Articles Archives - Page 7 of 8 - MES Solution - FreePoint Machine Monitoring System

How to Know if you are Ready to Implement Machine Monitoring

September 11, 2017/in Articles, Machine Monitoring, Manufacturing, Technology

The simple and straight answer is that, if you are a manufacturer and haven’t yet implemented machine monitoring, then you are ready. Machine monitoring offers a wide range of benefits including increased efficiency, engaged employees and an improved bottom-line. Machine monitoring solutions, such as FreePoint Technologies, can be set-up and running the very same day. However, if you aren’t convinced, and are looking for a few more reasons to implement machine monitoring, here are 3 signs you are ready to make the transition:

Machine Operators Aren’t Engaged

A clear sign that something needs to change at your manufacturing facility is that your employees do not appear to be engaged in their work. When a machine operator is not engaged several things can result, such as loss of job enjoyment, more frequent sick days and less drive/commitment. Productivity can take a negative downturn as the employee simply stops delivering at a high or efficient rate.

man in factory lab coat operating machine control panel stainless steel door

A Machine Operator Engaged With His Task

At FreePoint, we believe in the importance of empowering and engaging employees with modern technology. Manufacturing processes need to be re-humanized and provide an environment for workers to play a larger role in identifying productivity improvements using factual, real-time process information. Machine monitoring enables that. When our customers share their machine data with their employees, the machinists begin to feel engaged and have a sense of accountability. When management invests in a machine monitoring system, it demonstrates to their employees that they are committed to increasing productivity and continuous improvement.

Lack of Information

Not having enough information on the performance of your operators and machines when making important decisions such as hiring new employees, purchasing new machines or quoting your next job can have a negative impact on the outcome.

With machine monitoring installed, you now have access to real-time and historical data of your machine’s performance. The monitoring system can measure data such as downtime, uptime, part count, OEE and more. This information gives you the ability to make better, more informed decisions with confidence.

Downtime is Consuming too Many Resources

Every manufacturing plant strives to run its operations as lean and efficiently as possible, and one of the largest obstacles that stand in the way is machine downtime. Downtime consumes valuable resources that could have been used for productivity.

With machine monitoring, the data collected can tell you when a machine is down and what type of fault may have caused the issue. Email and text alerts can also be set up to send alerts to supervisors. Knowing this valuable information can help to shed light on what is causing the issue and help to prevent it from happening again in the future.

Are you experiencing any or all of the above challenges in your facility? If so, you may be ready to implement machine monitoring. Get in touch with us today to learn how we can help engage your employees, provide you with meaningful data and limit the downtown of your machines.

Image Processing Now Available

August 24, 2017/in Articles, Manufacturing, Technology

We are excited to announce the completion of our image processing system project!

We can now incorporate “image capture” and “image analysis” in our ShiftWorx platform. The first system we installed has successfully processed over 1 million images in the first 3 days and continues to process around 300,000 images per 12 hour period.

With this new module, we can offer image data to help our customers determine quality, productivity and in some applications, empirically quantify “value adding” actions in ways they have never been able to before.

The next phase we have planned for this project is to include a locally-hosted web interface (hosted from the Xi) for custom data entry to be included with the daily log files.

Product Specifications

Computer vision (CV) system consists of up to 4 industrial USB cameras with moisture‐resistant lenses interfaced with a single FreePoint Xi Image Processing System. Cameras support compressed and RAW pixel formats with hardware triggering for instant image acquisition and download. The system is offered as a “bolt‐on” product that runs independently and in parallel with the customer’s existing industrial process. The FreePoint system supports colour and greyscale cameras with global shutter (no electronic/rolling shutter image distortion) at resolutions from 64×64 up to 1280×960 pixels. This CV system implementation operates continuously at 9 frames/second with real‐time image processing and data logging and was tested at up to 20 frames / second (hardware trigger mode).

