In today’s global economy, manufacturing industries cannot gamble becoming ineffective and incompetent. The production reality in today’s increasingly competitive world claims competence and quality with endless and bettered processes. It is carping to reduce the production costs, strengthen production line and machine use and adaptability to improve not only product quality but services as well. Any production company with a successful growing business, may be quite satisfied with their results. But, how much they really know about the operational efficiency of their factory. How can they improve their production capacity without any data?. Hence, in order to achieve first-rate production efficiency, production monitoring is decisive. But, the traditional approach of OEE manufacturing & machine monitoring system lacks its ability because it is expensive to apply, has lots of hurdles in data sharing, imperfect integration with other systems, and provides more security threats as well. To overcome these challenges and to achieve a successful transition to Industry 4.0, manufacturing industries should adopt the latest technologies that can incorporate obsolete systems with recent systems. Here comes the MQTT protocol which has its own critical features in solving all the industrial challenges with the Pace DPR. Let us see how we can link the different levels of the shop floor in a manufacturing industry & automate them with MQTT broker over Pace DPR.
Key Issues in Traditional Production Management
Data Silos : Present day Industries often have machinery from a broad range of suppliers that generate data in unique formats which gives rise to data silos. This becomes the barrier for wide survey & decision-making across the whole industrial operations.
Lacking visibility : Deep visibility into the individual asset’s performance is lacking in the traditional SCADA systems and it is restricted to the shop floor. Assets can’t be managed anywhere, any time because the machines / equipment data can be viewed & accessed only inside the plant.
Network Latency : The connection between the industrial equipment & the production management should be highly available. When the connection fails unexpectedly in low bandwidth scenarios, it will cause severe damage to the equipment.
Security Threats : Industrial tracking & visibility is necessary for industrial manufacturing. Some Industries are monitoring data by connecting every user’s mobile phone to the mod bus interface on the individual monitoring console. This mandated the professional to be near every production control dashboard to view the status. Besides that, security issues will prevent them from connecting the mod bus protocol directly to the internet.
Connecting the Industry with MQTT
The Pace DPR is well adapted to address the issues mentioned above, and it serves as a quantitative tool for determining productivity within an industry. The Pace DPR is built over our broker which is with MQTT protocol. MQTT has an attribute, Last Will & Testament which permits any application to trigger a message when there is an unexpected disconnection between devices & server. For example, considering a scenario for manufacturing use cases, when a manufacturing equipment fails, then the entire production line will be instructed immediately to take action in order to prevent equipment damage. This enables monitoring of manufacturing equipment, SCADA networks, sensor devices, and scenarios involving low bandwidth, such as radio and cellular networks.
When it comes to data silos, one common server/platform which can break down the data silos that exist at different levels of automation is necessary. This can be reliably done by MQTT Broker which uses MQTT protocol for communicating reliably between devices thus avoiding unwanted data silos. And also, security threats arise when the equipment is directly connected to the internet. Hence, the solution should be connecting the production line with multiple equipment in one server & making it available in a more secured way. In that case, MQTTRoute comes with a device level auth and TLS/SSL to make secure connection between the gateway and MQTT broker. And also, the Mod bus MQTT Gateway that comes as part of the Bevywise IOT Solution collects all data from production line and send it to the Central MQTT Broker. In addition, the Mobile app can be connected to the MQTTRoute and the data generated can be monitored using the collected data.
Over the past few months, we were building products / solutions for Manufacturing Industry above our MQTT Broker. Our focus was to enable manufacturing Industries to connect their machinery in a reliable and scalable manner using MQTT. One such ready to deploy solution is Pace DPR, the production / machine monitoring system. This IIoT application will automate the complete data collection, analysis and decision making process of manufacturing industry.
Why MQTT is used in production management system?
