Are You Collecting Enough Data?
Does the data from the machines on your shop floor answer the top 3 questions?
Improved data collection leads to more valuable insights. Data is collected with cameras, sensors, and PLCs. It is important to get visibility into your line at the right locations, so data is complete and meaningful.
Here we are using an example two-piece can making line and discussing:
First, you need to know where there is already visibility into your line. Where are your sensors?
In this example, the line is currently running with only 2 sensors (the green dots). What would be the benefit of adding 15 additional sensors, or even 20 additional sensors?
NOTE: One complication is the wider conveyors that could be conveying many cans in a row. Traditional sensing methods cannot be utilized effectively in these areas; therefore, a more complex sensing method, such as vision cameras, may be required. Or, a simpler option is to track infeed and discharge per machine immediately before and after wider conveyors.
With the sensors collecting data, here are some of the attributes which can be monitored.
Cupperproduction and spoilageinfeed count stroke count low speed loss spoilage count spoilage percentage discharge count machine status and efficiencynormal speed time faulted time standby infeed time (starved) standby backup time (blocked) low speed time production efficiency percentage run efficiency percentage process variablesmachine speed (parts/minute) trend machine strokes (strokes/minute) trend current coil id coil usage tonnage lube system status cup jams die jams | Bodymaker/Trimmerproduction and spoilageinfeed count short can/tear off count low speed loss spoilage count spoilage percentage discharge count camera spoilage % (if traceability between bm and camera) machine status and efficiencynormal speed time faulted time manual stop time standby infeed time (starved) standby backup time (blocked) low speed time production efficiency percentage run efficiency percentage process variablesmachine speed (parts/minute) trend bm vs trimmer faults over travel oil consumption
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With this information, the questions asked at the beginning of this article can be answered with confidence.
The Acumence Team Can Help!Do you need someone to guide you in this process? The Acumence team can help! We will make recommendations on achieving critical visibility or complete visibility, explaining the difference in upfront cost, verse potential process improvements. Contact the Acumence Team to have a free conversation about opportunities to achieve high levels of operational excellence by detecting, analyzing, and eliminating production losses. CLICK HERE TO CONTACT THE ACUMENCE TEAM.
What is Acumence?People and software that help can manufacturers create less spoilage and increase production. Acumence by Flexware is designed explicitly for high-speed processes and can help manufacturers achieve operational excellence by detecting, analyzing, and eliminating production losses. Providing actionable information through real-time views and historical metrics, Acumence makes it possible for users to identify and avoid losses in performance while maintaining production activities through customizable dashboard experiences that can be tailored to customer preferences. |