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OVERVIEW | INTERNET OF THINGS

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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https://www.inventcom.net/success-stories/internet-of-things/overview
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]
Machine States
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]
Output Quantity
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]
Operational Data
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]
Quality Data
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]
Scheduling
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]
Dashboards Overview
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]
Production Supervisor
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]
Overall Equipment Effectiveness OEE
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]
Production Loss Analysis
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]
Equipment Downtime Analysis
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]
Production Slippage Trend
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]
Equipment Idle Time Reasons
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]
Equipment Efficiency Analysis
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]
Equipment Scrap Analysis
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]
Batch Performance
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]
Production Performance
Modified: 2017-06-19