Priced from: $3,290

Visual Display and Performance Management Tool

The all-new XL800 lean manufacturing tool is the ultimate plant floor productivity tool. By combining large ultra-bright displays with on-board data collection and integrated Ethernet communications, we've developed a powerful productivity enhancing tool that delivers critical real-time data to all levels of your enterprise – all in a single, highly-integrated package. Imagine your choice of 100+ real-time process variables viewed on the plant floor and at your PC via a simple web browser. Think of it as your personal production assistant (that never goes home).

• Create exceptional process involvement
• Eliminate unplanned down time and recover lost capacity
• Inform, alert and motivate employees!

A tremendous amount of production-focused intelligence and utility has been designed into the XL800 lean manufacturing tool. What used to take a tangle of expensive PLCs, difficult to maintain software and custom programming is now a thing of the past. The XL800 lean manufacturing tool is simple to install, easy to understand and fast to show results!

Standard Features

• Ultra-bright low-power LEDs
• Dynamic pixel effects (e.g. sparkle)
• Ready-to-use graphics library
• Up to 1,000 messages and graphics
• Six programmable inputs
• Integrated SPDT form C relay output
• Optional expansion I/O cards
• 10/100 Ethernet, RS-232, and RS-485

• 100+ real-time process variables
• 8 production monitor modules
• Automatic run/down detection
• Real-time OEE calculations
• 32 programmable setpoints
• Time scheduler w/real-time clock
• FREE expert technical support

Typical Applications

The XL800 lean manufacturing tool is an extremely powerful visual display with literally limitless configurations. Any of the 100+ process variables can be combined with messages and/or graphics on the four available data field sizes to develop a display that fits your specific needs. Because the extreme flexibility of the XL800 lean manufacturing tool there are no hard display configurations – consider it your open canvas.

The following represents a brief list of popular applications:

Focus On	Description
Key Performance Indicators (KPI)	This configuration (shown above) was developed to show all critical process information at a glance. Operators and supervisory staff alike receive real-time production data that informs, alerts and motivates. Production issues that can potentially sap productivity are now addressed immediately.
Production Data with Integrated Call System	In addition to real-time production data, this configuration utilizes the Program Executioner feature to post a “call for help” message on the bottom line of the display. Maintenance, Supervisor, QC, and Setup messages are displayed at the touch of a button. A Response Time is also displayed to show how long the line has been waiting for assistance.
Long Takt Time Production Pacing Tool	The goal of this display was to involve line operators by giving them responsibility for producing a quality product in a long takt time environment. A Daily Goal, a takt-based Target Count, an Actual Count, a count down Takt Timer and the Time of Day combine to provide all the information needed to establish accountability.
Critical Cycle Time	This configuration displays the takt-based Target Count, an Actual Count, the Average Cycle Time and the Last Cycle Time in environments where it is critical to meet production goals. Displayed variables are shown in green when on pace or red when the line is falling behind and flash when supervisory intervention is required.
OEE Plus	OEE is the main focus of this configuration with underlying variables exposed to enable operators to have a positive effect on the outcome. Displayed variables: Good, Reject, Cycle, Run Time, Down Time, Standby Time, OEE %, Availability, Performance, Quality with an area of the display dedicated to scrolling daily motivational messages.

See the XL800 lean manufacturing tool in action via our live webcam

Product Description

The XL800 lean manufacturing tool is an incredibly flexible power-packed platform that integrates six products for the price of one display:

• Visual Display that informs, motivates and enables
• Production Monitor with plug-and-play simplicity
• I/O Processor that's programmable and expandable
• Communication Hub with Ethernet, RS-232, and RS-485
• Program Executioner with point-and-click configuration
• Data Warehouse with hundreds of data registers

Visual Display

Ultra-bright LEDs provide twelve vibrant colors and shades. Outstanding brightness, an exceptional viewing angle and anti-glare lensing ensure crisp clear viewing across the factory floor!

Dynamically partition the screen into up to sixteen independent regions, each of which hosts its own visual control. Controls include Text Boxes, Variable Boxes, Image Areas and more. Link real-time data into attractively formatted messages that automatically respond to plant-floor events (e.g. a line going down).

An extensive graphics library designed for plant floor applications is standard. Virtual animation effects include flash, sparkle, and color roll, while pixel shading adds detail and realism to images. Over 100 professionally designed fonts make it easy to produce attractive messages that command attention.

