Bevywise IoT Application – Production Monitoring Solution using MQTT

Bevywise IoT Application – Production Monitoring Solution using MQTT

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 lessen 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 its 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 machine monitoring & machine monitoring system lacks its ability because it is expensive to apply, 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 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. Let us see how we can link the different levels of shop floor in a manufacturing industry & automate them with MQTT-based messaging framework.

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 assets’s performance is lacking in the traditional SCADA systems and it is restricted to the shop floor. Assets can’t be managed anywhere, anytime 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 phones to the modbus 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 modbus protocol directly to the internet.

Connecting the Industry with MQTT

The MQTT messaging protocol is well suited to address the above mentioned issues and it acts as a reliable messaging systems within a Industry. This is because 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. And also, MQTT has very low overhead in its protocol which makes it compatible to transmit data over low-bandwidth networks. 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 equipments 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 Modbus 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 in the internet and is becoming more & more popular within smart manufacturing and Industry 4.0.
The reason why production management projects can rely on MQTT as a messaging protocol is that its publish/subscribe framework. We all know that, MQTT clients will send data to a central MQTT server/broker from there the data will be transferred to the clients who subscribe. Consider the scenario in which the MQTT clients can be a manufacturing machines, a peculiar sensors, SCADA systems, or MES, etc. MQTT supports bi-directional messaging & it allows for measured data to be transferred from machinery to the cloud. And also, if integrated, ERP/other systems such as SCADA can create a command to be sent across the shop floor. The central MQTT broker/server will track all the client connections (equipments/sensors/other systems) and the subscribed topics for each of the clients. Hence, MQTT can be more reliably used in the manufacturing industry for exchanging data between the machinery & 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 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 & can help them make a necessary change in their manufacturing process that leads to the big improvements on the production floor. 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 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 decision on improving manufacturing productivity.

During the development of this IIoT application, we came to know that MQTTRoute is doing its core part right 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.

Conclusion

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.

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Unlock the True Potential of Predictive Maintenance in Manufacturing

Unlock the True Potential of Predictive Maintenance in Manufacturing

Manufacturing Industry is the fast growing industry which is expected to continue to grow in the next few years. However, there are some complex internal challenges every manufacturing is facing today. One such challenge which has a great impact in the Industry’s production line is Downtime. Each & every production & manufacturing sector faces machine failure & downtime practically every day. People may think that the machine repair / failure / breakdown is a normal occurrence in manufacturing industry. It’s just a bitter truth when people are handling with machinery that perform a repetitive task. However, it is essential to remember / note that every second of machine running earns money. Just think a while, if machine sits idle for a prolonged time. You can’t complete your order on time, lose your reputation & finally, there will be a drawback in ROI. No matter what the failure is, it can bring about delay in overhaul, dissatisfied customers, and potential losses with respect to productivity and income. Then what is the solution for this problem?? The answer is Predictive Maintenance. In this article, let us see how predictive maintenance in manufacturing industry allows manufacturers to lower maintenance costs, extend equipment life, reduce downtime.

What’s wrong in reactive maintenance?

Industries of today most probably work on a maintenance schedule. Alternatively stated that / that is to say, they hear suggestions from the equipment manufacturers with whom they schedule maintenance. However, the previously mentioned viewpoints are not up to the level as failures and breakdowns still do occur. Ultimately, this is unimaginable & no possible way that a manufacturer can foretell every circumstances, conditions, or technique of functioning.

Besides that, some industries follow reactive maintenance, this is when machines are serviced or repaired only when they actually fail or break down. This is even worse, which is more or like waiting for a failure to happen. There is a say that, While reactive maintenance can have a place in a well-rounded maintenance strategy, it shouldn’t be your go-to for all repairs. But this is not the case in this industrial competent world. That is reactive maintenance can no longer help manufacturers in any way. This is because the unpredictable nature of reactive maintenance does not keep systems running in optimal as a new condition. And also, there will be safety issues & waste of time in finding the fix & maintenance backlog.