FreePoint Xi Image Processing Module

FreePoint image processing module supports custom image analysis including (but not limited to) image segmentation, feature and shape detection / recognition, optical measurement (dimensions, surface area, etc.), colour and feature binning, noise rejection, format conversion, image and data logging and local/cloud‐based file hosting and data analytics.

Camera installation is as simple as a 1⁄4”‐20 bolt with appropriate straight or right‐angle mounting bracket. All systems come with trigger and data cables with support for 24VDC and 120/220VAC 60/50Hz power. Image processing system configuration and setup to be performed by a FreePoint technician same‐day.

For more information on our image processing capability or to request a demonstration, email info@getfreepoint.com

Hacker Studios Presentation

August 3, 2017/in Articles, Technology

Digital Manufacturing: The Future of the Factory is Now

June 29, 2017/in Articles, Manufacturing, Technology

Over the past few decades, IT has penetrated deep into manufacturing, making it a core component of all industrial systems of today. The need for reduced development time coupled with the demand for customized products has only increased its need. Today, Digital Manufacturing and machine monitoring the most comprehensive answer to challenges that plague the current manufacturing landscape.

Digital Manufacturing makes use of an integrated, computer-based solution that is made up of components such as simulation, 3D visualization, analytics, etc. that enhance collaboration between different manufacturing units and harmonizes various processes. At the turn of the century, technologies such as Computer Aided Design, Computer Integrated Manufacturing, Digital Mockups, etc. reached maturity, forming what is today known as Digital Manufacturing.

Digital Manufacturing solutions have now become a key requirement for reaping the long-term benefits of product lifecycle management (PLM). It allows vital integration between PLM and other industrial assets, enabling design & manufacturing units to exchange valuable information with each other. As an end-result, manufacturers can cut costs and achieve their throughput goals in an efficient and timely manner.

Digital Manufacturing makes use of the vast ocean of data collected from various industrial units, simulating them so that processes can be optimized. Feedback is used iteratively from actual production operations to keep the managers up to data of ongoing tasks. Manufacturing engineers are able to create a completely virtual environment that includes:

Tooling
Assembly Lines
Work Centers
Facility Layout
Resources

How Will IoT Help?

From 2012 to 2014, the number of sensors has increased more than five times, thanks to the reduced cost of these technologies. As Digital Manufacturing is based on the data provided by sensors distributed across an industrial unit, the use of IoT is necessary for improving the digital model’s accuracy, flexibility and responsiveness. IoT and machine monitoring technology will provide manufacturers with an in-depth view of all that is happening within the production process. The data collected would be reflected upon the digital manufacturing application, and an intelligent analysis would allow manufacturing engineers to control assets’ setpoints for maximum efficiency.

As a whole, Digital Manufacturing would pack the following benefits:

A consistent approach to product design.
Optimization of manufacturing processes.
Reduction in commissioning costs through robotics & automated programs.
Creation of optimal factory models so throughput peaks at maximum efficiency.
Facilitation in sharing of quality, real-time information across the organization.

An automotive original equipment manufacturer or OEM serves as the best example of Digital Manufacturing. Through proper integration of digital services, the entire manufacturing processes can be virtualized, allowing designers to study the effects of new layouts and ideas. This would allow the early detection of any error before the design hits the assembly lines.

Companies such as Intel, Ford, GE, etc. have already implemented solutions based on Predictive Maintenance, allowing them to anticipate prospective zones of failure and eliminate the production of defective items.

While digital manufacturing, may seem like a thing of the future for most companies, manufacturers (big or small) don’t have to wait for the implementation of new equipment to start seeing positive results. At FreePoint Technologies, our simple and noninvasive machine monitoring software connects with each of your current machines; regardless of brand, type, complexity or age. Going beyond the machine, we also focus on engaging and empowering your employees, equipping them with real-time data to see tangible progress, and allowing them to make informed decisions.

Get in touch with us today to learn more.