MQTT is a global standard for connecting devices that is getting momentum in smart manufacturing and Industry 4.0. MQTT clients, as we all know, send data to a central MQTT server/broker, from which it is distributed to clients who have subscribed. Consider the case where MQTT clients are manufacturing machines, peculiar sensors, SCADA systems, or MES, among other things. MQTT enables for bi-directional messaging and the transfer of measured data from machines to the cloud. ERP/other systems, such as SCADA, can also create a command to be delivered throughout the shop floor if they are integrated. All client connections and subscribed topics for each client will be tracked by the central MQTT broker/server. As a result, MQTT may be utilised more safely in the manufacturing industry for data exchange between machines and the entire production line.
Thus, the reliability and scalability of MQTT made us to build a production management system over MQTT Broker.
A little on Pace DPR : MQTT Platform for smart manufacturing
Bevywise MQTTRoute is a profoundly extendable, adaptable, and versatile MQTT Broker utilized for gathering information from IoT edge devices in which it is easy to transfer data to and from associated machines / equipments in a dependable and quick way. Hence we have built Daily production monitor, Pace DPR over MQTTRoute for OEE manufacturing industry as part of one of MES initiatives. This production monitoring solution built using MQTT will ease the production managers to analyze and improve OEE score & can help them make a necessary change in their manufacturing operation process that leads to the big improvements on the production floor. Let us see the overall equipment analysis below:
OEE – Overall equipment effectiveness analysis: This stage determines the manufacturing machine’s OEE value, which is used to estimate the complete effectiveness of the equipment’s performance in carrying out a specified task, based on actual data on availability, performance, and quality. It determines the amount of manufacturing time that is truly productive. OEE is a measure that calculate OEE values for total units in the manufacturing industry. The OEE values are calculated after the three parameters have been measured.
Availability analysis: The value of the three components that are needed to estimate the value of total equipment efficiency are directly related to availability (OEE). The availability of time for machine manufacturing tasks is defined.
Performance analysis: The efficiency of a machine’s performance in carrying out the production process is measured by its performance. The amount of production and the optimum run time of the operating process are used to calculate speed losses, which describes how the engine’s 100 performance is dependent on the amount of planned production time and the ideal cycle time of the operating process.
Quality Analysis: A Quality score is a comparison of the number of good parts versus the number of rejects, or it describes the equipment’s ability to generate items that meet the criteria. Quality concerns quality losses, such as the number of damaged products associated with equipment, which is then transformed into time by determining how much time the equipment is utilised to manufacture the damaged product.
By providing data on KPIs that tied up with the real-time status of your shop floor, which makes this machine monitoring system an extremely useful tool for improving productivity. Performing analysis with the shift based cumulative reports & hourly production reports, will uncover areas to improve OEE manufacturing by connecting dots & eliminating the gap between machine performance & its efficiency. This boosts the preventive maintenance of assets by tracking & monitoring machines at individual level which allows operators to see when & where the flaws in the production line occurs. The real-time data on OEE & production is just a number unless it is turned into an excellent insight & action. This will help you turn the obtained data into actionable insights and make necessary decisions on improving manufacturing productivity. The loss analysis will gather information so that OEE measures may be analysed to track performance decline. This could take the form of data collection for a specific time period in which you’ve established a performance benchmark. If you have the data to improve world class OEE, especially through the use of IIoT-enabled devices, you should use every opportunity to boost your company’s success.
During the development of this IIoT application, we came to know that broker is doing its core part right with the Pace DPR and that’s why we are able to build such a best production / machine monitoring system that can address all the challenges, a manufacturing company meets.
Many manufacturing companies are beginning to deploy production monitoring solutions in their shop floor to achieve greater efficiency and flexibility. Several factors favour use of MQTT as the standard protocol for modernizing the messaging framework of an Industry. Due to the performance scaling capabilities of MQTTRoute, Pace DPR as a production management system is well suited to provide an accurate picture of overall production operation in manufacturing Industry.
Moreover, our recent update on MQTTRoute that transforms MQTT Broker into an IoT application framework will help you build a complete industry 4.0 application faster with much ease.
Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.
Also read – Building Fleet Management with MQTT Broker