Why Predictive maintenance is key?

The predictive maintenance is an operation wherein the maintenance demand and prerequisite of machinery in a production line / shop floor are forecasted. That is the machine failure will be predicted & fixed before it occurs. In contrast with reactive maintenance, predictive maintenance makes use of acquired data from each machine hinge on its normal pattern of operation or performance. Any tiny or precise variation or instability with the threshold data identified by sensors will fire up subsequent alerts so that production managers can reasonably anticipate the requisite for maintenance work. In such a way, any harm or issue remains isolated, so other parts remain unaffected, and total equipment failure is avoided. And also, when it comes to preserving the lifespan of machines, predictive maintenance is the clear winner.

The major advantages, the predictive maintenance can provide for manufacturing industry are

  • Limits unplanned downtime
  • Optimize planned downtime
  • Maximize equipment lifetime
  • Reduce maintenance Expenses

Let us see the above advantages in brief.

Limits unplanned downtime

Unplanned Downtime costs manufacturers an approximately $22k per minute and almost every industry loses 10 to 30% of productivity. Therefore, unforeseen failures are one of the key players in maintenance costs because of their pessimistic influence due to reactive and unplanned maintenance action. Making use of predictive maintenance to curb this cost is demanding in highly competitive manufacturing industries. And also, ability to anticipate or foresee system breakdown before failure has a strong optimistic impact on machine running which shoots up productivity and diminishes downtime, breakdown and maintenance costs. Monitoring machines digitally collect streams of data in real-time and the data is subjected to analysis to show patterns on any provided machine. Based on identifying the pattern & historical data, manufacturers can detect the machine it means probably to encounter a failure, and for which maintenance can be scheduled effectively.

Optimize Planned Downtime

Planned downtime is scheduled time when production equipment is restricted or close down to permit for planned maintenance, repairs, upgrades or testing. Planned downtime for maintenance is peculiarly necessary for retaining critical assets well & fine, but it can also be used to diminish needless maintenance on fewer vital equipment. Each part of equipment needs maintenance at a certain point, but it can be difficult to stop production assets when you have lots of allocations to meet and machines appear to be operating without a problem. The reality is, planned downtime needs to happen, even if it appears like everything is already working properly.

Preventive maintenance can regularly be scheduled using the collected data from machine functioning & also at times where there is less impact for production order. Not only that there is also an additional benefit which is an requisite maintenance of this nature will constantly lengthen the life on a machine that would be hard, and expensive, to put back. Boosting uptime and the existence of a an equipment will eventually bring in remarkable cost savings.

Maximize Equipment Life span

Do we really know the life time of our equipments?? We may have the rough estimate how long the assets and equipment will last but how confident are we in that estimate? It could be much more or much less – and we won’t know until it’s too late. However, it is crucial to determine the equipment life and improve maintenance strategy. The inspection of machines will help manufacturers identify the condition of present production equipment and identify upcoming faults. Dealing with predictive maintenance will help them boost accuracy of equipment by the data collected on the manufacturing floor.

As machines get old and based on their degree of usage, the maintenance schedule will vary, which can be overseen through predictive maintenance. Fragment of the machine will react to the manufacturing strain distinctly across time. The ultimate rise in maintenance that is anticipated by the way of data patterns will let out when a machine set foot on a turning point on cost in opposition to performance. The requirement to put back substantial pieces of a machine ultimately, or the whole department, is made to deal with, by being capable to predict that demand and plan for it, both from a money & time view point.

Reduce Maintenance expenses

Apart from other necessary expenses in production line, a huge amount of money is spent on maintenance expenses. This will be an average of 40% in the overall revenue. We can’t sit at ease without repairing the machines / equipments but we can avoid / prevent costly repairs and or replacement of parts or machines. This is because predictive maintenance allows manufacturers to detect fault, isolate & fix issues before severe damage occurs. Moreover, since preventive maintenance is intended to pre-empt significant damage to equipment, there will be no need for extensive repair work as well as emergency servicing.