Smart Manufacturing: What You Need To Know

June 13, 2017/in Articles, Machine Monitoring, Manufacturing, Technology

In the 80s & 90s, “Smart Manufacturing didn’t exist. Industries streamlined their limited automation processes led by PLCs & controllers through practices such as Lean Manufacturing. While these “practices” were termed as game-changers, their value only diminished at the turn of the century, and today account for minor incremental returns. Fast forward to 2017, and these practices are now being replaced by “smart technologies” that promise a more holistic approach towards increasing efficiency and innovation.

Advanced manufacturing technologies spearheaded by concepts such as Smart Manufacturing, IoT and Digital Factory are already making headlines and rapidly transforming the global industrial landscape. The word “smart” is simply an objective that has found profound use in today’s devices, phones, houses, grids and industries alike. Smart Manufacturing is a term reserved for industrial automation and includes the:

Design
Deployment
Management

of the entire manufacturing lifecycle, enabling preemptive management of industrial assets through real-time information & execution.

The road towards Smart Manufacturing started in 2014 when the US Department of Energy released its Notice of Intent for Smart Manufacturing. From thereon, the US Government has promoted this concept through its renewed, cross-sector public-private partnership called Advanced Manufacturing Partnership.

Systems based on Smart Manufacturing principles are designed with advanced information processing capabilities, deep-rooted communication and synergistic integration of all available resources. The final goal is to automate the processes of monitoring & control, and in turn, increase productivity and efficiency.
The technology particularly works on some specific areas of interest, which include:

Advanced Sensors
Control Systems & Data Analytics
Predictive modeling
Interoperable Communication Platforms
Application Toolkits
Testbeds

Smart Manufacturing, IoT and Digital Factory are already making headlines and rapidly transforming the global industrial landscape. Smart Manufacturing Technologies plan on driving the industrial revolution through three progressive phases:

Phase 1:

Integration of all assets whether they are located at individual plants or enterprise headquarters to instill immediate improvements in costs through coordination.

Phase 2:

The data collected from these assets will be fed into real-time simulation models to develop manufacturing intelligence to allow decisions to be taken based on facts and not predictions. Furthermore, this will allow industrial assets to respond flexibly to changing market requirements.

Phase 3:

As the manufacturing intelligence grows through the accumulation of Big Data, productivity, efficiency and safety of the entire chain of operations will increase.

How Smart Manufacturing Links to Other Automation Technologies Like IoT

It’s simple, Smart Manufacturing is a comprehensive upgrade to all outdated industrial systems. The Internet of Things (IoT) and Industrial Internet of Things (IIoT) are components necessary for the success of Smart Manufacturing, as its very core is dependent upon reliable networking between industrial assets.

Examples of Smart Manufacturing

Smart Manufacturing upgrades existing concepts so that a better response can be issued in the face of any problem. These include:

Machine Monitoring, which gives manufacturers the ability to monitor their machines in real-time, and accumulate data which can then be analyzed.

Advanced Robotics or smart machines operate autonomously and require little human interventions, communicating directly with manufacturing systems.

Integration with Supply-chain, real-time communication between supply-chain assets and manufacturing assets allow not only flexible outputs but provide a competitive edge through the use of Big Data Analysis.

In a nutshell, Smart Manufacturing is an integration of industrial automation technologies and is bigger than any single concept whether its IoT, Smart Machines or Digital Factory. The final goal is a more coordinated approach towards manufacturing during normal operation or crises.

While “Smart Manufacturing”, may seem like a thing of the future for most companies, manufacturers (big or small) don’t have to wait for implementation of new equipment to start seeing positive results. At FreePoint Technologies, our simple and noninvasive machine monitoring software connects with each of your current machines; regardless of brand, type, complexity or age. Going beyond the machine, we also focus on engaging and empowering your employees, equipping them with real-time data to see tangible progress, and allowing them to make informed decisions.

