM Production Manager - Products will open.
You can view, expand or reduce the list of workpieces which are
managed on the production database and modify data for the
individual workpieces by using the following buttons:
Create New Adds a new workpiece
Delete Deletes the selected workpiece
Clear Deletes the data for the selected
workpiece
Save Saves the modifications made to the
selected workpiece
Cursor forward Displays the next or previous
Cursor back workpiece from the list
COSIMIR® Construction
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Defines the design data for a new

workpiece
Quality Data Settings Enters the setpoints for quality checks
View Quality Data Displays the quality data which has
been obtained
Report Prints out the list of workpieces
Home Returns to the initial screen of the
production database.


Managing the list of workpiece production processes

2. Click on the Products button.
3. The database mask iCIM Production Manager – Production Data
will open.
You will see a list of production processes. A production process
describes how a workpiece is produced.
You can view, expand or reduce the list of workpiece
production processes which are managed on the production
database and modify data for the individual production processes
by using the following buttons:
Add Adds a new production process
Delete Deletes the selected production process
Modify Saves changes which have been made to the
production process
Clear Deletes the data for the production process
currently being edited
Cursor forward Displays the next or previous
Cursor back workpiece production process from the list of
possible production processes for the workpiece
in question
Report Prints out the data for the selected production
process
database.

We recommend that you do not modify the production processes

entered for the workpieces as standard on the production database.

Managing the list of machines (resources)

2. Click on the Resources button.
3. The database mask iCIM Production Manager - Resources will
open.
You can view, expand or reduce the list of machines managed on the
production line and modify data for the individual machines by using
Add Adds a new machine
Delete Deletes the selected machine
Modify Saves the modifications made to the selected
machine
Clear Deletes the data for the selected machine
Report Prints out the data for the selected machine
database.


Managing the list of pallets

2. Click on the Pallets button.
3. The database mask iCIM Production Manager - Pallets will open.
For the pallet number you have selected, you can view all the
workpieces which use this pallet by using the following buttons:
Report Prints out the selected list
database.

Managing the current contents of the automated warehouse

2. Click on the Stock Contents button.
3. The database mask iCIM Production Manager - Stock Contents will
open.
This shows the contents of the automated warehouse for the
production line. A double automated warehouse is utilised as a
stock station. This is made apparent by the number of storage bins.
A single stock station has 40 storage bins, and a double stock
station has 88 storage bins. The storage bins are arranged in rows of
eight each. 40 storage bins are displayed simultaneously.
These stock contents will be used for the production of a product.
Each warehouse location is characterised by a location number, a
part number, a colour code and an order number.
You can monitor the current stock contents, modify individual
storage locations directly or completely overwrite the stock contents
with one of two presets.
This is achieved by using the following buttons:
Modify Saves the modifications made to a selected
storage location
Reset Deletes the data for the selected storage
location and fills the location with a
standard preset
Scroll forward and back Displays the next, or the previous
40 storage bins
Copy from Stock User Saves a user-defined preset for the stock
contents
Copy from Stock Init Saves the standard preset for the stock
contents
Report Prints out the current stock contents
Home Returns to the initial screen of the


Managing the standard preset for the automated warehouse

2. Click on the Stock Init button.
3. The database mask iCIM Production Manager – Stock Init will open.
This shows the standard Factory Control preset for the stock
contents. The corresponding preset is displayed depending upon
whether your production line includes a single or a double
automated warehouse. The single automated warehouse has 40
storage bins, and the double automated warehouse has 88. Storage
bins 1 through 48 are at the back of the double automated
warehouse, and storage bins 49 through 88 are at the front. The
stock contents make provision only for production orders with the
order number 0. Once the production of a product is started, this
preset is accepted as the current stock contents. You can monitor
the stock contents and also modify these by using the following
buttons:
Modify Saves the modifications made to a selected storage
location
Reset Deletes the data for the selected storage location and
fills the location with a standard preset
40 storage bins
Report Prints out the current stock contents
database.
We recommend that user-defined modifications should be carried out in

the Stock User mask provided for this purpose.


Managing a used-defined preset for the automated warehouse

2. Click on the Stock User button.
3. The database mask iCIM Production Manager – Stock User will
open.
This shows a user-defined preset for the stock contents. Either the
single or the double automated warehouse is displayed here,
depending upon which automated warehouse you select for your
production line. The single automated warehouse has 40 storage
bins, and the double automated warehouse has 88. A user-defined
preset is required for user-generated production orders.
The user-defined stock contents preset makes provision only for
production orders with an order number greater than or equal to 1.
Before a timed production order is started, it is necessary to accept
the user-defined preset for the automated warehouse as the current
stock contents.
You can monitor the stock contents and also modify these by using
Modify Saves the modifications made to a selected storage
location
Reset Deletes the data for the selected storage location and
fills the location with a standard preset
40 storage bins
Report Prints out the user-defined stock contents
database.


Managing the master customer data

2. Click on the Stock User button.
3. The database mask iCIM Production Manager – Customers will
open.
You will see a list of customers.
You can view this list, add to it and make deletions by using the
following buttons:
Create New Adds a new customer and associated data
Delete Deletes a customer
Save Saves modifications to the data for a selected
customer
Clear Deletes data for a selected customer
Cursor forward Displays the next customer
and cursor back or previous customer on the list
Report Prints out the list of customers
database.


4.10 There are two kinds of production orders:

Generating and modifying • Production orders which are executed as son as the relevant
the order list for a machines are available
production line • Production orders which are to be executed at a certain time.
Time-related production orders are managed in the Orders timed list. All
other production orders are entered in the Orders listed list. These two
lists form part of the production database. They are generated by means
of appropriate production database input masks.
Below is a description of the database masks for the two order lists.

Database mask for definition of a production order for the Orders listed list
Field Description
Working No. This is a number from a consecutive series used to identify the production
order. This number is allocated automatically by the production database.
Part No. This relates to the product which is to be produced.

Possible entries are offered to you in a selection list.
Order No. Only the order number 0 is permissible in this case.

Each production order is allocated an order number. As standard, the
production control system works with the order number 0. For this reason,
each new production order is preset with the order number 0. The stock
contents generated as a standard by Factory also relate to the order number
0.
Customer No. This relates to the customer for whom the production order is being
produced.
Possible customers are offered to you in a selection list.
Resource This entry describes the machine which is to produce the desired workpiece.
The production line machines which are able to produce the desired
workpiece are offered to you in a selection list.
It is also possible to select no machine for the order. The production control
system will then search automatically for a suitable machine. Data on the
production process for the desired workpiece is stored on the production
database and is evaluated by the production control system.

Database mask for definition of a production order for the Orders timed list
Field Description
Start Date This is the start date for the production order.
Permissible entries are all dates which lie in the future and are entered in
the format DD.MM.YYYY.
D = day, M = month, Y = year
Start Time Start time for the production order.

Permissible entries are allthose in the format HH:MM:SS.
H = hour, M = minute, S = second
Order No. Permissible order numbers are all integers greater than or equal to 1.
Each production order is allocated an order number. As standard, the

production control system works with the order number 0. The stock
contents generated as a standard by Factory also relate to the order
number 0.
Timed production orders always need an order number greater than or
equal to 1, since materials need to be reserved for these orders. In the case
of timed orders, you must ensure yourself that all the stock contents are
suitable for the order in question. This means that all the workpieces
necessary for the production of the desired product must be available in
the automated warehouse with the appropriate order number. The best
way for a user to define a stock preset is by means of the database mask
under Stock User.
Customer No. This relates to the customer for whom the production order is being
produced.
Possible customers are offered to you in a selection list.
Batch Size Here, you enter the number of products to be produced.
Part No. This relates to the product which is to be produced.

Possible entries are offered to you in a selection list.

Database mask for definition of a production order for the Orders timed list
Field Description
Resource This entry describes the machine which is to produce the desired
workpiece. Machines are also referred to in COSIMIR® Factory as stations.
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The production line machines which are able to produce the desired
workpiece are offered to you in a selection list.
Macro (macro process Here you select the macro process task which is to be used to produce the
task) desired product.
The possible macro process tasks are offered to you in a selection list.
Generating an order list for production orders without a defined start

time
production line has been loaded in Factory Simulation.
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the Project menu.


open automatically.
6. Click on the Database button to view the production database

tables and modify these if necessary.



8. Modifications to the production database may be made only by

authorised persons and are therefore password-protected. Click on
the Login button. Select the Usertype entry. Then enter the
password. If you have not changed the password since you installed
COSIMIR® Factory, the default password will still be valid.
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Once you have logged in as a User, enter under Password: Festo


9. Click on the Orders listed button in order to open the order list for
production.

10. If you wish to add a new order, enter the order data in the fields
under Modify Order.
– The value for Working Number will be entered automatically by the
database. You need do nothing at this point.
– Select the part number of the product which you wish to produce.
The possible products will be offered to you in a selection list.
Select, for example, part number 42144 for a base plate.
– Accept the number 0 as the order number. You can then use the
standard preset contents of the automated warehouse.
– Select the customer for this order. All the customer managed in
the database will be offered to you in a list.
– Select the machine on which the product is to be produced. The
CNC milling machine Mill155 is offered.