Transform PDM approach with IoT

The Internet of Things has an immense effect on the manufacturing sector, which give rise to increased automation, & more efficient operations. While the application of digital technologies can bring benefits across the value-chain, it is feasible in the area of predictive maintenance that the most significant impact can be derived. The use of sensors and data analysis means companies can pinpoint patterns in equipment condition and performance, and identify exactly when an issue might occur. Such foresight eliminates unplanned downtime, delivering substantial productivity benefits.

Moreover you can’t predict what you can’t measure / analyse. Accurate data is essential. You need to evaluate your ongoing production status, or set up a threshold of data on machine performance. To perform this, OEE ( overall equipment effectiveness) , an industry standard can be used. This lends a hand in examining each machine to check the performance degree and also to know how frequent has the machine been down, which part is undergoing issues often, how the machine maintenance can be scheduled and so on.

Hope this article provides you a better understanding & importance of predictive maintenance in manufacturing. We will be happy to discuss about your requirements at your shop floor to help you achieve successful machine maintenance.

5 Trends that Dominate Manufacturing Industry Today

5 Trends that Dominate Manufacturing Industry Today

“The only thing that never changes is change itself ― D.B Coulson”.

Every day something new in technology is rising and it is replacing something good with the best. Likewise, digital perspective is changing the manufacturing industry. As industrial revolution has an effect on manufacturing since decades, now digital transformation is at the helm of changing the manufacturing industry. The transformation of traditional approaches to digital in manufacturing is the talk of the town. Digital transformation will not completely change the traditional manufacturing practices. However, digital transformation is a combo or consolidation of traditional manufacturing processes intensified with up-to-the-minute impending technologies, in order to function cooperatively to steer manufacturing ahead and tackle inefficiencies in the current sector. Digitization of Industry which is driven by latest technologies will have a great impact to transform production and revamp businesses, triggering greater efficiency and finer relationships between manufacturers, distributors and clients. This article explains what are the top 5 manufacturing industry trends that dominate today.

Connecting Industries digitally

The vital part of industrial automation which is the centre of digital transformation is internet of things. The core of internet of things is all about connectivity & communication. According to the recent report, the number of devices connected to the internet reached 22 billion worldwide and it is expected to reach 38.6 billion devices by 2025, and 50 billion by 2030. The number itself indicates that how IoT attracts a substantial amount of attention among businesses? The deployment or adoption of IoT is paramount & prime in manufacturing industry. This is because of the far-reaching ways this connected technology has streamlined and simplified various manufacturing processes. With central networks linking with machines / equipment in manufacturing industry, the complete industrial process will get automated & help to grasp processes independently, flexible to change, generate orders, understand quality issues and even assign tasks to other machines. This can provide real-time response & alerts in need to make necessary decisions at correct time. Hence, IoT is one such manufacturing industry trends that is gaining more importance today. This is due to the fact that in some way interconnected industry is intelligent & capable of making its own decisions.

Drive greater efficiency & competency

The research unveils that the Industrial IoT Platforms market is expediting in 2020 and it is one of the more dominating manufacturing industry trends as more and more industrial manufacturers lay out their transformation into IoT data-driven companies. The implementation of IoT data controlling & managing facilities at numerous centres & locations will help production crew to access relevant data, facilitate quicker, more collaborative and transparent communication.

Moreover cloud computing is providing more hope to manufacturers that it grows more stable, they begin to dive into the digital transformation with more confidence. With the context of this digital transformation or digitization, manufacturers are sinking money into new technologies that leverage the capabilities of IoT, cloud, and big data analytics to enhance their ability to innovate and to maximize their business ROI. Industrial IoT Platforms are being deployed as the mid pillar of these manufacturing circumstances enabling remote call on, ceaseless sensing potentiality from equipment on the production line, giving access to new flow of data, and supporting new capabilities such as predictive maintenance. The predictive maintenance results in the improvement in the condition monitoring processes which gives manufacturers / production managers a scope to manage Overall Equipment Effectiveness (OEE) at the production level and thus it increases OEE performance in the range of 75% to 85%.