References

http://www.mesa.org/en/resources/MESAWhitePaper52-SmartManufacturing-LandscapeExplainedShortVersion.pdf
https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/about-us/company-overview/TIMEMagazineSPMcoverstory.pdf
https://energy.gov/sites/prod/files/2015/02/f20/smart_mfg_industry_day_chan.pdf
http://www.us-tech.com/RelId/1707353/ISvars/default/From_Machine_Monitoring_to_Smart_Manufacturing.htm

Fanshawe Industry Day

June 12, 2017/in Articles, News

Featured Article in the London Free Press

June 10, 2017/in Articles

We are featured in today’s (March 27, 2017) London Free Press!

The article, titled Closing the knowledge Gap, explains how companies like FreePoint Technologies is growing London’s tech sector and putting the muscle into the region’s all-important manufacturing base.

Read the full article here.

BDC Study: Industry 4.0 – The New Industrial Revolution

June 5, 2017/in Articles, Manufacturing, Technology

Often referred to as the Fourth Industrial Revolution, Industry 4.0 will have a profound impact on all manufacturing sectors across the world. But are Canadian entrepreneurs ready? In the first study of its kind, BDC takes an in-depth look at how Canadian small and medium-sized businesses are adapting to this new revolution, offering valuable insights and recommendations to help make your digital transformation a successful one.

The BDC report on Industry 4.0 includes:

Why it’s important to start investing in this area right now
3 ways to introduce Industry 4.0 into your manufacturing business
How 3 companies are using new digital technology to transform their business
4 tips for getting your business started with digital technologies
How digital technology is dramatically improving productivity, growth and product quality for Canadian manufacturers

Click here to view:

Fact Sheet

Complete Study

Industry 4.0 – The Modern Industrial Revolution

June 1, 2017/in Articles, Manufacturing, Technology

The world underwent a massive technological change with the discovery of solid state technology. The 1960s & ’70s saw a major technological upheave, which later on came to be known as the 3rd Industrial Revolution. Through the application of electronics and use of computer technology, conventional assembly lines were given the first stint of automation.

Fast forward to the 21st century, and the world had transformed into a global village, with all the credit going to one entity, i.e. Internet. This very entity is the majority contributor & motivator behind the modern industrial revolution, Industry 4.0.

Industry 4.0 involves a series of groundbreaking innovations in production and leaps the industrial processes towards higher productivity. It shifts the handling of all production processes to a chain of autonomous devices, interlinked with each other along the entire value chain.

Here’s a better way to look at it. Imagine a model of a “smart factory”, where all physical processes from maintaining heat to checking assembly lines are monitored by an array of sensors. These sensors, in turn, are connected to computer units that monitor & control their output based on the sensory inputs. Furthermore, the bulk of all this data is fed into a business-centric computer system that receives inputs regarding customers’ requirement & market conditions.

Finally, a decision is taken by the Control System to scale up/down manufacturing based on real-world parameters in real-time.

The major features of Industry 4.0 can be summed up as:

Interoperability: Cyber-physical systems allow the use of multi-platform hardware/software.
Virtualization: Control programs are able to simulate manufacturers’ requirements based on real-world data.
Decentralization: Ability of control systems to work independently.
Real-time capability: Removes the uncertainty factors within the supply-chain.
Modularity: Industry 4.0 flexibility allows for quick customization & upgrades.

Industry 4.0 isn’t waiting to be implemented, rather it has already started gaining acceptance in several industries. The following companies have already changed their course to suit the canons of Industry 4.0:

Bosch Rexroth, a German Engineering Firm that develops mobile applications, machinery applications and factory automation services
Siemens, a well-known name in the world of industrial automation, Siemens has begun to integrate its solutions in a more streamlined manner in line with Industry 4.0
SAP, an Enterprise Software company that has started a collaboration with various clients on producing implementable Industry 4.0 models

Industry 4.0 hard at work at SIEMENS

Other companies like Wittenstein, General Electric, Festo, Rockwell Automation, etc. are also in line and are gradually leading the Industrial Revolution.