11. Click on the Add button in order to add the order to the list of
production orders.

12. Generate the data for a further order.

13. Add the new order to the order list.

14. If you wish to change an order, highlight the relevant entry by

clicking on a field of this entry. The order data will then appear in the
input fields under Modify Order.

15. Carry out the modifications.

16. Click on the Modify button in order to write the modified order back
into the list.

17. You can also delete individual orders. Select the desired order.

18. Click on the Delete current button. The highlighted order will be
deleted from the order list after a confirmation.
Note Modifications to orders can be made only if the order concerned is not
being executed by the production control system.

Generating an order list for timed production orders
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the Project menu.


open automatically.





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9. Click on the Orders timed button in order to open the list of timed
production orders.

10. If you wish to add a new order, enter the data for this order in the
fields provided.
– The field with the start date is preset with the current data. You
can change it at any time.
– The current time of day is preset as the start time. Enter the
desired start time.
– It is best to accept the preset value 1 as the order number. Timed
production orders always required an order number greater than or
equal to 1.
– Select the customer for this order. All the customers managed on
the database are offered to you in a list.
– Enter the quantity of products to be produced. Select, for
example 2.
– Select the part number of the product which you wish to produce.
The possible products are offered to you in a list. Select, for
example, part number 42144 for a baseplate.
CNC milling machine Mill155 is offered.
– In the macro field, select the macro process task which the
machine is to use to produce the workpiece. For the production of
the baseplate, select ProdBaseplate.


11. Click on the Add button to add the order to the list of timed
production orders.

12. Generate the data for a further order.

13. Add the new order to the order list.

14. If you wish to modify an order, highlight the desired entry by clicking
onfield of the entry concerned. The order data will be transferred to
the input fields.

15. Carry out the modifications.

16. Click on the Modify button in order to write the modified order back
into the list.

17. You can also delete individual orders. Select the desired order.

18. Click on the Delete button. The highlighted entry will be deleted
after confirmation.
Note Modifications to orders can be made only if the order concerned is not
being executed by the production control system.

4.11 Production orders for a production line are generated in two lists. These
Executing and monitoring two lists form part of the production database.
the order list for a
production line The execution of the lists is started in the Factory Control visualisation
window. Here you can track the execution of active orders in a 2D
display of the production. The Factory Simulation program section
provides a highly realistic representation of the production sequence.
For more precise data on the status of individual production orders,

track the two order lists on the Online production database.
Starting the execution of the order lists Orders listed and Orders
timed
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the Project menu.


open automatically.

6. Before you start the execution of the order list, you must check the
stock contents. To do this, open the production database by clicking
on the Database button. The click on the Stock Contents button.
7. If your order list contains only production orders with the order
number 0, you can accept the standard preset for the automated
warehouse. To do this, click on the Copy from Stock Init button.
Note To order to carry out modifications to the stock contents, you need write
authorisation for the production database. Write authorisation is
specific to certain user groups and is awarded when you log into the

8. If your order list contains production orders with an order number

greater than or equal to 1, you must accept the user-defined preset
for the automated warehouse as the current stock contents. Note:
Timed production orders always have an order number greater than
or equal to 1.
Now click on the Copy from Stock User button. The user-defined
stock contents are accepted as the current stock contents and are
now available for use in production.
9. Now start the execution of your order list. To do this, click on the
Orders Listed button if you have generated a simple order table and
now wish to execute this. If you have entered production orders with
a defined start time, click on the Orders Timed button.
10. You can recognise that an order table is being executed by the fact
that the relevant button is highlighted in blue.

Tracking the execution of Orders Listed
1. Ensure that the desired order list is being executed. You can
recognise this by the fact that the Orders Listed button is
highlighted in blue.
2. Click on the Database button to activate iCIM Production Manager.
3. Click on the Orders Listed button.

4. The database mask for Orders listed will open.

Three sections are provided in order to allow you to see at a glance
the processing status of orders:
Orders scheduled Order waiting for processing.
Orders running Order being executed.
Orders finished Order completed.

5. As soon as an order is completed, it is entered in the Orders

finished section.
6. If you wish to remove all completed orders from the list, click on the
Clean up button.

Tracking the execution of Orders Timed
1. Ensure that the desired order list is being executed. You can
recognise this by the fact that the Orders Timed button is
highlighted in blue.
2. Click on the Database button to activate iCIM Production Manager.
3. Click on the Orders Timed button.

4. The database mask for Orders Timed will open.

In order to be able to see the processing status of an order at a
glance, selectthe fullscreen view of the list by clicking on the
Fullscreen View button.
All the available data on the execution of the order will be displayed:
State idle Order waiting for processing.
State running Order being executed.
State finished Order completed.
State failed Execution of order has failed.
5. As soon as an order is complete, it is given the status finished.

Click on the Back button to return to the database mask Orders
timed.
6. If you wish to remove all completed orders from the list, click on the
Clean up button.

4.12 Three database masks are provided for stock management:

Managing the automated • Stock Contents:
warehouse for a The Stock Contents mask is used to manage the current stock
production line contents of an automated warehouse. This stock is used during the
production of a product.
• Stock Init:
The Stock Init mask manages the standard preset for the automated
warehouse. These stock contents are automatically accepted as the
current stock contents when production line operation is started.
The stock contents generated by the system take into account only
production orders with an order number 0. Note: The production
orders prepared in the visualisation window are allocated the order
number 0.
• Stock User:
The Stock User mask is used to create a user-defined preset for the
automated warehouse. The user-defined stock contents generated
by the system take into account only production orders with an
order number greater than or equal to 1. Order numbers greater
than or equal to 1 are, for example, allocated for timed production
orders. Before the start of production, users must ensure that the
user-defined preset for the automated warehouse is accepted as the
current stock contents.
There are two variants of the automated warehouse, namely the single
and the double automated warehouse. The single automated
warehouse is comprised of 40 storage bins, and the double automated
warehouse has 88. 40 storage bins are displayed simultaneously in the
database window. If you have selected an automated warehouse with
more than 40 storage bins for your production line, you can scroll
through the entire contents of the warehouse by clicking the arrow
symbols.
The storage bins numbered 1 through 48 are located in the back row of
the automated warehouse in the 3D model, and the storage bins
numbered 49 through 88 comprise the front row.

Double automated warehouse, back row
Double automated warehouse, front row
Each storage bin is idendtified with a location number, a part number, a

colour code and an order number.
In addition to this, each storage bin has a zone code. The zone code
takes the various height levels of the storage bins into consideration.
The user cannot access the zone code, nor is it directly visible. The zone
code is managed internally by the production database. The production
database requires this zone management function in order to correctly
store and withdraw parts.

All of the storage bins in the single automated warehouse have the
same value: They are all flagged with the same zone code, which is
identified as Zone 0. In this way, any part can be stored in any bin
regardless of its geometric dimensions, and regardless of whether it
represents a raw material, a semi-finished product or a finished
product.
As opposed to this, the storage bins in the double automated

warehouse are assigned to three different zones:
• Zone 1 includes the storage bins numbered 57 through 64. This
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corresponds to the second row from the bottom at the front section
of the automated warehouse. These bins are low and can only
accept an empty pallet for a baseplate (part number 82201) or a
penholder (part number 82200).
• The storage bins in the top row make up an additional zone. This
zone includes the storage bins numbered 41 through 48 and 81
through 88, and is designated Zone 7. High parts can be stored
here, for example complete desksets.
• The third zone is comprised of all of the remaining storage bins and
is designated Zone 4. Any parts with the exception of complete
desksets can be stored in these locations.
When parts are withdrawn on the basis of the corresponding part

number, they are always taken from the storage bin with the lowest
possible number.
When parts are placed into storage, the lowest available storage bin
number with the appropriate zone code is selected.
If the user enters new parts to the database, they are automatically
assigned to zone 7.
It is currently possible to set down precisely one workpiece on a pallet

in each storage location.
If you need several examples of the same workpiece, you must reserve
an appropriate number of storage locations with the relevant part
number.

You can modify the following data for a storage location:

• Part number for storage location
• Number of order for which the workpiece is to be available.
We recommend that you do not modify the standard preset for the
automated warehouse Stock Init. These stock contents are matched to
the prepared production orders in the visualisation window.
Modifications to both stock contents workpieces and order numbers can
be made in the Stock Contents list of current contents and in the used-
defined list Stock User.

Modifying the current contents of the automated warehouse
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the Project menu.


open automatically.





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9. Click on the Stock Contents button to open up the current stock

contents for production operation.
10. In order to modify an individual storage location, click on the desired

location and make modifications to the part number and/or order
number. Then click on the Modify button. The current storage
location contents will be overwritten.

