As a plant manager or team lead, you have the essential responsibility of keeping your operators motivated. Helping them gain new perspectives on their work can improve employee engagement and, ultimately, your bottom line. When employees are provided with narrative software resources to see how their contributions make a difference, they become much more interested in putting in a productive day.
You’ve likely heard the term Internet of Things (IoT) in reference to smart home technology but how does it relate to your shop floor? In its simplest definition, IoT means “things” that are connected to the internet, physical objects such as your home, office or car. In smart manufacturing, it’s known as Industrial IoT (IIoT) or Industry 4.0, the fourth industrial revolution. It provides manufacturers with the ability to connect all machines and equipment in their plant to the internet to gather real-time, actionable data. With Freepoint, connecting machines is quick and easy on both legacy and new machines.
The following case study demonstrates how FreePoint Technologies has successfully helped a customer increase efficiency by 69% over a one-year time span and saved them $325/day.
The customer is a modern machine shop located in the border region in Mexico. The shop has 4 Electrical Discharge Machines (EDM) that are critical to the company’s production. The following figures demonstrate the impact of FreePoint Technologies’ system.
The image below (the before scenario) shows pertinent productivity information from these 4 machines from a typical day in October 2015. The blue bars illustrate the EDM machines’ run times for a 24 hour period and the white gaps indicate the setup time between each run. Both the run (blue bar) & setup times (white bar) vary depending on the job. The shop, in the before scenario, required 24 hours of scheduled production time to produce a total of 43.5 hours of “value adding” activity using the 4 machines on that day.
The screenshot below illustrates the exact same 4 EDM machines shown one year later (October 2016). Similar to the previous scenario, the blue bars still vary in accordance with the jobs being run on each machine, however, the setup times (the white gaps between the blue bars) are now consistently smaller than the 2015 snapshot. The result from integrating FreePoint Technologies’ system is that less time is being lost between productive “value adding” periods. For the customer, this means that more value adding activity (specifically 57 hours on this day) occurred in less scheduled production time (two 8.5 hour shifts vs. three 8 hour shifts). All of the recovered lost machine time was then aggregated, and the machines were freed up for an entire shift. Not only does this decrease production cost for parts being produced, but it increases the plant’s capacity and ability to take on more work.
The image below compares the month of October 2015 to the same month, one year later in 2016. As illustrated in the graph, every day of the month in October 2015 had machine activity, meaning that employees were in the shop running the machines. In 2016, the machine activity occurred only on weekdays, freeing up most weekend shifts as well. This allowed the customer to increase their capacity and take on more business. The machine’s efficiency went up from 33% on a typical 24 hour day in 2015 to 56% on a typical 17 hour day in 2016 representing an increase of 69%.
At that rate of productivity improvement, the system as implemented paid for itself in 20 days, and the cost of the ShiftWorx subscription is recovered in the first day of every month. It’s hard to beat that kind of ROI!
For more information on how a FreePoint system can benefit your plant, please contact firstname.lastname@example.org
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:
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
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:
Integration of all assets whether they are located at individual plants or enterprise headquarters to instill immediate improvements in costs through coordination.
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.
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.