Smart production

The aim of preventive maintenance of machines is to reduce maintenance costs and increase product reliability. The two simplest methods to achieve this are:

• Measure and record the energy consumption of each machine – This step allows you to compare the energy consumption with the machine output at a given time. The data obtained will serve as a basis for comparison and setting targets for improvement measures. Such analysis will allow you to identify where and how you can reduce energy consumption while maintaining or even increasing performance.

• Temperature measurement of key components and other parameters – It is important to monitor the temperature of key machine components such as motors, bearings, valves, pumps, as well as changes in current for each such part. In addition, it is advisable to monitor other parameters such as vibration frequency, etc. An early warning message should be given when any suspicious anomaly occurs, so that maintenance can be started in advance to avoid any risk of machine downtime. Early diagnosis and response to potential problems can significantly reduce the risk of sudden stoppage of production and associated losses.

Traceability systems are a key element used to ensure food safety. In the food and beverage industry, this system is essential to maintain product quality and health safety. AVEVA Edge offers FDA 21 CFR Part 11 compliant tools that include:

• Electronic records (event logs, warnings and reports)
• Electronic signature (security system)
A proper monitoring system not only facilitates the achievement of management objectives, but also saves time and human resources (costs). This means that factory managers can more easily monitor machine performance and perform preventive maintenance before any problems occur. Early identification and resolution of potential problems can contribute to the smooth running of production lines and have a major impact on the efficiency and productivity of the entire plant.

It is recommended that traditional factory operators who choose to implement Industry 4.0 start with the concept of OEE (Overall Equipment Effectiveness) to improve production efficiency and reduce costs. OEE is an aggregate indicator that expresses the overall equipment efficiency based on Availability, Performance Efficiency and Quality Rate, i.e. OEE = APQ.

For example, to improve OEE, you can monitor the operation of a three-colour light bar installed on a production machine to determine its availability, install sensors capable of extracting parameters from the machine such as production quantity, motor speed, power consumption and machine temperature as a basis for production capacity and yield.

Whether the machine is in operation and what recipe is used to produce which products should be determined based on the MES software output and the ERP work order. The most important part of the machine control mechanism is the configuration of the temperature controller. To avoid incorrect parameter settings due to human error, a local automatic reporting mechanism is required so that the settings used are linked to the machine that is in operation. This should be implemented so that it is convenient to allow supervisors to perform further monitoring and control.

OEE can help factory owners understand the use and degree of control required by the machine, while the supervisor is able to understand the information presented in real time, giving him the ability to improve product quality and ensure equipment reliability, gradually improving the control process so as to maximize the efficiency of production lines.