11. You can also overwrite the stock contents. Use the Copy from Stock
User button to accept the user-defined preset for the stock contents.
If you wish to overwrite the current stock contents with the standard
preset provided, click on the Copy from Stock Init button.
4.13 If you wish to create a new workpiece in the production database and
Creating a new workpiece produce this, carry out the following steps:
in the production 1. Create the workpiece with its features.
database 2. Enter the design data for the workpiece.
3. Define the production process for the workpiece.
4. It is also possible to define quality data for certain workpieces.
All this data together forms a database entry for the selected workpiece.
The various data items are, however, stored in different tables.
Entries in the production database are made using special database

masks. You require full write authorisation to make modifications to the
list of workpieces. These are reserved as standard for the Instructor
user group. The Instructor can, however, allocate the necessary write
authorisation to the User group.
Below is a description of the input fields of the relevant database

masks.

Database masks for the definition of a workpiece
Field Description
Part No. The part number is a numerical value which unambiguously identifies a
workpiece.
Permissible values are integers greater than or equal to 1. The part
numbers of workpieces present in the database are offered to you in a
selection list. Part numbers are, for example entered in an order table in
order to produce a desired product. Part numbers are also transferred to
process tasks in order to activate the relevant processing program.
Note:
You should not modify the part numbers of existing workpieces. Data on
workpieces is stored in various tables in the production database. Part
numbers are used for access in all cases.
If a part number is changed in one table, the same change must be made in
all the other tables.
Product Name The product name unambiguously identifies a workpiece. We

recommendthat a text which is understandable to the user should be
chosen as the product name.
Permissible names are texts of 35 characters and consisting of the
following characters: Numbers, letters, underscores, blank spaces.
Description This field is used to enter a detailed and easily understandable description
of the workpiece. The field can also be left empty.
Permissible descriptions are texts consisting of 255 characters as follows:
Numbers, letters, underscores, blank spaces.

Field Description
Type This is the type of workpiece.

A distinction is made between:
– Self-produced workpieces
– Outsourced workpieces
In the case of outsourced workpieces, details of the supplier must also
be entered
in the appropriate field.
– Pallet
The permissible entries for Type are:
– Produced for self-produced workpieces
– Supplied for outsourced workpieces
– Pallet for pallet
The possible entries are offered in a selection list.
Group The group represented the colour code for a workpiece.

Every workpiece can be allocated a colour code. The colour is evaluated in
the visualisation of the warehouse. For example, blank workpieces can be
identified with one, colour, finished workpieces with another.
Each colour is allocated a certain number.

10 colours have currently been set up. These are:
0: Purple 1: Dark pink 2: Yellow
3: Light blue 4: Light pink 5: Light yellow
6: Blue 7: Green 8: Red
9: Light green 10: White
Supplier The supplier of the workpiece if this is outsourced.

Permissible descriptions are texts consisting of 55 characters as follows:
Numbers, letters, underscores, blank spaces.

Field Description
Location This is for the storage location of the workpiece.

Workpieces are stored at two different locations within a production line.
These locations are:
– Automated warehouse
– Feeders. Feeders are local storage locations within a station. Feeders
include magazines and belts with workpiece storage and transport.
Permissible entries for Location are:
– Stock for automated warehouse
– Feeder for local storage location within a station
On Pallet Here, the part number of the pallet on which this workpiece is transferred
into store and transported.
The possible part numbers are offered in a selection list.
On Pallet is preset with the part number 0.
Costs This field is used to enter the manufacturing costs for a workpiece.
The manufacturing costs are preset with the value 0.
Price This is the net sales price for the workpiece.

Price is preset with the value 0.
Currency This entry describes the currency for the prices.

Possible currencies are offered in a list box.
Currency is preset with EUR.

Database mask for the definition of the geometrical structure of a workpiece
Field Description
Part No. Part numbers are offered in a selection list.
Construction1 This field is used to enter the assembly instructions for the workpieces.
These are necessary for the visualisation of the workpiece.
Example: First comes a baseplate, then a penholder is fitted to the second

hole of this.
Each workpiece has at least one gripper point and one gripping point.
GRP = Gripper point (active)
GP = Gripping point (passive)
This data is used to generate assembly instructions in pairs for two
workpieces at a time.
We recommend that you generate the construction data for a new

workpiece by copying appropriate construction data from an existing
workpiece.
Construction2 This field is currently unused..
Construction3 This field is currently unused..

Database mask for the definition of the production process for a workpiece
Field Description
Part No The part number is a numericalvalue which unambiguously identifies a

workpiece.
All the data in this data record belongs to the selected workpiece. This data
must known in order for the workpiece to be produced.
Product Name This shows the product name of the workpiece.
Description This shows a description of the workpiece.
Resource Class (machine Here, the station class is entered which is to be used to produce the
or station class) workpiece with the selected part number.
The following station classes are available and can be entered:
– Station Festo Mill
– Station Festo Turn
– Station Festo MillAndTurn
– Station Festo Stock
– Station Festo Assembly
– Station Festo Quality
Use Resource Type An entry is made here to specify whether the selected workpiece is to be
(machine or station type) produced by the station class or an example of the station class. An
example is a specific machine from the selected station class.
This entry is important if, for example, the production line includes two
machines of the selected station class. If production is to carried out on a
specific machine, the name of the machine in question within the
production process must be specified. The specific machine is
characterised by a machine or station name (resource name)
The following entries are permissible as machine types:
– Resource Class
– Resource Name
The possible entries are offered in a selection list. The preset for the
machine type is Resource Class.

Field Description
Resource Name If a specific machine is specified in the Machine Type field, i.e. by the entry
(machine name or Resource Name, the name of the machine in question must be entered in
station name) this field.
The possible machine names are offered in a selection list.
Use Macro (macro Here, the macro process task is specified which the selected machine
process task) needs to carry out in order to produce the workpiece.
The possible macro process task for the selected machine or machine class
are offered in a selection list.

Field Description
Strategy (transport Here, the production or transport strategy is entered which the machine is
strategy) to use.
There are three strategies, as follows:
Single:
In this process, there is a starting product from the automated warehouse,
a station (machine) and an end product. Optionally, starting products of
which stocks are held locally in the station can also be used. The end
product is given the specified Part No.
Examples of this process are the milling or turning of a workpiece.
Parallel two:
In this process, precisely two starting products from the warehouse are
assembled. Assembly products of which stocks are held locally in the
station can also be used. These products are used to create an end
product. The end product is given the specified Part No. This is set down on
an empty transport pallet. The second transport pallet travels empty to the
warehouse.
Test:
In this process, a workpiece is tested. If the quality of the workpiece is in
order, it is allocated a Part No.
If the workpiece does not pass the quality test, it is given a new part
number. This part number indicates that the workpiece is defective.This
workpiece has a special status. It is transferred into the automated
warehouse but does not, for example, have an associated production
process.
The possible entries for the production strategy are offered in a selection
list.
Mill Here, the program number of the Mill program is entered which is to
produce the desired product.
The program number is linked to the selected machine and macro process
task.

Field Description
Turn Here, the program number of the Turn program is entered which is to
produce the desired product.
The program number is linked to the selected machine and macro process
task.
Subparts 1 Here, the first workpiece is entered which is to be used as a starting

(supplied) workpiece.
This type of starting workpiece is always transported from the automated
warehouse to the machine.
Subparts 2 Here, the second workpiece is entered which is to be used as a starting

(supplied) workpiece.
This type of starting workpiece is also always transported from the
automated warehouse to the machine.
Subparts 3 (supplied) This field is not currently used.
Subparts 4 (supplied) This field is not currently used.
Subparts 1 Here, once again, the first workpiece is entered which is to be used as a
(local) starting workpiece. This workpiece is, however, stored locally in feeders in
the station, A feeder can be, for example, a magazine.
This local store is managed automatically and does not require attention by
users.
The possible part numbers are offered in a selection list..
Subparts 2 Here, the second workpiece is entered which is to be used as a starting

(local) workpiece. This workpiece is, however, stored locally in feeders in the
station, A feeder can be, for example, a magazine.
users.

Field Description
Subparts 3 Here, the third workpiece is entered which is to be used as a starting

users.
Subparts 4 Here, the fourth workpiece is entered which is to be used as a starting

users.
Part No. on Fail This is the part number allocated to defective workpieces.
Certain rules should be observed when making the entries:

• New workpieces must have the same geometrical dimensions as the
standard workpieces already in the production database. The
machine and robot programs for the processing and assembly
stations are based on certain assumptions relating to the
geometrical form of the workpieces and the sequence in which they
are processed. It is thus useful when generating a new workpiece to
base this on the data record for a suitable existing workpiece.
• In order for a workpiece to be produced, its design data must be
known. The design data is written in a fixed syntax. If you do not
wish to undertake a deeper study of this syntax, we recommend that
you use the design data of a suitable existing workpiece for the new
workpiece.

