Overall Equipment Effectiveness (OEE) Application to Maximize Productivity on a Production Filling Line
The harsh nature of the production environment,which experiences strong vibration, extreme temperatures & wet and dirty conditions, meant that it was difficult to install automated equipment to detect failures, record information or transmit it to management.
- UNO-2372G: Intel Atom/Celeron Small-Size Modular Box Platform with 2 GbE,4 USB, 4 COM, 2 x mPCIe, HDMI, DP
- AIM -35: 8" Industrial-grade tablet / mobile POS system
- WISE-4051: 8-ch Digital Input IoT Wireless I/O Module with RS-485 Port
The oil manufacturer wanted to be able to automatically record assorted production data along the production line. A hardware device (controller) needed to be developed which would be placed directly at the filling line, where PLCs are installed, to capture production data. An industrial grade Wireless-LAN infrastructure also needed to be developed and deployed for the system to connect. The production data needed to be accessible to the managers, requiring a web-based dashboard for managers to review and analyse data.CGI and Advantech proposed an end-to-end solution to monitor the production line, identify faults and report on them as they occur, enable simplified and guided reporting by machine operators, and automatically update a management dashboard with pertinent information.The dashboard aggregates and displays the critical information managers use to plan production changes, plan maintenance and to help identify reliability problems. Dashboard widgets allow flexible visualization and easy customization deliver optimal views depending upon manager roles and priorities. CGI designed the dashboard to provide continuous real-time information on status together with instantaneous alarms when failures occur. While the dashboard is presented in management offices, and can run on any browser-based computer, the data itself is collected and processed directly from the harsh environment of the factory floor.
For the production environment, CGI and Advantech selected the UNO-2372G as the main computer and dashboard server for its rugged, fanless and modular design. The UNO will support cellular connection allowing global implementation,however the initial deployment operates on-premise at the primary site. It monitors the production processes and machine PLCs which enables reporting while the factory operates correctly.The status of machines on the production line is monitored by an Advantech WISE module, the WISE-4051, leveraging its time stamped data logging capability to ensure precise recording of failure data, enabling accurate down stream interpretation, analysis and problem resolution.Finally, the machine operator is not left out. Instead of the wasteful and inaccurate paper system, the solution uses the Advantech AIM -35 rugged tablet. CGI built a dedicated interface that allows the operator to simply enter the pre-defined failure modes which correlate with the time stamp from the WISE and the production information collected by the UNO. The solution further correlates failure timestamps with the affected production orders, working shifts and the failed machines automatically. Downtimes are shown instantly on the CGI web-based dashboard. Managers can identify major downtime causes in real time and respond immediately to get machines up and running, resulting in higher overall productivity.Managers can also review and analyse historical data to make better informed decisions about production efficiency and machine health. Monitoring machine downtimes for a period of time, allows managers to derive information such as the top 5 downtime causes, overall equipment effectiveness, live machine performance, predictions, production orders affected,and on-time production achievement. Root-cause analysis provides a better understanding of why technical failures are occurring and how best to minimize machine downtime in the future.