Efficiency, as well as accuracy at the production lines, empowers a better production and usage of the available resources. A production monitoring system is a process that is used to track the overall performance of the production line in real-time. It is important to help the industries to attain realistic production goals, at minimized downtime and increase yield. This tool enables both the management and the production team to continually analyze real-time production status with respect to reliability, availability and maintainability of the equipment and machines.
Task of Real-time Production Monitoring System
The system gathers data from several sections of the production line and is send it to employees and managers working on the line. The data that is gathered by the monitoring system is utilized in improving the efficiency of the production line. The data access should be understood precisely in order to rectify the several faults at the production level and to instantly recognize them to improve efficiency. Precise Data management and production monitoring system is equally important in enhancing production performance.
Data must be gathered at each shift end and distributed precisely in order to fulfill the production goals. The capability of the PMS to gather production information on a real-time basis would empower the production team to acknowledge, in a timely manner, to resolve any production-related concerns that may arise. This system should also dynamically recognize and react to the faults by notifying the concerned personnel in the departments before they escalate.
The main task of a PMS is to help the production team to manufacture their best within the available resources. Apart from that PMS supports enhancing quality matters and minimizing overheads. The system gets data signals related to the processes – whether they are running evenly or if they are facing any concerns.
Data examples include
This is the total count of parts set for production by the management. We can say that it is the goal set by the management for the shift. The running goal depends on the cycle time of the produced parts.
This is the total time span for the particular parts to be produced. This is generally set by the production planning and control department. The cycle time will be programmed into the PLC.
This is the total count of parts or items prepared that are out of specification. This number takes for rework and scrap. A few sensors will be enclosed into the system to recognize the event of faults and then a signal will be created by the PLC to add a number to the reject list.
This is the length of the time when the workers have no productivity as decided by the management. A switch will be utilized to create pulses for the display to record the duration of no productivity.
This board will be utilized to track the production interruption time as per the departments included in the production process.
Production Planning and Control
When the operator recognizes that they are running out of raw materials, then the operator needs to press the switch to alert the specific department. At the same time, the display will catch the time taken to resolve the fault.
Once the data has been gathered and reviewed by the employees and managers, they can make suitable changes to the production line in relation to speed, daily production targets, production rates, etc. The monitoring software will also present all the new values on a dashboard to the employees and set the production line to complete the daily targets.
What Advantages Can Customers Get from the System?
The Real-time PMS is very beneficial to production companies due to the following reasons:
- It is simple to install and utilize.
- It is well suited to several types of production line computers.
- It can be utilized with wireless networks.
- SMS/Email alerts are sent in case of machine or equipment breakdown in any part of the production line.
- It can be certainly upgraded in the future along with the production line.
Advance Benefits of using Production Monitoring System
Easy Document Management
Simply create and handle essential Documents right from engineering drawings to Control Plans.
Alerts & Notifications
Notify the right person on email or SMS at the right time when an action requires to be taken in your factories such as an idle time pocket, variations in product or process and more. Track incidents via workflows with reassignment, declaration and full audit tracking.
Real-time Inspection & Production Visibility
Digitize and coordinate your crucial tasks on your factory and analyze operational metrics as well as production status in real-time.
Customizable Machine Interlock
Depends on rules set by you and driven by the Control Plan, protect rejections by interlocking the machines dynamically.
OEE with Advanced Analytics
Analyze and improve OEE with real-time insights at the factory or machine level.
Remote Process Monitoring
Analyze key process parameters in real-time, depends on Control Plans and recognize issues that can be resolved at an early stage before they hamper production performance.
Cross Machine Compatibility
Well suited with ALL machines and processes from milling to VMC machines, Die Casting to Forging, CNC Machining to Molding and more.
With the defined resources available on the industrial shop floor, the application of utilizing a real-time production monitoring system is critical. The PMS should be completely utilized so that whatever resources available within the industrial sector were not wasted but utilized to the optimum to enhance the production yield. By taking these important steps industries can enhance and maintain a more effective production line.
Smart Factory Solutions is having the perception of being the chosen solution provider in the area of manufacturing execution systems and assist industries to move towards Industry 4.0.
- data access
- early stage
- The Future