• The actual production of a workpiece is carried using the macro

process tasks of a station. The execution of a macro process task
follows a fixed sequence. It is thus necessary to observe certain
requirements when formulating the production process for a
workpiece:
These include:
– The sequence in which various starting components are fed from
the automated warehouse is fixed and must be maintained.
– The types of starting components held ready at local storage
locations within stations are fixed and must be maintained.
The necessary information on the mode of operation of macro
process tasks is summarised in a table.
Production processes for penholders

Penholders are made in a number of variants. These differ in their
material and design. They are designated Type 1 to Type 5.
Penholders can be produced by different production processes. They
are typically produced as turned workpieces.

Production Production Production Production

process 1 for process 2 for process 3 for process 4 for
penholder penholder penholder penholder
Station Turn Mill&Turn Mill&Turn Mill
Macro process ProdPenholder ProdPenholder ProdPenholder ProdPenholder

task Mag
Strategy Single Single Single Single
1st starting Blank for Blank for Empty pallet for Blank for
workpiece from penholder on penholder on penholder penholder on
warehouse pallet pallet pallet
2nd starting – – – –
workpiece from
warehouse
1st starting – – Blank for –

workpiece local penholder
workpiece local
3rd starting – – – –
workpiece local
Mill program 0 0 0 Aluminium

Type 1: 100
Type 2: 101
Type 3: 102
Type 4: 103
Type 5: 104
Brass
Type 1: 120
Type 2: 121
Type 3: 122
Type 4: 123
Type 5: 124


penholder penholder penholder penholder
Turn program Aluminium Aluminium Aluminium 0

Type 1: 100 Type 1: 100 Type 1: 100
Type 2: 101 Type 2: 101 Type 2: 101
Type 3: 102 Type 3: 102 Type 3: 102
Type 4: 103 Type 4: 103 Type 4: 103
Type 5: 104 Type 5: 104 Type 5: 104
Brass Brass Brass

Type 1: 120 Type 1: 120 Type 1: 120
Type 2: 121 Type 2: 121 Type 2: 121
Type 3: 122 Type 3: 122 Type 3: 122
Type 4: 123 Type 4: 123 Type 4: 123
Type 5: 124 Type 5: 124 Type 5: 124
Production processes for baseplates
Baseplates are made in a number of variants. These differ in their

material and design. They are designated Type 1 to Type 5.
Baseplates are typically produced as milled workpieces.


baseplate baseplate baseplate baseplate tested
untested untested untested
Station Turn Mill&Turn Mill&Turn Quality
Macro process ProdBaseplate ProdBaseplate ProdBaseplate Test

task Mag
Strategy Single Single Single Test
1st starting Blank for Blank for Empty pallet for Baseplate on
workpiece from baseplate on baseplate on baseplate pallet untested
warehouse pallet pallet
workpiece from
warehouse
1st starting – – Blank for –

workpiece local baseplate
workpiece local
3rd starting – – – –
workpiece local
Mill program Type 1: 140 Type 1: 140 Type 1: 140 0

Type 2: 141 Type 2: 141 Type 2: 141
Type 3: 142 Type 3: 142 Type 3: 142
Type 4: 143 Type 4: 143 Type 4: 143
Type 5: 144 Type 5: 144 Type 5: 144
Turn program 0 0 0 0

Production processes for desksets
Desksets are produced in a number of variants. These differ in the

components fitted and according to whether they are tested or not.
Components must be fitted in accordance with a defined specification:
The third hole is reserved for a penholder, while a thermometer and
hygrometer may be fitted to holes 1 and 2. Below is a list of examples of
the production processes for a number of deskset variants.
Production process for Production process for Production process for

desksets with desksets with desksets with
penholder in 3 hole
rd
P P penholder and pen in hygrometer in
3 hole
rd
P P 1 hole and with
st
P P
penholder in 3 hole
rd
P P
Station Assembly Assembly Assembly
Macro process task AsmDeskset AsmDeskset AsmDeskset
Strategy ParallelTwo ParallelTwo ParallelTwo
1st starting workpiece Baseplate on pallet Baseplate on pallet Baseplate on pallet

from warehouse
2nd starting workpiece Penholder on pallet Penholder on pallet Penholder on pallet

from warehouse
1st starting workpiece – – Hygrometer

local
2nd starting workpiece – – –

local
3rd starting workpiece – Pen –

local
Mill program 0 0 0
Turn program 0 0 0

Production process for Production process for Production process for

desksets with desksets with desksets with
thermometer in 2 hole
nd
P P thermometer in 1 st
P P penholder in 3 hole,
rd
P P
and penholder with hole, hygrometer in 2 nd

P P baseplate tested
pen in 3 hole
rd
P P hole and penholder
with pen in 3 hole
rd
P P
Station Assembly Assembly Assembly
Macro process task AsmDeskset AsmDeskset AsmDeskset
Strategy ParallelTwo ParallelTwo ParallelTwo
1st starting workpiece Baseplate on pallet Baseplate on pallet Baseplate tested on

from warehouse pallet
2nd starting workpiece Penholder on pallet Penholder on pallet Penholder on pallet

from warehouse
1st starting workpiece – Thermometer –

local
2nd starting workpiece Thermometer Hygrometer –

local
3rd starting workpiece Pen Pen –

local
Mill program 0 0 0
Turn program 0 0 0

A simple example will be used to explain the creation of a new

workpiece in the database.
Example A new baseplate is to be added to the production database:

• The baseplate is to be given the part number 100001.
• In terms of design, this baseplate is identical to the baseplate with
part number 42141. It will, however, have a coloured anodised
finish applied at a later stage.
The baseplate with part number 42141 is made of aluminium and is
of Type 2.
• The baseplate with part number 42141 requires a blank baseplate
with part number 42010 as a starting workpiece.
• A pallet with part number 82201 is used to transport the baseplate.
• The baseplate is to be produced on a CNC milling machine.
Note: In order to modify products and the associated production data,

you need the appropriate write authorisation for the production
database.
Creating a new workpiece in the production database
menu.
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the Project menu.


open automatically.

6. Click on the Database button to open iCIM Production Manager for

the production database.

8. .Modifications to the production database may be made only by

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Note: The User group has generally limited write authorisation in
comparison with the Instructor group.

9. Click on the Products button in order to open the list of workpieces.

The production database currently includes data for 64 workpieces.
10. If you wish to create a new workpiece, you have a choice of two
methods for making entries.
– Method 1: Use the data record for a workpiece which is already in
the database and modify the entries as necessary.
– Method 2: Use a blank data record as a basis and make all the
entries for the new workpiece yourself.
Decide which method you wish to use before you click on the Create
New button.

11. Now create a new baseplate with the part number 100001. Use the
data record for the baseplate with the part number 42141 as a basis.
To do this, select part number 42141 from the list of workpieces.

12. Click on the Create New button. A window will open to allow entry of
the new part number. Enter the part number 100001 and confirm
your entry with OK.
13. A further window will open. You must now decide whether to use the
currently selected data record as the basis for the new data record.
Click on the Yes button.
14. You must now decide how you wish to work with the design data for
the new workpiece. Three options are offered. In this example, we
will let the system create an empty data record for the design data
and we will then fill in the design data ourselves. Confirm your
selection by clicking on the OK button.

15. The entries for the workpiece with the part number 42141 will now
be automatically accepted for the new workpiece with the part
number 100001.

16. Now check which entries you need to change for the new workpiece.
– Choose Baseplate type 2 anodised as the name.
– Enter an appropriate description for the new workpiece.
– Enter for example the number 40 for manufacturing cost..
– Enter for example the number 80 as the sales price.
– For all other entries, accept the existing values.
17. Now click on the Save button to store the changes in the new data
record. The data record with the properties for the new workpiece
now forms part of the production database.

Creating design data for a new workpiece
1. Ensure that iCIM Production Manager has been started.

2. Ensure that you have write authorisation to carry out modifications
to the production database.
3. Click on the Products button to open the list of workpieces.

4. Ensure that the desired workpiece with the part number 100001 is
present in the lists and that all the entries for the workpiece are
correct.

5. Click on the COSIMIR® Construction button in order to open the list

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with the descriptions of the geometrical design of the workpiece.

6. Now select a workpiece which has the same geometrical design as

the new workpiece whose design data you still need to enter.
A suitable choice is the baseplate with the part number 42141.
7. Click on the Copy button. The design data for the workpiece 42141
will be copied to the clipboard.

8. Select the part number of the new workpiece. The new workpiece
has the part number 100001. No design data has as yet been
entered for the new baseplate.

9. Click on the Paste button to accept the design data from the
clipboard.
You will receive a warning that the current design data for part
number 100001 is being overwritten. Acknowledge this warning.
10. Click on the Save button to store the new design data for part
number 100001.

