Internet of Things
HARNESSING REAL-TIME MONITORING The most powerful use of sensors comes from combining the real-time data they generate with real- time production and process monitoring functionality that is integrated with the MES and ERP systems. Real-time production monitoring helps bring meaning to the counts from sensors by capturing production cycles that can take mere milliseconds and displaying averages, such as X amount of product per minute. Counts in ERP and MES software also support automated workflows, such as materials orders, inven- tory updates, production scheduling, and other shop floor and accounting processes.
When combined with statistical analysis, real-time production and process monitoring can help establish parameters for performance, wear, etc., as well as track and flag when production cycles and processes meas- ured by machine sensors head outside an acceptable range. The data can be used by an MES for sched- uling production, ensuring quality, and performing preventative maintenance, among other processes. The metrics or key performance indicators (KPIs) tracked will be specific to each manufacturer’s prior- ities. But starting with too many KPIs can ground monitoring and analysis initiatives to a halt - defocusing efforts while consuming valuable staff
Instrumentation Monthly November 2024
time. So, management should prioritise creating a short list of KPIs most relevant to the business. Once the company is regularly tracking metrics against these KPIs, new KPIs can be added.
GETTING STARTED ON YOUR JOURNEY TO IOT SUCCESS
To get started, the most successful manufacturers get sensors and monitoring working on one machine and begin collecting the sample information everyone agrees is important to that machine. Once the data coming in looks the way the team wants it to, the approach can be applied incrementally to other machinery. It is better to start with a machine where the team understands how the interface works and can be successful. Even if getting up and running is easy, the team will still learn things through the process, and that knowledge will help with the rest of the installation and give everyone confidence that the results are going to be as expected.
Manufacturers also should first hook up sensors and monitoring to a well-performing machine from which the team can collect data and create a baseline of understanding. This will serve as a springboard against which to measure other machines. And, when first monitoring the data from sensors, it’s important
to note that sensors placed on different parts of a machine will often produce different results - even if the type of sensor is the same.
Additionally, there are physical implementation factors to consider. Many successful manufacturers have relied on their in-house maintenance teams for the install instead of using outside electricians, since the installers need to be familiar with their equipment, machines and the building. Also, because the amount of metal on shop floors can leave WiFi and wireless devices unreliable, consider using wired connections to each machine rather than wireless ones. Finally, plan for the future by having network drops on every machine. This will ensure that all machines have network capacity as the team expands the installation of sensors across the shop floor and begins to collect data.
By following these best practices for bringing sensors and real-time monitoring to existing machinery, manufacturers can quickly gain insights to improve their efficiency and correct issues that have been losing money. And longer term, this can translate into greater efficiency, productivity and profitability.
DELMIAWorks
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