Process > Plant Maintenance | Automation World

Chris Hough, ProMach/ZPI

OMAC Tackles Machine, Operator Efficiency

Providing updates at the Automation World Conference & Expo, group leaders outline efforts to provide guidance on line-level OEE implementation and machine interface standards.

Polytron’s PolySim three-dimensional animated simulation was on display at ProFood Tech, demonstrating the following real-world case study. A well-known global consumer goods manufacturer had several bottling lines that were underperforming. There was pressure to make upgrades and improvements in order to meet KPIs; mitigate investment risk; and meet growing market demand. Lines needed to operate more efficiently and profitably. The company's goal was always clear: Increase production by 50 percent. They decided to pilot some changes on one line before universally reconfiguring the others. Fixated on the wrong issue Prior to Polytron’s engagement with this company—and fixated on line speed and throughput—the client determined that one of the machines on the line needed to be replaced as the culprit of poor performance and limited capacity. The new machine had the capacity to run at 300 bpm when coupled with improved bottle handling, but would that be enough to get them to the output goal? Without clar

Line Simulation IDs OEE Improvement Opportunity

Polytron used its platform at ProFood Tech to demonstrate a case in which OEE metrics were improved in a real-word bottling application.

Daimler’s truck assembly plant includes 1,500 ft chassis assembly lines with more than 125 workstations on each.

Data Foundation Helps Daimler Trucks Improve OEE

The maker of large-duty trucks like Freightliner and Western Star brands overhauled downtime issues on its long assembly lines with the implementation of SCADA and MES platforms.

Artificial Intelligence Makes Its Way Inside Machines

Artificial Intelligence Makes Its Way Inside Machines

Omron unveils a controller that executes machine learning to perform predictive maintenance.

Engineering a Digital Transformation

Engineering a Digital Transformation

L&T Technology Services rolls out “Factory D.0,” a set of technology and engineering services designed to help manufacturers identify areas within the organization that will benefit the most from digitalization.

Frank Latino, Festo

Pneumatics in the Age of IIoT

Using Industrial Internet of Things pneumatic solutions to improve OEE, energy efficiency and agile manufacturing.

Discover the Secrets of a Successful Automation Project

Discover the Secrets of a Successful Automation Project

Learn about planning and project management, building your machine or automated system, and technologies to improve manufacturing outcomes. Automation World’s free resource features 150 pages on managing automation projects from start to finish.

Amway’s Rob Dargie details the OpX Leadership Network’s remote equipment access tool.

OpX Tools Help Manufacturers Improve Operational Excellence

Detailing existing and upcoming tools available free through the OpX Leadership Network, industry experts explained how they can make your entire operations run more efficiently.

At work centers, operators can add from a defined list of codes to indicate the root cause of downtime.

Real-Time Monitoring for Sheet Metal Machines

To help its manufacturing customers integrate OEE measurements with enterprise systems, The Aquila Group has implemented data visibility systems with Opto 22 platforms.

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Packaging and Processing OEMs Continue on Digital Path

As digitization of the factory catches on, automation continues to be a focus, says PMMI Business Intelligence.

At Rockline Industries’ Wisconsin plant, these lines include slitting, filling, capping and labeling machines, along with conveyors to move product along to different stations.

Digital Transformation Begins With Real-Time Monitoring

An industrial packaging company invests in real-time KPI software to push its overall equipment effectiveness levels for its Wisconsin plant.

Inside the OpX Leadership Network: Benefits and Best Practices

Inside the OpX Leadership Network: Benefits and Best Practices

The second in a two-part series showcases feedback from companies that have used OpX Leadership Network tools, explaining benefits and suggested uses.

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Food Processors Measure Equipment Efficiency

And they look to OEMs for any improvement in machines to maximize uptime and increase yields, according to a new study from PMMI Business Intelligence.

As chair of the OpX Leadership Network Executive Council, Greg Flickinger sees an opportunity to advance the operational excellence of not just a single company, but of an entire industry.

Inside the OpX Leadership Network: Tools and Checklists

In our first of two installments on PMMI’s OpX Leadership Network and the value it provides to companies of all types, we explain four free tools and checklists that save manufacturers time and money.

Analytics for OEMs

Analytics for OEMs

Rockwell Automation is getting ready to roll out FactoryTalk Analytics for Machines, a cloud-based subscription service offering OEMs visibility into their systems deployed at customer sites around the world.

Pharma end users recommend improvements from OEMs

Pharma Packaging Machinery Buyers Turn to Automation to Deliver Increased Uptime

OEE, for the past several years, has not been a major focus for pharma packagers like it has been for their peers in food and beverage. A study by PMMI Business Intelligence shows the times are changing.

In 2012, an international food company saw a significant decrease in downtime and increased a single line’s production to 4.8 million cans per year using TrakSYS OEE and manufacturing operations management software. Their results are displayed in this chart.

OEE: A Management Strategy

Overall equipment effectiveness is most often seen as a tool for use in production operations. However, it is increasingly viewed as a strategic management tool for continuous improvement and connecting the enterprise to the plant floor.

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Earning the Data

With data collection, start simple and then build on that foundation.

Screenshot of GE Digital's Plant Pulse Optimizer

Using Visualization to Close the Performance Gap

As the focus on plant optimization via device and system data increases, a higher level of attention is being paid to data visualization to better direct process improvement efforts.

Figure 1: Mitsubishi Electric’s AX Facility Visualization software can detect folks and display probable causes (top). It can also display fault frequency (bottom) and combine it with cost information to enable users to prioritize predictive maintenance.

Getting to the Heart of Improvement Opportunities with Visualization

Cut Energy Costs With Real-Time Feedback

Figure 1: Connecting a shop floor network to a manufacturing execution system (MES) using a gateway PC and conventional communications protocols requires custom code to perform multiple interim steps. Substituting an event-driven appliance like Mitsubishi Electric’s MES Interface IT eliminates multiple steps and makes the system more resilient in the face of change.

Connectivity’s Role in Improving Factory Management

MES Interface Brings Shop Floor to Top Floor

Figure 1: Mitsubishi’s High-Speed Data Logger samples data at 1-ms intervals, making it easier to study anomalous behavior.

A Data Strategy to Maximize Performance

Comprehensive data capture is the first step in developing full factory visibility for improved overall equipment effectiveness.