Moving Manufacturing data to the cloud

Data and analytics are the key catalyst of an organization’s digitization and transformation efforts. Substantially IoT platforms comprise a communication network and a framework for monitoring, troubleshooting and managing the connected devices and controlling the network and data obtained from connected devices. The cloud can be used to store, access & connect data from devices. Manufacturing industries can make use of these data stored in cloud from research to clinical trials to manufacturing to the supply chain. The cloud-based infrastructure will enable operators / manufacturers in the manufacturing industries to connect all ecosystems and enable real-time communication between globally disparate production systems. And also it connects all the data from the numerous data silos and helps manufacturers in managing, implementing, accessing, and maintaining this critical data. Moreover Cloud eliminates the need of inaccurate paper log sheets in monitoring & managing production line and hence holding its place in top manufacturing industry trends.

Machine Learning for predictive monitoring

Manufacturing Industries will often face labor costs, high product defects, longer unplanned downtimes, lower transition times, and slower production. This will surely cause a drawback in their overall production system. In this condition, artificial intelligence and machine learning will be more ubiquitous in producing and assembling items, helping in reducing cost and time of production. Predictive algorithms can be used to scheme machine maintenance adaptively instead of a fixed schedule. These applications are just a tip of the iceberg. Machine learning can be used elaborately in different ways in manufacturing process. With the help of machine learning algorithms, predictive monitoring will work successfully that is equipment breakdowns can be foreseen before they occur and the machine maintenance can be scheduled quickly. This can reduce the manufacturing downtime by 15%.

Artificial intelligence (AI) will also help in product inspection and quality control. ML-based computer vision algorithms can master from a set of samples to discern the good from the distorted. In specific, anomaly detection algorithms can be used to find the possible unnecessary defects.

Automate & Streamline Processes

Manufacturing industry is a highly competitive industry which makes it vital importance for them to have an integrated solution that can boost competence, lessen costs, shoot up sales and profitability on the other hand empower the organization to bring about error-free, tactical and strategic decisions. An ERP system can satisfy all these business requirements. ERP combines all features with respect to businesses such as resources, operations, monitoring, reporting, sales, accounting and finance, etc. and enables them to operate steadily as smooth as a pan cake.

The reason why every manufacturing industry should adopt ERP system is that it streamlines business with prominent flexibility and drives automation. The complete manufacturing data will be available with perfect visibility in all departments such as development, designing, inventory, procurement, production, finance, sales, delivery and more. Besides that, every member in the team can monitor the production data in real time which brings in efficiency in the production line, improves productivity and helps industries maintain their customer commitments.

The change is extensible and with a few small changes, manufacturers can better their data, make better connections between systems and teams and eventually make their business more digital, finally leading to a better customer experience.

Hope these top manufacturing industry trends will help you better your production process & increase efficiency. We will be happy to discuss about your requirements at your shop floor to help you adopt successful digital transformation.

5 Problems Smart Manufacturing can solve for your Industry

5 Problems Smart Manufacturing can solve for your Industry

Manufacturing is the round the clock dynamic industry, where manufacturers confront new troubles and concerns day after day. Manufacturers will be heavily haunted by these production problems that pop up out of the blue, habitually at the worst possible time and involve a great deal at stake for the manufacturing industry. The industrial manufacturing process operators / production managers will mostly be out of ideas about the challenges associated with terribly complicated & intricate production operations, and they probably have been up nights endeavouring to clear up usual production problems. The dramatic challenges in the manufacturing industry will surely enforce them to rethink on powerful manufacturing strategies. Hence, there is a new landscape emerging, digital transformation that requires manufacturers to move and change at lightning speed. Their responsibility of monitoring and overseeing production increases to solve out the existing & emerging production problems. This article lists a few of the top concerns that manufacturers are grappling with and some potential solutions to achieve operational excellence.