Creating a production process for a new workpiece

2. Ensure that you have write authorisation to carry out modifications
to the production database.

4. Select part number 100001.

You will receive a warning that no production process has as yet
been defined for this part number. Acknowledge this warning.

5. Now define the production process for the new baseplate with the
part number 100001. Make all the necessary entries in the database
mask.
– As machine class select the entry Station Festo Mill, as the
baseplate is to be produced on a milling machine.
– As machine type select the entry Resource Class. This will allow
the examples to be produced by any machine of the Festo Mill
station class.
– The field for Resource Name should be left empty, since a class
has been selected as machine type.
– As macro process task select the entry ProdBaseplate from the
list.
– As transport strategy select the entry Single, as exactly one blank
needs to be transported from the warehouse to the milling machine.
– The first starting workpiece need ed from the automated
warehouse is a blank with the part number 42010. Select this entry
from the list. No further starting workpieces are required from the
automated warehouse.
– The milling machine does not store any starting workpieces locally.
The relevant input fields should therefore be left empty or filled with
the preset 0.
– Consult the documentation to find which CNC program is required
for the production of a baseplate type 2. This is the milling program
with the number 141. Enter the program number in the appropriate
input field.
– No lathe program is required. The entry for the Turn program
should therefore be left unchanged.
– If the production of the new workpiece results in a defective
workpiece, this should be given the part number 0.The appropriate
input field is already preset with this value.

6. Now click on the Add button in order to transfer the new data record
with the production data for the workpiece with the part number
100001 to the database.

Producing a newly-created workpiece

2. In order to produce a newly-created workpiece, generate an
appropriate production order. There are two kinds of production
orders:
– Production orders without a defined start point
– Timed-controlled production orders with a defined starting time.
Production orders are managed in two order lists.
3. Ensure that you have the write authorisation necessary in order to
generate production orders.
4. For the purposes of example, a new baseplate with part number
100001 is to be produced by means of a simple production order. To
do this, click on the Orders listed button.

5. The database mask iCIM Production Manager – Orders listed for

simple production orders will open.

6. Enter the data for the desired order in the fields below Modify Order.
– The value for Working Number will be entered automatically by the
database. You do not need to do anything here.
– Select the part number of the workpiece which you wish to
produce. The new baseplate has the part number 100001.
– Accept the value 0 as the order number. You can then use the
– Select the customer for this order. All the customers managed in
the database will be offered in a list.
– Select the machine on which the baseplate is to be produced.. The
CNC milling machine Mill155 will be offered.

7. Click on the Add button in order to add the order to the list of
production orders.

8. Before you start the execution of the order, you must check the
stock contents. To do this, switch to the production database
window. Then click on the Stock Contents button.
9. As the order list includes a production order with the order number
0, you can accept the standard preset for the automated warehouse.
To do this, click on the Copy from Stock Init button.

10. Switch to the visualisation window for operator control and display
of the process. Now start the execution of your order list. To do this,
click on the Orders listed button.

11. You can track the production of the desired workpiece in the
visualisation or the 3D production line simulation display.

4.14 Baseplates can be put through a quality test. This examines the drilled
Creating and evaluating holes in the plates. To allow a check to be carried out, setpoints must be
test data for a workpiece available for the test data.
The setpoints and the test data recorded during production are stored
in the production database.
Two database masks are provided for the entry of setpoints and the
evaluation of test data. You can access these masks as soon as you
have opened the list of products.
Database mask for the definition of test setpoints for a workpiece
Field Description
Part No Part numbers are numerical values which unambiguously identify a

workpiece. All the data in this data record relates to the selected
component. The possible part numbers are offered in a selection list.
Name This shows the product name of the workpiece.
Description This shows a description of the workpiece.
Type This shows the type of workpiece involved.
Group This shows the group to which the workpiece belongs.
Set Point This shows the setpoint.

The setpoint is preset as standard.
The value 0 is entered here for workpieces which have not been tested or
cannot be tested.
Lower Limit Here the lower limit is entered.

All the measured values between the upper and lower limits are
permissible. If a measured value lies outside this range, the produced
workpiece concerned is defective.
The lower limit is preset as standard. The value 0 is entered here for
workpieces which have not been tested or cannot be tested.

Database mask for the definition of test setpoints for a workpiece
Field Description
Upper Limit Here the upper limit is entered.

All the measured values between the upper and lower limits are
permissible. If a measured value lies outside this range, the produced
workpiece concerned is defective.
The upper limit is preset as standard. The value 0 is entered here for
Low Warning Here, the lower limit is entered below which a warning can be output.
(lower value for warning) The low warning is preset as standard. The value 0 is entered here for
High Warning Here, the upper limit is entered above which a warning can be output.
(upper limit for warning) The high warning is preset as standard. The value 0 is entered here for

Creating the setpoints for the quality testing of a baseplate
menu.
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the Project menu.
open automatically.




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9. Click on the Products button to open the list of parts.

10. Click on the Quality Data Settings button to open the list of
predefined setpoints.

11. Select, for example, the baseplate with the part number 42143.

12. If you wish to modify the preset values, click on the desired field.
Modify the value, and then click on the Save button in order to save
the changes.
13. If you wish to work with the setpoints provided as standard, click on
the Default button. Accept the preset values for the selected
workpiece by clicking on the Save button.
14. The setpoints for the desired workpiece are now entered. Now
produce the workpiece and evaluate the test data.

15. If you wish to enter setpoints for a new workpiece in the database,
select the workpiece in question. For example, the baseplate with
the part number 100001 is a new workpiece for which no setpoints
are entered. You can see this by the fact that a 0 appears in red.

16. Click on the Create New button in order to create a data record for
setpoints. The setpoints are predefined as 0.

17. Now change the setpoints to the desired value by directly editing
the numerical values. If you wish to work with the setpoints
provided as standard, click on the Default button. Accept the preset
values for the selected workpiece by clicking on the Save button.
The setpoints for the desired workpiece are now entered. Now
produce the workpiece and evaluate the test data.

Carrying out quality testing
2. In order to produce a newly-created workpiece, generate an

appropriate production order. There are two kinds of production
orders:
– Production orders without a defined start point
– Timed-controlled production orders with a defined starting time.
Production orders are managed in two order lists.
3. Ensure that you have the write authorisation necessary in order to
generate production orders.

4. As an example, let us arrange quality testing for a baseplate with the

part number 42143. Production and testing of the baseplate are to
be carried out as simple production orders. To do this, click on the
Orders listed button.
5. The database mask iCIM Production Manager – Orders listed for
simple production orders will open.

6. Now generate an order to produce a baseplate with quality testing.

Enter the order data in the fields under Modify Order.
The value for Working Number will be entered automatically by the
database. You need do nothing at this point.
Select the part number of the product which you wish to produce.
The possible products will be offered to you in a selection list.
Select, for example, part number 46143 for a base plate (tested).
When this order is executed, a baseplate with the part number
42143 will be subjected to quality testing.
– Accept the number 0 as the order number. You can then use the
– Select the customer for this order. All the customers managed in
the database will be offered to you in a list.
Quality station will be offered.


7. Click on Add to transfer the order into the list of production orders.

8. Before you start the execution of the order list, you must check the
stock contents. To do this, click on the Stock Contents button.
9. As your order list contains only production orders with the order
number 0, you can accept the standard preset for the automated
warehouse. To do this, click on the Copy from Stock Init button.

10. Now switch to the visualisation window for operator control and
display of the process. Start the execution of your order list. To do
this, click on the Orders listed button.

Evaluating the test data for a baseplate

3. Now click on the View Quality Data button.

4. The iCIM Production Manager – Quality Datawindow will open.

The most recently recorded quality data will be displayed. In the
example shown, all workpieces have been produced fault-free. The
setpoints and actual values coincide.
If you wish to view quality data for other workpieces which have
already been tested, select the desired part number. This display
will then be updated accordingly.

4.15 Various programme components work together in COSIMIR® Factory. If

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Exiting COSIMIR® Factory

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you want to exit COSIMIR® Factory and close the individual programme
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components, you have to make sure that the Production mode has been
deactivated.
Exiting COSIMIR® Factory:

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1. If the Factory Control component has been started, deactivate the

Production mode. Click Production in the Project menu to this end.
The tick mark next to Production is cleared from the display.
2. The Stop production window appears.
Stopping production causes proper shutdown of all components and
drivers. The shutdown procedure may take a while, during which
time the window remains open.
3. If the window is not closed automatically, errors have occurred

during deactivation of the production mode. Stop production
manually in this case by clicking the Cancel all processes button. If
the production mode still has not been deactivated, click the Abort
communication button.
4. As soon as the Stop production window is cleared from the display,
all of COSIMIR® Factory’s programme components can be exited.
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Exit Factory Control first, and then Factory Simulation.