But how does implementing Industry 4.0 and its associated concepts affect you and your plant?

Intelligence

In addition to monitoring your machines & equipment, Industry 4.0 solutions will safely control these systems and intelligently predict upcoming faults based on the measurements taken. The deep interconnectivity of each unit will ensure that its tracking & assignment is carried out automatically, irrespective of the complex user requirements.

Greater Productivity

Industry 4.0 will greatly increase the productivity of any manufacturing division. Through meticulous use of resources, control systems would be able to perform a wide variety of tasks in the most efficient manner possible. Not only will wastage of raw materials and energy be curtailed, but the productivity will increase as well as each product will have precision & refinement.

Shorten Time to Market

No matter how efficiently or accurately a product is made, it’s worthless without considering the actual market requirements. An Industry 4.0 solution would encompass the entire lifecycle, from production to consumption, so that manufacturers get real-time requirements regarding the market.

Increased Flexibility

Products can be manufactured based on user requirements, and not on a single design, all the while maintaining the economic efficiency of the plant. Minimum manual interaction would result in maximum plant efficiency, resulting in greater profits, a diverse market share, and tougher competition.

While “Industry 4.0 – The Next Industrial Revolution”, may seem like a thing of the future for most companies, manufacturers (big or small) don’t have to wait for implementation of new equipment to start seeing positive results. At FreePoint Technologies, our simple and noninvasive machine monitoring software connects with each of your current machines; regardless of brand, type, complexity or age. Going beyond the machine, we also focus on engaging and empowering your employees, equipping them with real-time data to see tangible progress, and allowing them to make informed decisions.

Receive a Grant up to $100,000 for Installing Machine Monitoring

May 25, 2017/in Articles, Machine Monitoring, Technology

A partnership between the Automotive Parts Manufacturers Association (APMA) and the Ontario Centre of Excellence (OCE) created the Automotive Supplier Competitiveness Improvement Program (ASCIP) program to fuel productivity enhancements among automotive suppliers in Ontario. This pilot program provides grant funding towards installing machine monitoring equipment and software to make the applicant more productive, innovative, or competitive.

Manufacturers who receive the grant are eligible to put the money towards FreePoint’s Machine Monitoring Software.

Funding Snapshot: ASCIP Technology Adoption Stream

Amount

Up to 50% funding coverage up to $100,000 in grant funding for a $200,000 project.
Reimbursement is based on completing project milestones and submitting proof of expenses.

Eligible Applicants:

Ontario automotive supplier (at least 50% of total revenues must be generated from the auto sector).
SME ( Only one application per company.

Eligible Projects:

Projects must increase suppliers’ capabilities to deliver shorter design cycle times, be more productive and more responsive to changes, and take advantage of new business opportunities.
Projects are assessed on their ability to improve product lifecycle management through IT and/or productivity enhancements to manage the entire lifecycle of a product efficiently and cost-effectively.
Projects cannot start before being approved for funding and cannot exceed 2 years.

Eligible Expenses:

Labour – Capped at 25% of the project budget.
Contractors – Two alternative quotes will need to be submitted with the application. Consulting costs are capped at 25% of the project budget.
Software (ex. Machine Monitoring)
Implementation costs
Equipment – May be eligible if it directly relates to a software implementation and leverages benefits of that software.

Timelines:

Intakes for 2017 applications close on November 7 at 2:00pm (Application review meeting: December 11, 2017).

Key Information:

Find out more information on the Automotive Supplier Competitiveness Improvement Program

Is your business eligible for the Automotive Supplier Competitiveness Improvement Program?

Grant Deadlines

Next Steps:

For more information on how to take advantage of these savings by installing machine monitoring with FreePoint Technologies, get in touch with Paul Hogendoorn at paulh@getfreepoint.com.

Information sourced from Mentor Works.