INDUSTRY 4.0

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Internet Of Things(IoT) Applications For:

  • Machine to Machine Communication

  • Energy Management

  • In Logistic and Transfer Systems

 

Online OEE: Overall Equipment Effectiveness:

  • Why the Preferred OEE Calculation?

    OEE scores provide a very valuable insight – an accurate picture of how effectively your manufacturing process is running. And, it makes it easy to track improvements in that process over time.

    What your OEE score doesn’t provide is any insights as to the underlying causes of lost productivity. This is the role of Availability, Performance, and Quality.

    In the preferred calculation you get the best of both worlds. A single number that captures how well you are doing (OEE) and three numbers that capture the fundamental nature of your losses (Availability, Performance, and Quality).

MES: Manufacturing Execution System

Scope of MES:

  • Management of product definitions. This may include storage, version control and exchange with other systems of master data like product production rules, bill of material, bill of resources, process set points and recipe data all focused on defining how to make a product. Management of product definitions can be part of Product lifecycle management.

  • Management of resources. This may include registration, exchange and analysis of resource information, aiming to prepare and execute production orders with resources of the right capabilities and availability.

  • Scheduling (production processes). These activities determine the production schedule as a collection of work orders to meet the production requirements, typically received from Enterprise resource planning or specialized Advanced planning and scheduling systems, making optimal use of local resources.

  • Dispatching production orders. Depending on the type of production processes this may include further distribution of batches, runs and work orders, issuing these to work centers and adjustment to unanticipated conditions.

  • Execution of production orders. Although actual execution is done by Process control systems, an MES may perform checks on resources and inform other systems about the progress of production processes.

  • Collection of production data. This includes collection, storage and exchange of process data, equipment status, material lot information and production logs in either a data historian or relational database.

  • Production performance analysis. Create useful information out of the raw collected data about the current status of production, like Work In Progress (WIP) overviews, and the production performance of the past period like the Overall Equipment Effectiveness or any other Performance indicator.

  • Production Track & Trace. Registration and retrieval of related information in order to present a complete history of lots, orders or equipment (particularly important in health related productions, e.g. pharmaceuticals).

  • The Digitizing of the complete data from the log books into the web/tablet interface with the edit lock feature and also pulling the data from the SCADA into the common databank.

  • The Audit Interface which helps in the evaluation of the utility performance like the direct / indirect efficiency of the boiler in the runtime, cooling tower effectiveness in the runtime which is possible only if we are able integrate the complete data from the log books and the SCADA System.

Andon Systems in manufacturing and process operations

Andon is the Japanese term for a signalling system within a production process or plant. The Japanese use Andon systems as a communication tool to communicate the status of a production line or process to all production employees on the production floor. Andon systems are usually found in many forms, from simple status lights or traffic light systems to complete display boards in visible locations around the production plant. They are a common tool in the automotive and component production industry where they are an integral part of the Toyota Manufacturing system.
 

Andon signals and Andon board components:

- Production line status: producing, stopped, overload or idled
- Workstation status
- Production settings such as temperatures, pressures, weights, speeds, electricity or gas consumption etc
- Different times: current time, downtime, running period time
- Production volumes, working in progress (WIP) and products produced
- Call signs for supervisors and managers to a certain area
- Different production Key Performance Indicators (KPI's) or goals such as planned production.