5. Material which you can teach using COSIMIR® Factory T
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COSIMIR® Factory is a PC-based graphical 3D simulation system which

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provides an introduction to computer-integrated manufacturing. The

production lines created from pre-assembled automation components
reflect practical applications. The exercises are based on authentic
industrial handling operations and are designed to contribute to an
holistic learning process. COSIMIR® Factory allows you to provide
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training in methodological competence and competence of actions.
5.1
Learning contents and
learning objectives
Learning objectives COSIMIR® Factoryallows you to deal with and communicate learning
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contents from the following areas:

• Structure and mode of operation of production lines of different
degrees of complexity
• Structure and mode of operation of flexible production control
systems for production lines
• Programming of production control systems using process plans
• Production databases with data on products and blank workpieces
as the basis for and an integral part of computer-aided automated
production
• Basic functions of a production planning system.
Main learning objectives The general learning objective which can be met with COSIMIR® Factory
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is the development of skills in

• creating production lines using pre-assembled automation stations
• defining control sequences for production lines and
• simulating production line operation.
In accordance with this objective, COSIMIR® Factory covers all the

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material which can be taught using virtual production lines or

production cells.

5. Material which you can teach using COSIMIR® Factory
Learning-objective areas The following learning-objective areas are derived from the main
learning objectives:
• Ability to generate production lines in graphical form using pre-
assembled automation stations in COSIMIR® Factory
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• Ability to understand the basic structure of a production line

consisting of various automation stations. Important automation
stations include processing stations, test stations and transport
systems.
• Ability to understand the communication and control principle of a
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• Ability to understand the structure of a project for a production line

in COSIMIR® Factory.
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• Ability to generate and modify the production control system for a

production line, for example programming an original production
sequence for a production line.
• Ability to simulate the operation of a production line and create
simple operator functions.
• Ability to control the operation of a production line using individual
order tables.
• Familiarisation with production databases as an important element
of computer-integrated manufacturing.
• Ability to modify the contents of a production database and, for
example, create new workpieces.
5.2 The target group for COSIMIR® Factory is everyone whose professional
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Target group responsibilities include the planning and control of production lines or
who wish to acquire basic knowledge of these.
The applications of COSIMIR® Factory include:

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• Technical training in computer-integrated manufacturing

• Training at technical colleges and universities in the discipline of
industrial system planning
• Customers who have bought iCIM systems from the Festo Didactic
Solution Centre.

5.3 The following previous knowledge is required in order to work and learn
Previous knowledge with COSIMIR® Factory:
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required • Basic knowledge of control technology, the components of an

automated system, material flow, information flow and energy flow
in an automated system
• Basic knowledge of the information structure of automated systems,
networking between subsystems, hierarchies in networked systems
• Basic knowledge of manufacturing and production processes
• Basic knowledge of PLC programming
• Basic knowledge of robot programming
• Basic knowledge of CNC programming
• Basic knowledge of high-level-language programming
5.4 COSIMIR® Factory is a motivating multimedia learning package for the

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The learning concept of area of computer-integrated manufacturing.

COSIMIR® Factory
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COSIMIR® Factory offers an easy introduction to the subject of

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computer-integrated manufacturing. In a first step, users select a

product from a range of possible products. They then create a
production line for this product from automation stations. As soon as a
production control system has been automatically generated for the
production line,users can simulate the operation of the production line.
Depending on requirements and the level of users’ previous knowledge,
various material can be dealt with and reinforced. This includes:
• Production lines of different degrees of complexity
• Structure and mode of operation of a flexible production control
system
• Programming of a production control system
• Production databases and production planning systems.

The simulated planning and production processes have a strong

didactic quality:
• The production lines are practical and as authentic as possible.
• The facilities for experimentation with simulated computer-
integrated manufacturing ensure a close relationship to actual
computer-integrated manufacturing, the actual subject of the
training. Knowledge is tested and reinforced.
• Realistic experience with the simulated processes creates a new
quality of knowledge, turning theoretical knowledge into knowledge
proven in applications and industrial practice.
COSIMIR® Factory supports student-controlled discovery-based

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learning:
• The simulated operation of the production line behaves in the same
way as a real production line. Users can thus see immediately
whether they haveconfigured and programmed the production line.
They can also see the effect of operator error but without causing
damage to the production line. Users can thus draw their own
conclusions and evaluate these..
• Users can obtain technical documentation for the individual
automation stations as necessary. They can also research matters
such as the programming methods for production control systems or
production planning systems.
• Users can put their knowledge and skills into practice with a variety
of possible production lines.

What advantages does COSIMIR® Factory have for teaching?

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• COSIMIR® Factory is a PC-supported learning medium and thus

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offers a different learning method. Teaching can be made varied and

motivating.
• Authentic production simulation allows knowledge and skills gained
with real production cells or lines to be reinforced and consolidated.
• Virtual production lines offer an opportunity to practice
programming a production control system without causing damage.
• Simulated processes can be used to demonstrate and test out
conditions which would be too dangerous on a real production line.
• Efficient practical and action-oriented learning is possible even
without access to a real production line.
• With COSIMIR® Factory, several simulated examples can be used of
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a production line of which only one real version is available. This

increases system availability for training purposes.
• All the production lines simulated in COSIMIR® Factory are also
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available as simulated production lines. They thus form ideal

complements and combinations for teaching purposes.
• Simulation is the modern tool for training with automated systems
and computer-integrated manufacturing.

5.5 COSIMIR® Factory can be used in basic and vocational training in may
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Learning scenarios for different ways.

COSIMIR® Factory
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Here are some examples:

• COSIMIR® Factory as an introduction, for motivation, as preparation
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and as a knowledge database iCIM systems:

This is valuable for users who have a real iCIM system and wish to
understand and operate this.
With COSIMIR® Factory, users have the opportunity to generate a
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virtual production line corresponding to their real iCIM system. They

can then use this virtual production line to familiarise themselves
with the automation devices and stations within their system. They
can obtain the necessary information through on-line help and the
on-line assistant. As the control system for a production line can be
generated automatically, users do not need any knowledge of the
programming of production control systems in this phase. They can
simulate production line operation immediately and observe the
behaviour of the production line. Depending on their future tasks,
users can utilise COSIMIR® Factory to reinforce their knowledge of
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production planning or programming.

• COSIMIR® Factory as an introduction, for motivation and as
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preparation for the subject of computer-integrated manufacturing:

COSIMIR® Factory can be used independently of real systems. On
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the basis of a library of automation stations, users can plan and

generate simple production lines. The typical automation stations
available include stores management, robots, CNC machines and
transport systems. Users can find information on these devices via
the on-line help function and the on-line assistant. As the control
system for a production line can be generated automatically, users
do not need any knowledge of the programming of production
control systems in this phase. They can simulate production line
operation immediately and observe the behaviour of the production
line. Depending on their future tasks, users can utilise COSIMIR®
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Factory to reinforce their knowledge of production planning or

programming.

• COSIMIR® Factory as an introduction and a tool for the programming

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of a production control system:

COSIMIR® Factory can be used independently of real systems. On
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the basis of a library of automation stations, users can plan and

generate simple production lines. If uses have previous knowledge
of the programming of production cells or production lines, they can
program sequences for their systems themselves. Programming is
carried out using process plans. Process plans can be generated
freely or with support from COSIMIR® Factory. As soon as the control
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system for a production line is available, users can simulate

production line operation. This simulation of the production line
provides uses with an immediate confirmation that they have
programmed the production control system correctly.
• COSIMIR® Factory as an introduction to production planning
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systems:
COSIMIR® Factory supports simple production planning system
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functions. These include the creation of a new product and

associated parts list and the allocation of machines to the
production of this product
Product data is stored in a production database to allow automatic
production of the product.
If users now generate a production line for the desired product, they
an simulate and evaluate the production of the product in
accordance with their specifications.
• COSIMIR® Factory as a virtual production line with facilities for
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process visualisation:
For each production line, COSIMIR® Factory automatically generates
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a visualisation. This consists of a graphical representation of the

production linetogether with a number of central operator functions.
This visualisation can be modified using the facilities available in
COSIMIR® Factory. In this way, users can learn how to work with
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visualisation systems. It is also possible via an interface - the DDE

interface – to link the production simulation with typical industrial
visualisation systems. In this case, users generate a visualisation of
the production line on the “external” visualisation system.

6. Example:
Planning and simulating the production of a product
COSIMIR® Factory offers you an easy introduction to computer-

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integrated manufacturing. Using virtual production lines which you

generate yourself, you can familiarise yourself with all the working
steps from planning to production. The production simulation provides
an excellent way of tracking and analysing the behaviour of the
production line.
The systematic approach which you use for this and the knowledge
which you acquire can of course be applied to any other production line,
including real ones.
6.1 These are the learning objectives which you can meet by using
Learning objectives COSIMIR® Factory:
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Main learning objectives • Planning and generating production lines for specified products
using pre-assembled automation stations and simulating production
line operation.
• Understanding and evaluating a virtual production line.
Learning-objective areas • Understanding the product and the processing technology.

