IoT & AI Based Machine Monitoring System for Productivity, Quality and Delivery Improvement

Illustration - A Solution Provided by Teksun

What Are The Fruits Born By Machine Monitoring?

It is useful for both discrete and process industries. Machine Learning is more affordable. Sensors are available at lower prices. Edge Devices have become more versatile. The connectivity provisions, that is networking, have become more robust. The enables measurement and tracking of many vitial parameters and analyze them intelligently using data processing machines to create more value in many activities. 

Accurate Performance Measure:

Machine Monitoring can more accurate, timely performance measures without missing any period data, 

Real-Time & Quick Notifications:

Machine Monitoring allows you to automatically and reliably notify every manager and every technician the parameters of his interest or responsibility if a set threshold is crossed. This provision can be  easily configured in  your solution to the system.

Systematic Maintenance:

The featured system lets you tailor the repairs and maintenance as per the actual wear and tear of the Machine. It also allows  you to use a past record of both the parts’ and machines’ lifecycle, resulting in only the required maintenance at the needed time.

High Efficiency At Work:

Machine Monitoring helps you to get an accurate understanding of the production flow and backlog of orders. The data helps you to identify and eliminate bottlenecks and perfect production schedules. It empowers you with the information that’s required to balance lines and time production runs.

Resource Consumption:

With Machine Monitoring at your side, you have the ability to measure the exact input, output, and energy consumed. This information can further help you to reduce wastage.

No Manual Efforts Required:

Driven by automation and based on advanced technologies like Artificial Intelligence and the Internet Of Things, Machine Monitoring automatically gathers the required data and provides valuable insights to improve the operations. 

Personalized Performance Reporting:

Machine Monitoring facilitates you with tailor-made performance reports inclusive of all the important information fetched, compiled, and filtered from multiple sources. This also provides you with sure-shot, concise, and actionable data to expedite the entire analysis process.

Machine Monitoring Is Spread Across How Many Different Branches?

With branches, we mean the various applications or use-cases of Machine Monitoring. Yes! Machine Monitoring is spread across different cases as they comprise everything from monitoring, analysis, industrial sensors to the touch-screen interfaces mounted on machines. Also, not to forget that these systems are interconnected with IIoT or Manufacturing Application platforms.

For Overall Equipment Effectiveness:

 Machine Monitoring allows the operators to annotate reason codes for downtime, thereby helping in documenting the root cause at the source. Moreover, machine monitoring systems facilitate you to balance the production lines, track the operations, and plan the production. It also lays a foundation for calculating essential Machine KPIs such as quality, availability, utilization, OEE, etc.

Production Tracking & Job-Route Optimization:

Another use of Machine Monitoring could be found for Production Tracking & Job-Route Optimization.  Machine Monitoring brings you the merit of easily tracking WIP throughout the value stream. With the dashboards of Machine Monitoring systems, you can find the exact status of how close a particular run is to completion. It also lends you other valuable insights as well, such as whether or not you are meeting the production quotas. This collectively helps you with Job-Route optimization to gain the maximum benefits from your job.

Condition Monitoring:

It  helps you track the condition of each of your machines but also provides a complete understanding of part and asset lifecycle. The sensors attached to the system allow you to monitor different essential parameters such as temperature, noise, vibration, etc., and that too in real-time. This way, Machine Monitoring helps you optimize maintenance schedules and decipher machines’ behavior on the shop floor. It stands as an add-on when it comes to establishing a robust foundation of the predictive maintenance programs, provided that the system deals in collecting data about the Machine’s performance and health in the set local conditions.

Resource Monitoring:

One of the intriguing applications of Machine Monitoring is Resource Monitoring. As businesses are focused more towards cost-savings, the requirement of elevating the efficiency of assets; resource consumption. Organizations receive the privilege of easily measuring current, power drawn, and other resource usages such as injection wax, coolant, water, etc. This further helps manufacturing units optimize usage, plan inventory and buffers, reduce costs, and more.

Machine Monitoring also finds a place for applications like Program Optimization, Tool Life-Cycle Optimization, and more.

Increasing productivity of each and every input is to be attempted by industrial engineers.

Productivity Engineering of Metal Cutting Tools 

https://nraoiekc.blogspot.com/2020/09/alternative-metal-cutting-tools.html

Productivity Engineering of Cutting Fluids.

What’s The Way To The Roots Of Machine Monitoring?

These systems could be devised in a cloud-based SaaS platform, PaaS platform, or on-premise IT infrastructure of the organization.

Build Initial-Level Hypothesis for Problems:

The initial-level hypothesis matters a lot, as it gives you a basic idea of what’s lacking to achieve the set performance. Machine Monitoring has the ability to create new knowledge sources that could further help discover underlying issues. It further stands apt in enhancing clarity to your machining queries by plainly broadening the available information.

Create a Source Of Truth:

Establishing a source of truth could be different for different manufacturing set-ups, but more likely, it could be analyzing the state of the Machine; that’s all about collecting and organizing the relevant data.

Research Evaluation:

This stage brings you the condition of creating tailor-made states of machines that could let you record machine performance to your precise specification. This step allows you to send an automatic trigger notification to a supervisor/technician when certain predetermined thresholds are exceeded.

Educate The Operator:

An essential part comes here…By educating the operators regarding the Machine Monitoring systems, you enable them to use its application for various purposes. They can add details about downtime reasons, logging errors, process completions at source, etc. On the other hand, the application automatically tracks which operator is on duty, the machine program in operation, the number of hours on tools, etc. Hence, providing a holistic understanding of machine health and performance.

Build Tailor-Made Applications:

Yes! Tailor-made applications are a must when you wish to discover the root cause of machine performance issues. If customarily designed, Machine Monitoring systems can help you track quality and production throughout the value stream.

The Conclusion

Knowing how machines suit entire manufacturing processes is vital to enhance those processes. Comprehensive machine monitoring solutions that bring machines online and lead operator action to assist you in realizing these developments.

At Teksun, we strive jointly with our clients to devise integrated machine monitoring systems that derive immense value and faster scalability.

https://teksun.com/blog/strengthening-the-roots-to-productivity-with-machine-monitoring/