Poor Inventory Management

Be it any manufacturing industries, handling & managing inventory is immensely critical for industrial growth & creates various production problems. As a part of supply chain, from supervising and inspecting purchases from suppliers as well as customers, managing & protecting the storage of stock, controlling the amount of product for sale, to fulfilling order, inventory management is the base. No matter where the inventory is located: be it warehouse, multiple locations or consigned or drop-shipped from supplier, managing inventory better is an absolute for improved cash flow and reduced expenses. That being said, grasping the habitual challenges in inventory management began to be extremely important and industry heads are looking out for solutions to solve out the issues & improve customer satisfaction.

Quite few of the common challenges manufacturing industry faces with respect to inventory management are

  • Inaptly located material
  • Out-of-date material
  • Excessive stock
  • Stock theft

Inaptly located material – This will eat up a great deal of time of manpower and it is tough to identify a product among stocked.

Out-of-date material – Failing to recognize and utilize obsolete materials will lead to an increase in expenses and waste of the material.

Excessive stock – Poor stock control & management by the managers.

Stock Theft – Shortage or theft of inventory material lead to production downtime or delay.

A one step solution to tackle all these challenges is automating inventory management. The real-time inventory tracking system enables industries to forecast stock levels and streamline work operations. By getting the accurate information of indoor positions of each asset, there is greater inventory visibility. The inventory tracking system can account for any inconsistency in the stock levels and alert real-time. With an accurate inventory management system, it is easy to trace the point where the inventory went missing or got stolen.

Communication Barriers in production line

Manufacturers rely on global suppliers for their need on raw materials in order to complete the manufacture of their products successfully. Counting further parties such as contractors or vendors or other parties, to their supply chain will substantially shoot up the prospects of miscommunication and blunder. Also, the production may be carried out in distinct spots across the country, or even four corners of the earth, and diverse teams operating on components of one product. The thing is manufacturers must make sure that their supply chain is functioning properly.

The stumbling-block is that the diverse manufacturing team that may be operating throughout the territory or the globe don’t actually recognize where they are in the process. Manual updating will not be the correct solution. This is because they may miss out things & also it will be more time-consuming. On lacking an effectual means of communicating what’s actually taking place, there is virtually no possible way for all the teams operating on the production to view if there is any changes emulated in the production schedule and give them the opportunity to react promptly.

The potential solution to tackle these production problems and improve communication between supply chains is the use of real-time production monitoring systems. Such a good initiative will let supply chains to make use of data generated by the system to give real-time insights into how they are working. With an access to this real-time data also help improve performance and operational efficiency.

Risk of poor product quality

Quality is the essential factor for any manufacturing industry and the top quality outcome generates unwavering customer loyalty. It drives an requisite & crucial contribution to ROI and profitability. Keeping an eye on the equipment/products around the clock is immensely paramount to carry on a healthy inventory. The faults or imperfections in products will fail to meet customer expectations & can harm business reputation. And hence, finding defective material on a daily basis is essential for fixing the production problems or replacing it with another. Today, manufacturing industries perform this task manually every day and this consumes a lot of time. Hence, the precision real-time data on bad quantity in the production line only will help in avoiding the production of rejects.

Production monitoring system allows production managers / operators to record the number of bad items produced. Quality can be improved by analysing production data and the number of rejects in order to identify the flaws. Moreover, the reduction in rejects will help in improving product quality & customer reputations.

Lacking Machine Maintenance

Manufacturing downtime is one of the biggest challenges for every manufacturer / production manager out there. Most of the manufacturers are not truly focused on understanding the true cost of the machine downtime, which is why industry-wide costs remain in the billions of dollars. Failing to catch sight of your stressed or repaired equipment will result in the significant loss to the manufacturing industry. For instance, if a crucial part of your manufacturing equipment breaks down or fails at a key moment in the production process, you will lose substantial cost with an extensive impact on your industry’s bottom line.

