(I (IIoT) to Im Improve Overall Equipment Effectiveness (O (OEE) - - PowerPoint PPT Presentation

How to Utilize the In Industrial In Internet of f Things (I (IIoT) to Im Improve Overall Equipment Effectiveness (O (OEE)

Josh Davids President and CEO Scytec Consulting Inc. josh.davids@scytec.com 720-482-8250 https://scytec.com

• Established in 2001
• Focused on software and technology for manufacturing

data collection

• Members of MTConnect Technical Advisory Group
• Creators of Scytec DataXchange, Cloud and On-Premise

machine monitoring

About Scytec

Topics

• Review the opportunity and benefits of machine monitoring
• Why do machine monitoring projects typically fail
• How to be successful implementing machine monitoring
• How to achieve ongoing value from machine monitoring
• Discussion on MTConnect
• Overview and detail of IIoT
• Modern approach to Machine Monitoring

Annual new data stored by sector, 2010

87 116 166 207 245 256 273 276 336 375 424 773 776 911 1812

500 1000 1500 2000

Construction Consumer and Recreation Resource Industries Utilities Wholesale Transportation Insurance Education Securities Healthcare Professional Services Banking Retail Governement Manufacturing

Petabytes Industry Sector

SOURCE: IDC; McKinsey Global Institute analysis

Discrete manufacturing constitutes 1072 petabytes Process manufacturing 740 petabytes

Generating Data, But Not Using It….Yet

• In 2013 it was estimated that 4% of machine

tools were being monitored

• In 2014 79% of respondents indicated that

“optimizing asset utilization” is a “very to extremely important” driver for near term adoption of shop floor technology

Source: World Economic Forum Industrial Internet Survey, 2014

Not Only A Benefit – A Requirement

• Customers demanding it from Suppliers
• “If you’re not using a system then you’re not as efficient as

you could be, and you’re not going to continue to pass the cost of those inefficiencies on to us”

• Moving away from “Competitive Advantage”
• Moving towards “Required to Compete”

Benefits

• Manage by Fact
• Improve communication
• Eliminate mistakes
• Increase quality
• Increase utilization
• Increase profits
• Change the culture on the shop floor
• Better internal and external customer relations

Typical Reasons For Not Starting

• Large initial cost
• Plus on going support cost

Upfront Cost

• Can’t start with a few machines
• Inflexible licensing, old technology

Not Scalable

• Database and report servers
• Manual software updates

Maintenance

• Lack of flexibility when collecting
• Lack of flexibility when reporting

Data Accuracy

Reasons Machine Monitoring Project Fail

• No good plan on how to roll out
• Implement features too quickly
• Data is not useful or meaningless
• Poor adoption on usage of the system
• Missing proper support from leadership and management
• No buy-in from shop floor personnel
• Too difficult or time consuming to maintain

Change The Image – Change The Culture

• Just monitoring is data in one direction
• Big Brother
• A few people have access to the data
• The data will be used to punish the shop floor
• Use the system as a communication tool
• Also have operators enter downtime reasons
• Expose the real-time data using dashboards
• Use the charts in daily production meetings
• Allow operators to trigger notifications

Empower the Operator

• 1st Goal is to eliminate the yellow
• Enter downtime reasons
• Use PCs, Windows tablets or iPads
• Set rules: If down for more than 10 minutes you need to enter a reason
• Use Notifications: If down in “Unknown Downtime” for more than 10

minutes then send and email to the supervisor

What’s your Definition of In Cycle

• What if the machine is running in a low feed rate override
• Use of Program Stop and Optional Stop (M0 and M1)
• Short 15 second stops for automatic tool changes or probing
• A run for first article

Timeline – Green / Yellow

The List of Downtimes

• Keep the list manageable, don’t have too many
• Always have ‘Other’ in the list
• Garbage In – Garbage Out
• Use of ‘Other’ identifies a training need, or a need for an addition item in the list
• The use of ‘Other’ can trigger email or text notifications
• Some problems will magically disappear
• Other unknown problems will arise
• Root cause issues

