Lookout Optimizes Manufacturing Production Efficiency

Author(s):
John Dunlop - Bytronic

Industry:
Industrial Controls/ Devices/ Systems

Products:
Compact FieldPoint, Lookout, FieldPoint,

The Challenge:
Developing a production line-monitoring system that is capable of analyzing machine data to target key areas of concern for manufacturing staff in a high-volume, fast-moving consumer goods (FMCG) plant.

The Solution:
Creating a line-monitoring system using National Instruments Lookout HMI/SCADA software and FieldPoint distributed I/O to optimize manufacturing production efficiency on a variety of FMCG production lines.

Improved Manufacturing Profitability
FMCG production is a dynamic, finely tuned business that requires that every aspect of a line run smoothly for maximum productivity. Bytronic and OptimumFX developed and installed a line-monitoring system that helps to optimize manufacturing production efficiency on a number of high-volume FMCG manufacturing lines in the United Kingdom.

The line-monitoring system provides a user-friendly interface that displays real-time performance data and dynamic statistical analysis to the operator and records historical information on the complete production line. Knowing what is happening with each machine at a given time is important, but knowing the effect that a particular stoppage is having on production as a whole, is vital. As such, the system employs manufacturing theory techniques based on loss analysis to identify critical areas of disruption and report its findings to the operator. Decision makers can then use the loss analysis to assist in decisions on maintenance and continuous improvement, leading to greater machine utilization and improved manufacturing profitability.

Observing Production Line Status
The FMCG sector, like many areas of modern manufacturing, faces this new decade with increasing demands for the highest levels of productivity from its capital investment. Manufacturing staff must, therefore, make every effort to maximize plant efficiency throughout all areas of production.

In developing our solution to increase plant efficiency, we considered a number of production lines, all of which exhibited similar characteristics; namely that decision makers do not have the tools to observe the status of the production line in entirety and to analyze the upstream and downstream effects of stoppages.
We developed this system with these specific needs in mind, bringing a user-friendly PC-based solution to the factory floor. Using this system, operators can view the entire production line from a single viewpoint, which provides them with a dynamic status of the current level of efficiency. The view of production line status is demonstrated in the Main Overview screen. This screen shows a pictorial representation of the production line, in this case a bottling line. Animated graphics mimic the movement of the production line machinery, and numeric displays reflect the current status of the line.

Accessing Data Via Ethernet
Each machine on the production line is independently controlled with a programmable logic controller (PLC), which is connected to a high-speed Ethernet local area network (LAN). A server running Lookout HMI/SCADA software communicates with the PLCs to monitor and record the current status of each machine. To connect our system via Ethernet throughout th plant, we used FP-1600, FieldPoint distributed I/O modules, for additional inputs.

Lookout records parameters, such as availability, speed, and any fault condition of each individual machine, in its historical database located within the server. Operators can access this data in the Machine Status screen. This screen shows two hyper-trend objects providing an immediate link to the historical database.
The colour coding of the Machine Status screen gives operators easy recognition of problem areas and effects of stoppages up and downstream. Red indicates that the machine is not available; light blue indicates that the machine is lacking product, and dark blue shows that the machine is built back.

Lookout Total Plant Perspective
While it is important to record statistics on individual machines, it is vital to know the effect that a particular stoppage has on production as a whole, so, in addition to reporting on individual machines, our line- monitoring system displays analysis from the total plant perspective. Whenever disruption takes place, Lookout easily and rapidly identifies the most critical areas.

Two Lookout clients per production line, one located in the production office and one as a touchscreen on the factory floor, make use of structured query language (SQL) functionality to retrieve data across the network for further analysis.

The analysis employed in the system is based on the well-established technique known as six-loss analysis, which analysts use to assist in asset planning decisions, leading to greater machine utilization and improved manufacturing profitability. Lookout displays the six- loss analysis in the Loss Analysis screen. This screen shows areas of concern as bar graphs and time-based data.

Operators can either print, in a report format, or export, to external manufacturing systems, all of this data for audit purposes. Our line- monitoring system is also useful in the training production operators and in reporting the effects of modifications to the production line. For example, we have seen that the system is highly effective in evaluating the performance of new machines or even entire new production lines. At present, the line- monitoring system is monitoring the production of over 500 million units per year and is a key tool in manufacturing budget planning.

For more information, contact:

Bytronic Automation

Innovation Centre

Warwick Technology Park

Warwick, United Kingdom

Tel: 44 1926 623350

Fax: 44 1926 623351

E-mail: automation@bytronic.com

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