Then, How to overcome the unplanned downtime? The only solution to overcome the downtime is to prevent it from occurring.

Hence, regular predictive / preventive maintenance is essential in a manufacturing facility. It’s not just a matter of keeping the lights on and it is much more than using log sheets to record the event manually. It is key to making sure that the product makes it to market on time. Production monitoring systems will track how, when, where the downtime occurs & will help in preventing & managing the excessive loss. Recording the downtime & identifying the reason for downtime will significantly reduce the production issues & increase the production rate.

Shop floor Performance

A small alteration in the production line in the shop floor will have a great influence & effect on production performance & creates serious production problems. Therefore, an ideal shop floor running is required to strengthen the shop floor performance and to set the seal on sustainable efficiency of the production process. Hence, measuring the essential metrics of the shop floor is required to ensure the efficiency of the production. Each and every product managers, who is keen in boosting the production process and willing to lift the production to the next level, needs to collect and analyze the relevant data or suitable metrics. The perfect metrics will help the operators to find the weak spots in his production floor by providing all the necessary information and insights that every manufacturer demands to revamp and boost the production endlessly. The one such important metric is the OEE which has become an important measure for many manufacturing facilities as a way to examine shop floor productivity. It is a combination of three commonly used measures such as availability, performance and quality. Availability is the detection of the number of time industrial assets are functioning to provide an added value to the production process against being down. Performance is how optimal the assets are operating at their maximum speed of production. Quality is a measure that reflects the rejects as a percentage of production. By lacking OEE measurement, manufacturers will face several challenges including misunderstandings on the shop floor, finally resulting in poor production efficiency.

Hence, OEE measuring system can be implemented in the shop floor to enable real-time access to the machine productivity, availability and the operator availability and performance and also supports new capabilities such as predictive maintenance. With this new level of prognostic precision comes an improvement in condition monitoring processes, providing manufacturers a full visibility into their production line. This will drive greater efficiencies and productivity throughout operations in the shop floor, deliver higher-quality outputs, and increase profitability.

Finally, an exhaustive production monitoring system that provides an absolute view of the shop floor from production line to supply chain is a one-stop solution for all the production / manufacturing industry needs. Pace DPR, an IOT powered production monitoring system is one such digital transformation initiative that helps manufacturers decrease their go-to-market time-span and increase their product quality and revenue output. It helps industries extract data from Machines from digital signals on machine panels and Microcontrollers using Modbus, Profinet, MTConnect, OPC UA, etc. This manufacturing tracking system will increase the production efficiency by many folds.

To know more….Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.

Killer Tips & Tricks to win the Industry 4.0 Race

Killer Tips & Tricks to win the Industry 4.0 Race

Industry 4.0 is gaining momentum all over the industrial world. With the endless possibilities of innovation & technology, every production manufacturers are keen in adopting automation to succeed the race. However, most of them are giving consideration to the cost for adopting new technology i.e IoT Industry 4.0 against the capital gains. Others are hell-bent regardless of whether they ought to bide their time until the battle reveals the clear-cut evidence of the gains before starting out into this untold sector. Even now, others are hurt by the extravagant promises of overly intricate and costly technologies. At the end, all of them are working to crack what actually can be done to boost their productivity. Whether a small scale, or large scale industries, they need an exact strategic plan that helps them keep their business run successfully. To put it simply they need an effective way to tackle the challenges & lead the race. How ready are you to tackle the challenges & win the race?? keeping that in mind, here we provide the killer tips & tricks for every manufacturers to handle their production problems & boost productivity with IoT Industry 4.0.