Integrated Production Monitoring

One of the many innovative features of the XL800 lean manufacturing tool is the fully integrated real-time production monitor. Eight built in modules provide out-of-the-box focused data to help you understand and manage your production. Integration couldn't be easier. Add one or two sensors and you get a wealth of information! And it's scalable. Each item you add returns more data.

You Provide…	You Get…
One Sensor	Total Pieces, OEE Availability Current and Average Rate Cycle Time, Last Cycle, Average Cycle Run Time, Event Run Time Down Time, Event Down Time, Pieces to Goal
Second Sensor	Good/Reject Pieces, OEE Quality Good/Reject Percent, Good/Reject Rates
Takt Time	Target Count, Takt Timer Piece/Time Variance, Efficiency
Ideal Cycle Time	Target Cycle, OEE Performance Standard Cycles and Time Reduced Speed Cycles and Time Small Stop Cycles and Time
Goal Count	Pieces to Goal, Percent of Goal
Setup Switch	Setup Time, Event Setup Time
Time Schedule	Standby Time, Event Standby Time, Remaining Time (for breaks)

I/O Processor Features

Every XL800 lean manufacturing tool comes standard with six high-speed inputs and one relay output. Expand your I/O with a sixteen input expansion card and/or a six relay output card. Inputs can trigger internal counters, process timers or programs. Programs also let inputs act as “soft buttons” that change the operation of the display based on conditions that you define (e.g. a break on-the-fly button).

Relay outputs are for annunciation only, and are not designed or intended for control applications.

Three concurrent communication ports provide multiple options for reading and writing data to the XL800 lean manufacturing tool:

• 10/100 Ethernet (for the ultimate in data acquisition)
• RS-232 (single point connections to 57,600 bps)
• RS-485 (multiple point connections to 115,200 bps)

Program Executioner Features

A powerful set of commands allows you to “customize” your application by connecting triggers to programs. Triggers can be generated from inputs, setpoints, time schedules, com ports, production mode changes, etc. When a trigger is received, the associated program is executed.

Up to 1,000 programs can be created by simply stringing together predefined high-level commands to achieve your desired operation. There are dozens of commands available, including timer and relay control, numeric and string data manipulation, math operations, display screen control, and much more.

• Drive a stack light based on line speed or downtime
• Create a sixteen input counter
• Perform data conversions (e.g. Celsius to Fahrenheit)
• Create a maintenance call button with wait timer

Data Warehouse Features

A unified and structured data register architecture supports both numeric and textual data, making it particularly easy to acquire and track critical data. Hundreds of 32-bit signed numeric registers can be loaded with information from your PLCs, ERP system, and other sources. This data can be seamlessly reflected back via an embedded server for plant-wide viewing. The full set of process variables tracked by the XL800 lean manufacturing tool are also available for real-time data acquisition through any of the three communication ports.

Embedded Server

The XL Embedded Server provides instant access to production data for supervisors and managers—from anywhere in the world—with no software to install.

Plant floor data is viewable anywhere in the plant using a standard web browser.

Specifications

The following general specifications are standard for all XL Series products.

Item	Specification
High Speed Inputs	3-30 VDC Sink/Source
Relay Output	SPDT Rated 1A@ 120 VAC
Communication Ports	Ethernet 10/100 Serial RS-232 Serial RS-485
Rated LED Life	100,000 Hours Typical
Operating Temp. Range	0° to 55° C (32° to 122° F)
Humidity	0% to 95% Non-condensing
Power Requirements	90-230 VAC 50/60Hz

Dimensions and Weight

All XL800 displays share the same height and depth dimensions (13.7" H x 3.5" D).

Model	Dimensions	Weight
XL800-32080	13.7" H x 26.2" W x 3.5" D	17 lb
XL800-32120	13.7" H x 38.2" W x 3.5" D	25 lb
XL800-32160	13.7" H x 50.2" W x 3.5" D	33 lb
XL800-32240	13.7" H x 74.2" W x 3.5" D	50 lb

How to Order

XL800-ABC Example: XL800-32160T

Key	Description	Choices
A	Data Field Height	32 = 32 Pixels
B	Data Field Width	080 = 80 Pixels 120 = 120 Pixels 160 = 160 Pixels 240 = 240 Pixels
C	Display Color	R = Red LED (future availability) T = Tri-Color LED Digits