Page 86 - MetalForming October 2017

There’s IIoT
Additionally, specified containers must be ready to receive, hold and protect resulting products from damage and con- tamination. Finally, it is important to verify that the operation is able to create labels in the customer-approved format and with the right content.
In fact, labels can be as valuable as the product. Because most part suppliers work with customers striving to operate in a lean mode, any supplier’s product-labeling mistakes on containers and shipping documents, or in electronic data interchange communications, can significantly disrupt production flow.
Creating a Closed-Loop System
Basic control-systems principles and practical best prac- tices have established the importance of creating a closed- loop feedback system for any process to help minimize and prevent errors. Once this feedback loop is established to sup- port error-proofing at setup for production, these same con- nections can continue ‘listening’ to the equipment and tool- ing to monitor production activity and quickly identify trends. For example, if a machine-sensor signal begins to wander, an alert is sent via text, email or status light-poles. This form of prevention before product quality suffers, or equipment and tooling fail, can save significant cost and time.
Central to creating a feedback loop is the integration of the enterprise resource planning (ERP) and manufacturing execution system (MES) software with equipment sensors, machine controllers and computer workstations. Doing so provides reliable data and minimizes gaps and inaccuracies due to human error. If the software is designed well, the
analysis and reporting of the results will occur in real time when the information on readiness or ongoing production performance is actionable. After-the-fact reporting at end- of-shift, day, week or month can be useful for identifying trends, providing a big-picture view, and minimizing hard and soft costs.
It’s important to note that the soft costs associated with integrating and implementing MES software can contribute to the return on investment (ROI). Therefore, in calculating ROI, it is worth quantifying the prevention of downtime; containment, recovery and rework of non-conforming prod- uct; expedited freight; customer frustration and back charges; and staff time to address customer concerns. Manufacturers also should consider the benefits of closed-loop operations that optimize uptime and yield, improve delivery perform- ance, and foster customer goodwill.
Integrating IIoT With ERP and MES to Create a Closed Loop
When integrating ERP and MES solutions with IIoT con- trols, sensors and devices to create a closed-feedback loop, manufacturers should consider three factors for enforcing logic and verifying specifications:
• Status of resources must be captured and verified prior to start of production at a press or machine. Resources include raw materials/components, operators, tooling, con- tainers and labels. This information can be typed into a computer terminal or tablet by an operator. However, when possible, it is better to automate this input via a wired or wireless connection directly from the equipment and tools,
Metalforming and fabrication companies can ensure correct on-time production with connected monitoring enabled by ever-evolving technologies.
or by using an automatic/ manual hybrid that captures input via scans of barcodes or radio frequency identifica- tion (RFID) tags to assure accuracy. Modern MES solu- tions can support any or all of these methods.
• Modern manufacturing software stores and uses product and process specifi- cations. Product and process specifications are stored in the software’s database for use by the business logic on the plant floor to verify the nec- essary resources, including work instructions, available and ready for operator use.
• Communication method must be determined. You have three means for com- municating with your opera- tors when setup logic is sat- isfied and production can
84 MetalForming/October 2017
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