• Understanding the basic structure of a production line consisting of
several automation stations. Important automation stations are
processing stations, test stations and transport systems.
• Purposeful use of technical documentation for the planning and
generation of a production line.
Technical documentation is functional descriptions of the
automation stations, specifications of the products produced by the
stations, data on the process tasks of the stations.
• Graphical generation of production lines using pre-assembled
automation stations in COSIMIR® Factory.
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• Understanding the structure of a project for a production line in

COSIMIR® Factory.
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• Automatic generation of a project with a production control system

for a production line.

• Familiarisation with a real production line through the associated
virtual production line.
• Simulation of production line operation, and drawing conclusions
concerning the production process.
• Recognising the advantage of a simulated production process for
general industrial operations.
6.2 The procedure for the planning and simulation of a production line can
Methods be described as individual steps. The most important steps are listed
below.
The questions which appear opposite the individual working steps offer
suggestions and tips as to the precise points which you should study
and take into account.
Major steps Questions
Product – What product is to be produced?

– What is the part number of this product?
– What starting workpieces are required?
Production process for – What processing technology is required – lathe turning, milling, assembly?
the product – What is the production sequence?
– Is it advisable to arrange the machine is certain order relative to the
transport system on the basis of the production sequence?
Stations required in – What machines (resources) are required for the production of the product?
order to produce the – Should the production line be capable of flexible use and thus cover all the
product major processing technologies?
Production line for – Where are data and descriptions of the individual stations stored?
product
Project with – What is the structure of the project with the production control system?
production control – Where is the data on the devices and the structure of the production line
system for production stored?
line – Where is the program for the production control system stored?
– Is the program for the production control system complete?

6. Example: Planning and simulating the production of a product
Major steps Questions
Prerequisites for – Is all the necessary data available on the product and the production
production process for automated computer-integrated manufacturing?
– Is the necessary data entered in the production database?·
– Have the stock contents been correctly initialised?
Production simulation – In what mode must the production control system be in order for it to be
possible to start production?
– What methods are available to start production?
Evaluation/observatio – What starting workpieces are required?

n of production – Where are the starting workpieces stored - in the automated warehouse or
simulation locally on the appropriate station?
– How great is the depth of production? Are processed workpieces
transferred immediately to the next station to allow the next production step
to be carried out?
– When and how are individual production processes started? Can production
processes be carried out in parallel?
– How are the stock contents defined and managed – by the COSIMIR® T
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Factory system or by the user?

– What conclusions can be drawn from the simulated production process
regarding the production sequence?
– Can the productivity of the production line be increased? If so, by what
measures?
– How many workpieces can be managed in the warehouse?
– Are all the storage locations the same, or are there differences, for example
in geometrical dimensions?
Systematic approach to production simulation

6.3
Exercise: Planning,
simulating and evaluating
the production of a
baseplate
Exercise Generate a production line for the production of a baseplate with the
part number 42143. The baseplate is made of aluminium and is slightly
rounded. Work systematically and use the checklist for general
procedure. Simulate production with a test run.
Answers the following questions:
• What processing steps are required for the production of the
baseplate?
• What automation stations do you require for production?
• How can the contents of the automated warehouse be defined and
tracked?
Method 1. The baseplate with the part number 42143 is an aluminium blank.
The necessary holes and the rounding are milled into the blank.
Accordingly, the steps required for the production of the baseplate
are as follows:
– Fetch workpiece from warehouse
– Mill workpiece
– Return workpiece to warehouse.
2. The following automation stations are required in order to carry out
the necessary production steps:
– Conveyor belt
– Automated warehouse
– CNC milling machine.
3. Start Factory Simulation in order to generate the production line for
the production of the baseplate. To do this, execute the link
COSIMIR® Factory Simulation in the program group COSIMIR®
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Factory in the Microsoft Windows start menu.

4. Activate the command New production line in the File menu.
The window Create new production line will open.

5. Select the Projects directory as the storage location for the new
production line. Projects is created as standard as a sub-directory of
COSIMIR® Factory\Control. However, you can select any other
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directory as a storage location for your production line as well.

Enter the file name. Select COSIMIR® Workcells (*.mod) as the file
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type, then click on the Save button.

6. A model of an empty production line will open. When a new

production line is created, a number of settings are made
automatically:
– The system switches to the Edit mode
– Top view is selected as the view
– The Model libraries window is opened.

7. First add a transport system. Select, for example, the model

Transport System 6. To do this, click on the entry Transport System
6. The model and a description of this will be shown in a preview. If
no data is displayed, click on the More button. Now click on the Add
button in order to add the selected station.

8. In the same way, add the Station Stock model.

9. In order to ensure that the working and transfer points are correct
during production operation, the models must be appropriately
aligned and connected up.
First align the Station Stock model to the Transport System 6
model. To do this, click on the red coupling point of Station Stock.
Hold the left-hand mouse button down and drag the coupling point
to the bottom left-hand coupling point of Transport System 6.
Station Stock is now connected to Transport System 6. The position
and orientation of the Station Stock model will have been modified
automatically.

10. Now add the Station Mill 55 model. Connect the Station Mill 55
model to the bottom left-hand coupling point of the Transport
System 6 model.

11. As soon as your production line has been generated, exit from the
Edit mode. Change to the View mode to obtain a realistic 3D
representation of the production line. To do this, click on the Edit
mode command in the Execute menu. The tick next to the Edit mode
entry will disappear. You will obtain a 3D view of your production
line.

12. In order to obtain a perspective view of the 3D model, select, for

example, the Standard/Default Settings command in the View
menu. You can use the commands under View to move, turn or
zoom the view of your production line as desired.
13. Activate the Create Plant command in the Execute menu.

This command saves the production line model as a *.MOD file.
Simultaneously, an XML-format interchange file is created which
contains the data for the structure of the production line. This
interchange file requires the program section Factory Control in
order to be able to create the production control system for the
production line automatically.

14. The Save Plant File window will open.

Change to the directory in which the production line model is saved.
As standard, the Projects sub-directory of COSIMIR® Factory\Control
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is used for this purpose.

Accept the suggested file name and click on the Save button.

the link COSIMIR® Factory ProjectStudio in the program group
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COSIMIR® Factory in the Microsoft Windows start menu.

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16. You will see an empty project with the name Proj.lpj.
17. Activate the command Import COSIMIR® Project in the menu

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Extras/ProjectStudio in order to read in the data for the previously-

created production line.

18. In the Open window, select the XML file previously created by
Factory Simulation. The XML-format interchange file and the model
file with the file extension MOD are stored in the same sub-directory.
19. After the COSIMIR® Factory project has been opened, a 2D view of
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the production line will be displayed.

20. Now activate the Setup mode. To do this, select the Setup command
The Setup mode must be active in order for you to be able to create
or modify project elements. This includes the creation of programs
for the production control system.
21. In order to create a production control system automatically,
activate the Create project command in the Extras/ProjectStudio
menu.
22. A production control system has now been created for the
production line. You can recognise this by the new entries in the
project tree in the Project window.
23. Start the Production mode in order to simulate production line

operation. To do this, select the Production command in the Project
menu.


open automatically.
25. Three production orders are ready-prepared. You can trigger the
execution of one of these production orders by clicking on one of the
three buttons Penholder, Baseplate and Deskset. Run your mouse
over the buttons to discover which products can be produced.

26. Now click on the Baseplate button in order to start production of the
desired baseplate with the part number 42143. The button will be
highlighted in blue for as long as the order is being executed.

27. In the Factory Simulation program section, you can observe and
evaluate a realistic representation of the production of the
baseplate.
28. Once the production order is completed, you can initiate the
production of a further product.
Note: In order to execute an order, the production line must include
the necessary machines. If a machine is not present, your attention
will be drawn to this at the start of production. Try it out and
produce a deskset. Moreover, in order to achieve a speedy and fault-
free production sequence, the right starting workpieces must be
available in the automated warehouse.
29. If you wish to produce products other than those offered via the
buttons, use the order tables Orders listed and Orders timed.
30. The contents of the automated warehouse are automatically
initialised the first time production line operation is started. You are
responsible for the stock contents for further production. The
contents of the automated warehouse are managed in the

31. Click on the Database button to open the iCIM Production Manager
for the production database.

32. Click on the Stock Contents button to view the current stock
contents.
The specification of a 0 for each storage location means that the
workpieces are intended for orders with the order number 0. The
prepared production orders in the visualisation window all have the
order number 0. The contents of the automated warehouse are thus
matched to the production of the prepared orders.

33. If you wish to modify the stock contents, you need write
authorisation for the production database. Modifications to the
production database may be made only by authorised persons and
are therefore password-protected. Click on the Login button. Select
the Usertype entry. Then enter the password. If you have not
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34. You can modify the current stock contents and, for example,
overwrite them with the standard presets. To do this, click on the
Copy from Stock Init button. You can also modify individual storage
locations if particular workpieces are not available.
35. If you wish to cease production operation, deactivate the Production
mode. To do this, click on the Production entry in the Project menu.
The tick next to the Production entry will then disappear.

