Date post: | 16-Apr-2017 |
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INDUSTRIAL PERFORMANCE OPTIMIZATIONOVERVIEW OF THE RELAYR SOLUTION FOR MANUFACTURING
PERFORMANCE OPTIMIZATION SOLUTION OVERVIEW
The relayr Performance Optimization Solution creates a score that quantifies the productivity of planned production time in an industrial process. By capturing data from sensors within the industrial process equipment, the solution can benchmark and analyze the real-time performance of the overall process. Areas requiring improvement are then highlighted, allowing the associated equipment to be optimized. This allows operators to work towards a ‘perfect’ productivity score whilst continually monitoring how well the existing system is performing.
Blow MolderOPERATION STATUS
100%
92%
99%
97%STATUS
AVAILABILITY
PERFORMANCE
QUALITY
FillerOPERATION STATUS
94%
92%
96%
94%STATUS
AVAILABILITY
PERFORMANCE
QUALITY
LabelerOPERATION STATUS
94%
92%
96%
93%STATUS
AVAILABILITY
PERFORMANCE
QUALITY
PackerOPERATION STATUS
86%
74%
83%
81%STATUS
AVAILABILITY
PERFORMANCE
QUALITY
PalletiserOPERATION STATUS
100%
99%
100%
99%STATUS
AVAILABILITY
PERFORMANCE
QUALITY
Total
92,8%Total considering
all machines involvedin this process
A performance score of 100% represents perfect production: manufacturing only good parts, as fast as possible, with no down time. The score is calculated from three underlying factors: availability, performance, and quality. Each of these factors represents a different perspective of how close your manufacturing process is to perfect performance. Analytics can then be undertaken on the data to highlight areas requiring improvement, striving to perfect the manufacturing process.
PERFORMANCE OPTIMIZATIONSOLUTION ARCHITECTURE CHART
EXAMPLE OF A RELAYR PERFORMANCE OPTIMIZATION SOLUTION DASHBOARD
INDUSTRIAL PERFORMANCE OPTIMIZATION
OPTIMIZING THE PERFORMANCE WILL PAY GREATER DIVIDENDS BY ALLOWING A MANUFACTURING PLANT TO IMPROVE OPERATOR PERFORMANCE, AND LOWER OVERALL DOWNTIME
MAIN PARAMETERSWE WANT TO MEASUREWITH THE PERFORMANCEOPTIMIZATION PLATFORM:
Performance: takes into account slow cycles and small stops. A Performance score of 100% means the process is running as fast as possible.Quality: takes into account defects (including parts that need rework). A quality score of 100% means there are no defects (only good parts are being produced).Availability: takes into account unplanned and planned stops. An availability score of 100% means the process is always running during planned production time.
INDUSTRIAL PERFORMANCE OPTIMIZATION
RELAYR PERFORMANCEOPTIMIZATION SOLUTION FORPACKAGING LINESThe relayr performance optimization solution for packaging lines will be installed in the relayr cloud and will receive data from both existing PLCs and some new sensors that will be installed at the customer’s site. The users that may use the plat-form are the production line supervisors, plant managers and C level managers.
KEY FEATURES OF THEPERFORMANCE OPTIMIZATIONPLATFORM
Customized dashboard
Graphs and charts customized by filters
Rule engine for detecting alerts
“Off the shelf” packaged product and quick installation
Flexible packaging of services
Advanced analytics methods for historic data
Real-time notification about performance and quality issues
INDUSTRIAL PERFORMANCE OPTIMIZATION
Y
XZ
1.3
1.8
-1.8 0
5000
2500260
1160
71000:00
01:00
02:00
03:00
04:00
05:00
06:00
30db
40db
50db
60db
70db
80db
X1.8
Z1.3
Y-1.8
-40
125
43 DASHBOARD
GATEWAY DATAANALYTICS
SENSORKITS
PERFORMANCE
OPTIMIZATION
PLATFORMGENERAL ARCHITECTURE
MIDDLEWARE
PLC
PRODUCT LINE
THE FOLLOWING CHARTDESCRIBES THE PERFORMANCE OPTIMIZATION PLATFORM,INCLUDING ALL OF ITS MAINCOMPONENTS AND PROCESSES
THE INFORMATION FROM YOUR PRODUCT LINE IS STORED AND
PROCESSED ON A GATEWAY POWERED BY RELAYR VERTEX, THE
MIDDLEWARE WHICH ENABLES THE CONNECTION WITH MULTIPLE
SOURCES OF DATA BEING PUSHED TO OUR CUSTOMIZABLE
DASHBOARD
INDUSTRIAL PERFORMANCE OPTIMIZATION
THE SENSORS WE USE TORECEIVE DATA FROM THEMANUFACTURING FACTORIES:
MEASURED PROPERTY MIN VALUE MAX VALUE UNIT
TEMPERATURE
HUMIDITY
VIBRATION
ATMOSPHERICPRESSURE
AUDIO SPECTRUM
AIR PRESSURE
-30 70 ºC
0 100 %
0 25 Mm/s
0 1.6 Bar
0 127 NaN
0 10 Bar
THIS DATA CAN BE USED TO MAKE A “SMART ANALYSIS” OF HISTORIC DATA
FROM THE PRODUCTION LINES. WE CAN DO A SMART COMPARISON OF DATA
DURING SPECIFIC TIME FRAMES, BASED ON OUR RULES ENGINE MODULE.
INDUSTRIAL PERFORMANCE OPTIMIZATION
PERFORMANCEOPTIMIZATIONMETRICS FORMANUFACTURINGFACTORIES
Increase efficiency - The user will be able to view output related to the inventory which is used on each production line.Decrease machine downtime - The OEE should display accumulated data about downtime of a machine, production line, and/or factory. The user will be able to define thresholds and alerts.Visualize performance - The performance of the whole factory down to each indivi-dual production line will de displayed according to rules defined by the rules engine.Yield - Percentage of products which are created correctly: one of the most important parameters which are measured and tracked by the OEE platform is efficiency. That translates to how many “good” products can we produce in a specific time period.Energy cost per unit - How much we invest in energy for each unit which we produce at the production line.
INDUSTRIAL PERFORMANCE OPTIMIZATION
IND
USTR
IAL PER
FOR
MA
NCE O
PTIMIZATIO
N
relayr is a rapidly growing IoT company, providing enterpri-se middleware for the digital transformation of industries. Our goal is to enable manufacturers of all sizes to develop their own IoT solutions, from ideation to successful rollout within one business quarter.
www.relayr.io [email protected]