Page 42 - MetalForming-Apr-2018-issue

Fabrication: IoT
Calculate the OEE of the entire plant (OEE = Availability x Quality x Performance)
Estimate the time to fail in correlation with machine event failure probability
Plant OEE
Time to Fail
OEE by Equipment
Probability of Failure
Drill down to derive equipment level OEE and identify the bottlenecks
Establish failure probability of the machine based on the real time operational parameters
Fig. 2—Managers look at OEE at the machine level to track each production asset’s uti- lization rate, performance levels and quality. OEE also finds use for scheduling predic- tive maintenance of machinery.
• Return material authorization (RMA) rate and percent of manufac- turing—This represents the percentage of products shipped to customers returned due to defective parts or oth- erwise not meeting requirements. RMA serves as a good leading indicator of potential quality problems.
How Do We Move From Here to There?
“Over the last two years,” notes Phillips, of Connected Factory Global, “I have spoken with many manufac- turers about Industry 4.0—machine shops, metal fabricators, injection molders and assemblers, and compa- nies small to large. Three common questions I hear: What is IoT? Why should I care? Where should I start?
Industry 4.0, explains Phillips, col- lectively includes four system-design principles.
• Interoperability: The ability of machines, devices, sensors and people to connect and communicate with each other via IoT.
• Information transparency: The ability of information systems to create a virtual copy of the physical world by enriching digital plant models with sensor data.
• Technical assistance: The ability of computer systems to support humans by aggregating and visualizing information, thus enabling companies to make informed decisions and solve urgent problems on short notice.
• Decentralized decisions: The abil- ity of cyber-physical systems to make
how chaotic a plant floor can become. All of the machines in the example have at least 37-percent unexplained downtime. Such poor performance might become evident only after ini- tiating a real-time monitoring pilot.
Columbus identifies five quality metrics where IoT can help manufac- turers gain control of quality and mis- take-proof their operations:
• Manufacturing cycle time—Quan- tifies the amount of elapsed time from order taking to production. Real-time integration, applying Six Sigma to iden- tify process bottlenecks, and re-engi- neering systems to be more customer- focused will improve performance.
• Overall equipment effectiveness (OEE)—Many manufacturers consider this the most important metric to ensuring stable, profitable production operations. OEE measures the perform- ance of a given machine, product line, work team or entire production center. Managers look at OEE at the machine level to track each production asset’s utilization rate, performance levels and quality. OEE also finds use for sched- uling predictive maintenance of machinery (Fig. 2). The formula to cal- culate OEE: Availability x Performance x Quality.
• Production yield rates by product, process and plant location—Yield rates reflect how efficiently a machine or
process transforms raw materials into finished products. Yield rates also reflect the stability of OEE rates and the effectiveness of overall production workflow. Greater real-time integration, improved quality-management sys- tems, and greater supply-chain quality and compliance all positively affect yield rates.
• Perfect order performance—This metric indicates a manufacturer’s abil- ity to deliver complete, accurate and damage-free orders to customers, on time. The equation used to define per- fect order performance (perfect order index, POI): Multiply percent of orders delivered on time by percent of orders complete by percent of orders dam- age-free by percent of orders with accu- rate documentation by 100.
Conference Covers All of This, and More!
All of the experts interviewed here will serve as
presenters at the IoT for Metalformers and Fabricators
conference, April 18-19, 2018, in Nashville, TN. The
conference, presented by MetalForming magazine and
the Precision Metalforming Association, is designed
specifically to educate floor supervisors, manufactur-
ing engineers and managers, IT directors, and others
working in metalforming and fabricating plants on the coming wave of digital manufac- turing and plant-floor connectivity. In addition to the information covered in this article, attendees also will benefit from hearing case-study presentations describing IoT imple- mentations in metalforming and fabricating plants, and the results from those projects.
Learn more and register to attend at www.metalformingmagazine.com/iot/.
40 MetalForming/April 2018
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