Timeline Chart

Showing short cycle stops

Comparing Equipment Status

Data Entry to Qualify Downtime

• Enter from an iPad, Windows tablet or PC
• User defined downtimes
• Planned and Unplanned downtimes
• Trigger email from the Data Entry screen
• Modify the downtime list and all tablets and iPads sync automatically
• Receive feedback on the tablets
• All buttons controlled by permissions

• Sample Data Entry

screen

Now – Increase the Green

• Once there’s a good handle on the definition of run time and

downtime reasons improvements can be made

• People will still talk – the difference is now they hit the cycle

start button first

• Six Sigma tools can now be used effectively

Comparing Equipment Status

How to Achieve Ongoing Value

• Grow with the system
• The system needs to grow with you
• You’re not buying a product, it’s an on going service
• You in a partnership with the service provider
• Continual feedback on what works, what isn’t working
• Talk to the experts

Keys to Success

• Expose the Data
• Real Time Viewer on the Shop Floor
• Unlimited Reporting, Charting and RTV
• Communication
• Data Entry of Downtimes
• Email and Text Notifications
• Don’t Over Load Anyone
• Start Simple and Let the Software Grow with You

What is MTConnect

• MTConnect is an open and royalty-free protocol for

communication of data

• Commonly used between shop floor equipment and

software applications, such as Machine Monitoring Software

• Provides a common ‘language’ between machines
• Supported by many machine tool builders
• Lowers implementation costs across machines

Machines / Controls that MTConnect Capable

• Okuma
• Mazak
• Mori
• Mitsubishi
• Siemens
• Makino
• Num
• Doosan
• Fagor
• Fanuc I Series controls
• Some legacy machines

What Does MTConnect Do?

• The MTConnect Adapter continuously monitors machine operating

state and other data such as feed rate and overrides. The agent then makes that information available over an Ethernet network using an industry standard format that is open and compatible with a wide range of software.

MTConnect Architecture

• Adapter and Agent on the

CNC Control

• Only the Adapter on the

CNC Control

• Neither the Adapter nor

the Agent on the CNC Control

Adapter Agent CNC Machine #1 CNC Machine #3 Adapter CNC Machine #2 Agent Adapter Agent Application

MTConnect Architecture

• One Agent can serve

multiple Adapters

Adapter CNC Machine #1 CNC Machine #3 Adapter CNC Machine #2 Agent Adapter Application

MTConnect Architecture

• The Agent uses http as the

protocol, therefore can communicate over the Internet

Adapter CNC Machine #1 CNC Machine #3 Adapter CNC Machine #2 Agent Adapter Application

Internet

MTConnect Adapter

• The Adapter is not part of the MTConnect Standard
• The Adapter is the liaison between the machine control (or other devices

such as sensors) and the MTConnect Agent

• The Adapter has two primary functions:
• Get information and data from the machine
• Send the data to the MTConnect Agent

Adapter and Agent Examples

• The Adapter can be purely software
• The Adapter can be a hardware device
• The Agent could be included with the hardware Adapter
• Adapters may also be used to collect data from sensors or HMIs

Agent Output

• Data is output

in XML and can be viewed in a web browser

Scytec MTConnect Viewer

• Scytec provides a viewer

to easily visualize the MTConnect data

Why Use the Cloud

• Automatic software updates
• Better support
• Flexibility with licensing
• Pay as you go
• Does not hit capital expense
• Improved security
• Improved mobility
• Maintenance free
• Access the data from anywhere
• Interoperability

Typical Architecture

Https communication Firewall Friendly If the Internet connection is lost the Local PC stores data until the connection is reestablished

Customer Site

SSL encryption

What is IIoT

• IIoT (Industrial Internet of Things)
• IoT is the term used for collection of data being sent to the Internet for

some purpose

• Sensors
• Cloud storage
• Cloud analysis

What is the Benefit of IIoT

• High value for low cost
• Scalability
• Flexibility
• Enables capability that would normally be out of range for most mid-to-

small companies

Where are things going

• Changing what is ‘normal’
• Preventative maintenance based on actual spindle usage
• Predictive maintenance based on vibration and other sensors
• Analytics to find trends in usage

Software Examples

• MTConnect Examples
• Adapter
• Agent
• Viewing Data
• Collecting Data
• Dashboard
• Required Flexibility
• Collection rules
• Dashboard configuration
• Notifications