Throw off the Old Production metrics

The huge mistake that every production managers / production manufacturers doing today is believing in the raw data from old metrics. The drawback of the old methodologies is that the inaccuracy of the production data & it generates measurement errors. Struggling to gauge the volume of potential services, and lags between investments are the two drawbacks in measuring inputs when the traditional method is actually utilized in production. It is paramount to unpack the measures of productivity to understand the proximate and factors affecting productivity growth. In layman terms, “if an equipment is partially utilized or not utilized today, then the equipment is completely ignored from the productivity calculation”. This results in the incorrect measurement displaying the calculated productivity higher than the actual ones. Measuring the productivity data right is the first step to improvement. Manufacturing Productivity is a measure of how great the asset works compared to its fullest potential. OEE metric which is a direct combination of Availability, Performance & Quality which directly indicates the gap between the actual and ideal performance of your industrial operation. It reports the overall utilization of facilities, time and material for manufacturing operations. This ultimately helps the business work on the improvement of equipment effectiveness and thereby its manufacturing productivity.

Tip*

Manufacturing Productivity measurements are overlooked and calculated with skewed data. Measuring it right is with OEE – A combination of Availability, Productivity & Quality is the first step to improvement. Improving OEE will improve your overall efficiency & revenue.

IoT Industry 4.0 tip-1

Win the Downtime battle

One of the fundamental issues which manufacturers deals every day is the cost of downtime. Manufacturers wage to keep machines running figures eminently in Industry. Bringing down the cost analogous to these basic elements of manufacturing are among the most demanding challenges a manufacturer must address. A recent survey showed that the cost of a machine breakdown is more than just the maintenance labour and materials to make the repair. Roughly every industry loses at least 5% of its productivity by dint of downtime, and many loss as much as 20%. The awful part is that many of the industries are impotent to calculate the actual cost of downtime precisely. When the machines are idle, everyone’s attention will get averted from growing the business, whether it’s responding to new opportunities or innovating new products and services. Keeping an eye on how, when, where the downtime occurs will help you prevent & manage the excessive loss. A speedy move towards minimizing downtime is possible only when it is tracked precisely & cautiously. Hence, utilizing complete monitoring software that provides real-time view of shop floor will significantly provide the data on downtime events.

Tip*

IoT based predictive maintenance will proactively identify machine failures & push fixes. This reduces the equipment downtime by 50%.

IoT Industry 4.0 tip -2

Revamp Industrial Data Management

The conventional way of acquiring data that involves log sheets in which operators manually write down the production data will not lay out any improvement in the productivity. This is because the production data obtained can be inaccurate and the operator will frequently miss the downtime events. Then, How can they improve productivity without an accurate data? This finally results in operational waste, lost sales, productivity loss, disengaged employees & dissatisfied customers which cost manufacturing industry, $9.7M per year. An automated production monitoring system that collects data from each machine individually will report the production unit heads / operators real-time. This helps operators & production managers communicate with each other internally with an exact data to make faster decisions. Finally leading to win IoT Industry 4.0.

Tip*

Better data management can improve operational productivity level 50%. Act fast with an automated data collection & monitoring.

Keep Product Quality High

According to industry experts, the most critical issue that any manufacturing environment is facing through the production process is the cost of poor quality because of its direct effect on reducing the manufacturing process efficiency and that most of the causes are hidden and not directly noticeable. This finally results in chargebacks, lost sales, product returns, rework costs, and freight costs. The true cost of poor quality includes the tally of the costs from repair, rework, scrap, service calls, warranty claims and write-off from outdated finished goods can range between 5 and 30% of a manufacturing company’s total revenues, with the range for most companies falling between 10 and 20%. With the Quality management / monitoring system in hand this can be eventually avoided. The sensor fitted with the production machines will monitor machine health parameters & equipment calibration that checks whether parameters are approaching threshold & monitor variance in equipment behaviour. This alerts the quality manager if any issues are detected & finally improving the product quality. This results in gaining customer loyalty, business repetition, acquiring customer referrals, & improved market position.

Tip*

Catch the flaws before the product reaches the market. An Effective IoT based quality management will make a direct contribution to profits.

