OVERVIEW | INTERNET OF THINGS TOP
The Internet of Things (IoT) becomes reality for one of the top 500 fastest growing manufacturing companies in the US.
Although there's already much to read about the Internet of Things (IoT) for manufacturing in practice realization of such projects is extremely difficult business. Mainly because there's neither a common standard for communication between machines and business information systems nor a standardized method to pull out business relevant information from these devices.
However, by understanding and following some fundamental principles the customer was able to link together manufacturing processes with enterprise processes and master data in a simple and reliable way. This paper describes those principles, linking them together in a coherent journey covering the goals, the terms, the tools, and the decisions that were needed to successfully integrate the shop floor with the rest of the enterprise.
QUICK FACTS
Company
Location: Naples, Florida
Industry: Life sciences
Products and services: Medical devices
Revenue: US$ 1.5 billion
Employees: 3,000
Plants covered by the solution: 2
Manufacturing devices in total: 367
Production machines: 240
CNC controlled Machines: 100
PLC controlled machines: 140
Implementation partner: inventcom
Benefits
Minimized machine integration costs by only using software based solutions
Streamlined work order performance tracking across multiple plants
Enhanced visibility, integration, and efficiency by eliminating paper-based, manual business processes
Reduced time needed to detect machine issues
Enabled web and role-based dashboards for different employees to gain the insights they need too
Challenges and Opportunities
Acquire all information needed for process improvement and enhancement of transparency of the shop floor
Align data from production resources with business processes
Enable enforcement of measures to optimize flexibility, efficiency and effectiveness of the plant floor
Deliver convincing data that enables the customer to detect bottlenecks within the production and create error analyses.
Utilized Software Solutions
Oracle Manufacturing Operations Center (12.1.3)
Kepware Kepserver (for OPC capable shopfloor devices)
MTConnect (for controllers equipped with MTConnect client components)
Inventcom CNCnetPDM (for CNC and PC controlled machines)
Customer specific applications for scheduling, data import from ERP and operational data acquisition (SIP) based on Microsoft SQL Server
Customer specific program for transfer of data acquired by Kepware or MTConnect into Oracle DB (Data Service)
Objectives
Automatically acquire data about equipment status and production performance from highly diverse machines
Paperless gather data about work-order execution and scrap from machine operators
Collect scheduling information from different existent sources (ERP, customer specific solutions)
Output reports such as Throughput, Availability, and Overall Equipment Effectiveness
Report results about work order execution back to ERP
Implementation Highlights
Integrated all manufacturing devices with the existing IT infrastructure without the need for additional hardware at the shop floor
Transformed manufacturer specific machine output into homogenous, comparable data packets
Contextualized machine-data (states, part-counters) with work-orders, operations and part numbers
Automated data import from ERP, customer specific programs for scheduling and legacy applications into a single data repository
CONTENT
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Success Stories | Internet of Things | Machine States The initial requirement of the customer sounded pretty simple: ‘We’d just like to know whether our manufacturing equipment is producing or not’. When standing... [read more]Success Stories | Internet of Things | Output Quantity For any kind of measurement it’s imperative for manufacturers to know the amount of parts produced by the equipment. Now that the customer knew about the state of the... [read more]Success Stories | Internet of Things | Operational Data Of course automatic reporting of machine-states and part counter values by the manufacturing devices was great progress but the customer now needed to see this data in context... [read more]Success Stories | Internet of Things | Quality Data To be able to create reports about the produced quality additional data from the shop floor was needed. Although it would have been perfect to get this data directly from the... [read more]Success Stories | Internet of Things | Scheduling To perform any target to actual comparison and output Key-Performance-Indicators (KPI) such as Overall Equipment Effectivity (OEE) it was necessary to integrate scheduling data... [read more]Success Stories | Internet of Things | Data Processing Even having all required information in a single data repository again was good progress the next challenges were to put all data into relationship, build the desired reports and... [read more]Success Stories | Internet of Things | Dashboards Overview The customer's solution Oracle’s Manufacturing Operations Center (MOC) uses the concept of providing web- and role-based dashboards for different employees to gain the... [read more]Success Stories | Internet of Things | Production Supervisor This dashboard acts like an electronic whiteboard that automatically fetches data from the customers shop floor devices and provides real-time information about equipment status... [read more]Success Stories | Internet of Things | Overall Equipment Effectiveness OEE The standard of Oracle’s Manufacturing Operations Center (MOC) ships with a dashboard called ‘Plant Manager’ which includes several reports that output Overall... [read more]Success Stories | Internet of Things | Production Loss Analysis This dashboard outputs information about production loss distribution (B), effective production capacity (C) and production loss (D) for machines in a department of a plant... [read more]Success Stories | Internet of Things | Equipment Downtime Analysis This dashboard shows downtime reasons machines in one or all departments of a plant within a selected period (A). The pie chart (B) below the selection area outputs the... [read more]Success Stories | Internet of Things | Production Slippage Trend This dashboard, accessible from the equipment downtime analysis report outputs, in addition to total production value (A), production slippage hours (B) and a performance to... [read more]Success Stories | Internet of Things | Equipment Idle Time Reasons By using this dashboard the reasons for idle times of machines within a selected period (A) can be analyzed. Right to the pie chart (B) with percentage distribution of... [read more]Success Stories | Internet of Things | Equipment Efficiency Analysis For selected equipment in one or all departments of a plant (A) this dashboard outputs an analysis about the efficiency of the manufacturing resources within a period of time. In... [read more]Success Stories | Internet of Things | Equipment Scrap Analysis This dashboard shows an analysis about bad quality produced by manufacturing equipment in one or all departments of a plant (A) within a selected period. Right to a pie chart (B)... [read more]Success Stories | Internet of Things | Batch Performance This dashboard provides analytics tools for work orders executed within a selected period in all or single plants and product categories (A). The graph (B) on the left side below... [read more]Success Stories | Internet of Things | Production Performance This dashboard enables comparison of scheduled with actual equipment usage. Output can be limited to one or all departments in a plant within a selected period (A). The... [read more]Modified: 2017-06-19