6.4
Exercise: Planning,
simulation and evaluation
of the production of a
deskset
Exercise Create a production line for the production of a deskset with the part
number 52675. The deskset is made of aluminium and includes a
thermometer, an hygrometer and a penholder and pen. Depending on
which workpieces are available in the automated warehouse, either the
deskset can be assembled only or the starting workpieces can be
produced and used in a second step to assemble a deskset. Simulate
production with a test run and analyse the production process.
Answer the following questions:
• What starting workpieces are taken from the automated warehouse?
• What workpieces are held in stock locally in the assembly station?
• How great is the depth of production?
• Look at the definition of the production process for the deskset with
part number 52675 in the production database. Compare this with
your observations of the production simulation.

Method 1. The deskset with the part number 52675 consists of an aluminium
baseplate with a slight rounding. The penholder is also made of
aluminium and has 5 slots.
The processing steps for the deskset are as follows:
– Milling the baseplate from a blank.
– Lathe-turning the required number of slots in the penholder blank.
– Assembling a deskset from a baseplate, penholder, thermometer,
hygrometer and pen.
2. The production line for the deskset must include the following
automation stations:
– A conveyor belt, e.g. Transport 6
– An automated warehouse, e.g. Stock
– A CNC milling machine, e.g. Mill 55
– A CNC lathe, e.g. Turn 55
– An assembly station, e.g. Assembly RV-1A.
3. Create the production line for the deskset in the program section
Factory Simulation.
To do this, create a new production line with the name
Proj_Deskset.

4. Ensure that the Edit mode is active and that the library is being
displayed. Use the elements in the library to create the desired
production line. Connect the stations to the conveyor belt using the
appropriate coupling points.
5. Leave the Edit mode. To do this, activate the entry Edit mode in the
Execute menu. The tick next to the entry Edit mode will disappear.

6. Generate an appropriate 3D representation of the production line.

Select, for example, the command Standard/Default Settings in the
View menu.
7. Create the plant and the associated XML interchange file for the
production control system. To do this, click on the entry Create Plant
in the Execute menu.
8. Now start the program section Factory Control ProjectStudio.

9. Activate the command Import Plant in the menu

Extras\ProjectStudio. Change to the Projects directory and select
the required file. The data for the structure of the production line
will be read in.
10. After the command Import Plant has been executed, the production
control system will have data on the graphical structure of the
production line.
11. Now activate the Setup mode. To do this, select the Setup command
You can create and modify project elements of the production
control system only when the Setup mode is active.
12. Create a production control system for the production line. To do
this, click on the Create Project command in the
Extras/ProjectStudio menu.

13. The production control system for the production line has now been
created. You can recognise this by the new entries in the Project
window.
14. Start the Production mode in order to produce the desired deskset.
To do this, select the Production command in the Project command.


open automatically.
16. A ready-prepared production order is offered for a deskset with the

part number 52675. Click on the Deskset button to initiate the
production of the desired deskset.

17. Analyse the production process either in the Factory Control

visualisation window or in the Factory Simulation 3D display.
Result:
– The baseplate is taken from the automated warehouse as the first
starting workpiece and laid on the conveyor belt.
– Next, the penholder and pallet are taken from the automated
warehouse as the second starting workpiece and laid on the
conveyor.
– The Station Assembly robot accepts the baseplate and pallet and
sets this down at buffer location 1.
– The Station Assembly robot accepts the penholder and pallet and
sets this down at buffer location 2.
– The robot transfers the baseplate to the assembly location.
– The workpieces “Thermometer”, “Hygrometer” and “pen” are in
stock locallyin the Station Assembly.
– The robot fits a thermometer to the first hole
– The robot fits an hygrometer to the second hole.
– The robot fits a penholder to the third hole.
– The robot fits a pen to the penholder.
– The robot sets the deskset back down on the empty pallet at buffer
location 1.
– The robot sets the pallet with the assembled deskset down on the
conveyor belt.
– The robot sets the empty pallet used for the penholder down on
the conveyor belt.
– The deskset is transferred into the warehouse.
– The empty pallet used for the penholder is transferred into the
warehouse.
18. Continue to produce desksets until the stocks of starting workpieces
in the warehouse run out. Then observe the production process.
Result:
– In response to demand, the missing workpiece is produced and
transferred to the warehouse.
– In the next step, the newly-produced starting workpiece is fed to
the Assembly Station.
This type of production is also called single-stage production.

19. Now look at the description of the production process in the

production database. To do this, click on the Database button in
order to open the iCIM Production Manager.

20. Click on the Production Data button. The production process for the
selected product will be displayed.
21. Select the part number 52675 from the list of part numbers. You will
see the associated production process.
– The deskset is produced by the station class Festo Assembly
Station.
– Any machine of this class is to be used. This is why the entry
Resource Class is selected under Resource Type
– The deskset is produced by the macro process task AsmDeskSet.
– “ParallelTwo” is entered as the transport strategy. This means that
two starting workpieces at a time are fed from the automated
warehouse.
– Starting workpiece 1 from warehouse: Baseplate on pallet with

part number42143.
– Starting workpiece 2 from warehouse: Penholder on pallet with
part number 42104.
– Locally-stored starting workpiece 1: Thermometer with part
number 30000.
– Locally-stored starting workpiece 2: Hygrometer with part number
30001.
– Locally-stored starting workpiece 3: Pen with part number 30100.
– No CNC programs are required.
22. The production process is the formal description of the operations

which you can observe during production.


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COSIMIR® T

The copying, distribution and utilization of this document as well as the

1. What information will you find in this manual?_____________ 5

2. How to install COSIMIR® Factory ________________________ 8

2.1 System requirements _________________________________ 8

workstation licence __________________________________ 9

3. The COSIMIR® Factory system _________________________ 16

3.1 Overview of COSIMIR® Factory ________________________ 16

3.2 A production line in COSIMIR® Factory __________________ 23

3.3 Production control in COSIMIR® Factory _________________ 25

3.4 The structure of a project in COSIMIR® Factory ___________ 33 T

3.5 The pre-assembled automation stations ________________ 44

4. The most important operator functions of

4.1 Modelling a new production line _______________________ 63

© Festo Didactic GmbH & Co. KG • 548588 3

4.11 Executing and monitoring the order list for

5.1 Learning contents and learning objectives ______________ 298

5.5 Learning scenarios for COSIMIR® Factory _______________ 303

6. Example: Planning and simulating the

4 © Festo Didactic GmbH & Co. KG • 548588

What is COSIMIR® Factory?

COSIMIR® Factory is a PC-based graphical 3D simulation system which

offers an introduction to computer-integrated manufacturing.

• model production lines of differing degrees of complexity,

acquire comprehensive knowledge and experience of CIM plants.

The simulated production lines are also available as real iCIM

The expansion module makes it possible to control corresponding real

Target group This manual is aimed at

© Festo Didactic GmbH & Co. KG • 548588 5

• Chapters 3 and 4 describe the system and the main operator

• Chapter 5 deals with didactic matters. It lists the material taught by

possible uses in teaching.

Bold Bold type is used for command names, menu

Key 1 – key 2 A minus sign (-)between the key names

6 © Festo Didactic GmbH & Co. KG • 548588

COSIMIR® Assistant provides detailed functional descriptions and

technical documentation on the individual automation stations. Each

Supplementary information on programming production control

manual. COSIMIR® Assistant includes electronic versions of this manual

and the COSIMIR® Factory manual.

You need to have Adobe Acrobat Reader installed on your PC in order to

Factory, our telephone hot line is open to you at all times.

© Festo Didactic GmbH & Co. KG • 548588 7

COSIMIR® Factory is supplied as a CD-ROM, a USB dongle, a copy of this

instruction manual and a copy of a further manual with information on

Processor Pentium IV 1 GHz processor or better

Spare hard disk 800 MB

Operating system Windows 2000/XP; Microsoft Internet

Graphics card Card with 3D booster and OpenGL

Monitor 17“ with screen resolution 1024 x 768

Interfaces USB interface for dongle

Additionally Adobe Acrobat Reader version 6.0 or later

8 © Festo Didactic GmbH & Co. KG • 548588

workstation licence, operated on precisely one PC, to which the dongle

various type of PC workstations.

This is how to install the software under a single workstation licence.

1. Switch on your PC and launch Microsoft Windows.

3. Click on Run in the Start menu.

© Festo Didactic GmbH & Co. KG • 548588 9

6. Follow the instructions on the screen. Click on the Next button to

7. Familiarise yourself with the Festo Didactic licence conditions. You

10 © Festo Didactic GmbH & Co. KG • 548588

8. Now define the directory in which COSIMIR® Factory is to be