An Effective Production Monitoring System

Any production company to successfully execute the above mentioned tips requires a first-rate production monitoring system to know about the operational efficiency of their factory really. Hence, in order to achieve first-rate production efficiency, production monitoring is decisive. Moreover, when done with the right tools, production monitoring has the potential to transform an entire manufacturing industry. The perfect real-time production monitoring system could enhance the productivity and efficiency. A right production monitoring system with OEE calculation, perfect data management, downtime & quality analysis will significantly improve productivity.

Industry 4.0 tip - 5

Pace DPR, an explicit production monitoring tool has the potential to aggregate production information and makes it available to production managers with great clarity and simplicity. This will help production managers close the gap between production processes & planning & will help you lead the industrial race.

Hope the above listed Tips will help you frame the strategic plan for your production line to win with IoT Industry 4.0. To know more…..Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.

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Industry 4.0 – Are you ready to lead the race?

Industry 4.0 – Are you ready to lead the race?

Industries are now racing towards Industry 4.0. It is the future of productivity and growth of manufacturing Industries. The advancement of manufacturing technology is the hallmark of this revolution that can communicate and cooperate in real time between themselves and humans. The production reality in today’s increasingly competitive world demands efficiency and quality with continuous and improved processes while embracing the Industry 4.0. In order to stay competitive and succeed in the race, you have to push yourself to measure manufacturing productivity right. Hence, deploying an outright production monitoring software PaceDPR, that provides a real-time view of the shop floor will help you optimize your production flow. This article provides detailed view on how to gain momentum in Industrial race using OEE manufacturing system, PaceDPR.

Bird’s Eye view on production

The production process in the manufacturing industry can be optimized only when the production environment is provided with real-time data. The real-time monitoring can increase the operational productivity level by 50%. PaceDPR is an extremely efficient and effective tool that is designed to provide the real-time view of your complete shop floor. The real-time status will help you fairly understand the manufacturing process & reckon OEE pertinent to availability, performance & quality. The real time visibility on production will augment your focus on productivity & betterment activities & help you eliminate inefficiencies & bottlenecks.

Effective performance visualization

PaceDPR has been designed to guarantee perfect visualization of all the performance parameters and indicators collected from the production system using the real-time data dashboard displays and analytical reports. These tools are designed to offer transparent and accurate OEE manufacturing data with all the information needed to reduce production loss. The performance of the overall machines and the performance of each machine in a current day can be viewed separately as needed. This will help you analyse the productivity of each machine to overcome the production loss. The reports for analysing data collected can be archived by shift based cumulative reports & hourly production reports. This will allow you to discover the real production capacity of systems, production lines and machinery and will less the equipment maintenance cost by 25%. You could look deeper into the performance of each machine for deeper analysis and decision-making.

Tracking Manufacturing Downtime

Generally production environments are subject to various causes such as machine malfunction, downtime, failures and rejects that weakens the overall performance of machines, reduces production efficiency, causing economical loss to the Industry. Almost every Industry loses 5 to 20% of its productivity due to downtime. Hence it is necessary to understand the actual cost of downtime and ways to reduce it. However, the performance indicators & OEE manufacturing data alone are not sufficient to detect the causes of inefficiencies. The precise tracking of downtime events is essential to prevent and manage the excessive loss. Pace DPR will provide you an exact view on production line & help you identify bottlenecks, maintenance issues & other events that cause downtime. This information is essential to ascertain what and where the causes of inefficiency are in order to remove them. This helps you analyse the reason behind downtime that occurs due to set up, raw material shortage, scheduled maintenance, meetings and work breaks. By managing the downtime, the productivity loss and inefficiency can be lowered.

Take complete control over machines

PaceDPR best suits the Industries that run in single and multiple shifts. The evaluation and monitoring of machines can be done based on your shifts and the ideal cycle time of machines. You will be able to update your machine details to understand the performance in relevance to machines.

PaceDPR is the simplest & affordable solution designed to aggregate production information and makes it available to production managers with great clarity and simplicity. This will help you close the gap between production processes & planning & will help you lead the industrial race.

Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.

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