Introduction to SmartFactory
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Transcript of Introduction to SmartFactory
Company OverviewWhat we do:
Capture, analyse and visualise key performance indicators from the factory floor, using smart Industrie 4.0 technology including:
• Wireless data acquisition• IoT Gateways and PLC integration• Downtime analytics and reporting software• Real-time data visualisation• Business Process Automation (workflow digitisation, QMS, training
management, CMMS)• RFID tracking & identification (asset management and optimisation)
Who we are:• Based in University of Limerick• Thorough understanding of
manufacturing processes gained over the past 20 years
• Experience in electronics, medical device, logistics, pharma and high-speed manufacturing industries
Some of our clients & partners:
Solution PartnerSolution Partner
What we do:
We integrate the best in class Data Acquisition, Analytics and Visualisation tools to:• Maximise Efficiency: Leverage data to optimise operations• Reduce downtime: Keep processes running longer with a better understanding of
equipment• Identify Hidden Losses: Many losses are not easily identified without downtime
data• Increase Productivity: Anticipate and avoid constraints before they become an
issue• Increase uptime and maximise asset utilisation: Implement asset management
and preventative maintenance software tools • Improve Accountability: Make real-time data visible and actionable to the right
people, in the right location, at the right time
Net Production
`-Scrap-Rework/Recycle-Overfilling`
``
-Not at Target Rate-Ramp-Up/Down-Minor Stops
-Breakdowns-Process Failures-Lack/Quality of Materials-Paperwork/QC Checks-Utility Failures-Operator Error
-Changeovers-Maintenance-Start-ups/Shutdown-Wash-downs-Sanitisation-Meetings-Training
Quality Loss
Rate Loss
Unplanned Downtime
Planned DowntimeCapa
city
Util
isatio
n
OEE
Loss
OEE Loss Analysis
Value Proposition – the value we deliver to the customer• We capture, analyse and visualise key performance indicators from
the manufacturing, logistics and utility sectors, using Industrie 4.0 technology
• Our smart solutions reduce the resources required to gather and communicate critical information across an organisation and dynamically translate this data into actionable intelligence
• Highlighting losses in real-time has been proven to change behaviour, improve throughput and quality and has been shown to improve overall productivity by 5-10%
• We help identify hidden losses, thus reducing planned and unplanned downtime, increasing productivity and maximising efficiency
• Our thorough understanding of manufacturing processes combined with expertise in IT systems and architecture allow us to successfully navigate the convergence of IT and OT for our clients
• We have a proven track record of delivering high value automation and data acquisition projects, for multinational companies, for more than 20 years
Business Process Automation with real-time data acquisition, analytics and visualisation - The SmartFactory
Manumatic data acquisition (MDES): Barcode, RFID, Modbus and OPC UA enabled rugged tablet PCs to communicate with stand-alone / legacy equipment and sensors
Smart Factory Software SolutionsHistorian – log time based process dataLine View OEE – Downtime AnalysisData Analytics – incl. Statistical Process Control (SPC)Process Optimisation – identifying variable inter-dependenciesReporting – customisable reporting solutionVisual Factory – Real-time Data VisualisationSecurity Management – Layered hardware & software solutions
Smart Factory Automation SolutionsSmart Wireless (IoT) devicesSensors, RFID, Barcode readers, Laser codersDrivesHMIs & Controllers (PLCs/DCSs)Cobots, Robots & AGVs
Example of OPC Foundation Membership
Level 3 – Manufacturing
Operations Management
Levels 1,2: Industrial
Automation
Process Architecture & the ISA Standards:
Drill down from Factory view
Live Downtime Viewer with video clips linked to downtime event
=> Line view => Machine view
Analysing and visualising production data in real-time has been proven to change behaviour, improve throughput and quality and has been shown to improve overall productivity by 5-10%.
Data Analytics: best-in-class, industry proven, out-of-the-box software solutions with video downtime analysis
Data Visualisation: reduce the resources required to communicate critical information and dynamically translate this data into actionable intelligence
• Display your choice of information in real-time, on any screen or device, in any part of your organisation
• Smart Digital Display technology makes your data visible and actionable to the right people, in the right location, at the right time
• Present real-time KPI dashboards to motivate staff and drive productivity• Promote safety with dynamic messages and videos• Emphasise corporate objectives• Integration with digital meeting room displays• Screen-saver replacement – display corporate information instead of “flying
logos”
Data Visualisation Engine
• Paperless processes and workflows• Quality management (QMS)• Training management• Production management• Dispatch and Shipping management• Planning and Scheduling
• Rapid deployment using Matrix Solution Wizard and web-based user interface• Full integration with existing ERP and Accounts system• Digital Daily Management System & Kaizen boards
Business Process Automation: convert manual paperwork into lean digital workflows
Industry proven software, developed for validated environments
Compliant
• Process engineers can spend 10-14hrs/wk, maintaining daily management boards
• Information is often out of date• Focus should be on understanding and resolving issues, not printing graphs• Customisable interface to match standards on-site• White-board interface for problem solving and “why-why” analysis• Can be used for “How-to” training videos and SOPs• Screen-saver linked to data visualisation system, to display real-time data
when screen not in use
Digital DMS screens: eliminate the wasteful effort of preparing and printing paper reports and digitise the daily management process
Compare what’s included in our turn-key solution…
Data Collection Smart Factory Business Process Automation Smart
FactoryWired data collection from any PLC, via OPC P Quality management (QMS)
(21CFR11 compliant) PWireless data collection from any equipment P Training management PManumatic data collection from manual or semi-manual processes P Preventive Maintenance CMMS
Software PHigh-speed Historian data collector and SQL database P Production management PHardware - Tough-tablets, Industrial PC's and Servers, mobile workstations
P Dispatch and Shipping management P
Industrial Communications (Industrial Ethernet, Industrial Wireless LAN, Switches, etc.)
P Planning and Scheduling PBarcode & RFID (complete solutions including Tags, Readers and Middleware)
P Convert any existing workflow from “Paper to glass” P
Downtime Analysis Operational ExcellenceDowntime analysis (OEE, MTBF, MTTR, virtually any KPI) P Digital Daily Management systems PDowntime video analysis (MP4 video clip of lead-up to downtime event)
P Scope definition workshops and Project Management services P
Data visualisation (any content, on any screen, from virtually any data-source, in real-time)
P Energy monitoring P
Business Process Automation: DXM100 Controller
The DXM100 Controller is an industrial wireless controller that was developed to facilitate Ethernet connectivity and Industrial Internet of Things (IIoT) applications.
Business Process Automation: DXM100 ControllerProductivity Solutions
• Pick to Light• Call for Parts & Service• Production line status & monitoring
Predictive Maintenance / Continuous Monitoring• Vibration/Temperature: Motor, Engine, Generator,
Pump, Conveyor, Lift, Compressor, Fan, Blower & Gear Box
• Machine Run-time and Cycle CountEnvironmental monitoring and control
• Manufacturing Processes: Food & Beverage, Packaging, Clean Room / Electronics manufacturing
• Supply Chain & Storage: In-transit Visibility, Distribution, Receiving & Shipping, Raw Materials & Finished Goods, Server Rooms