Automated machine downtime
Automated machine downtime
(OP)
I am trying to determine the machine run time (10 CNC machines total).
We manufacture tool joints (drill pipes).
Currently a main server downloads programmes to each machine, corresponding ot the part to make. Each part takes approximately 10 to 15 minutes. Each time has a start cycle button that the operator must press before the cycle starts.
What i am trying to do is to get each machine to send a signal to the server (time of the day, status of the alarm) each time the operator push the start cycle button. From there, I can calculate the run time/ planned and unplanned downtimes.
Anybody has an idea of who can help me do this? There's got be some companies out there specialized in this kind of stuff...
Maxbreizh_ Houston.





RE: Automated machine downtime
Have you checked with the machine builder? Some controllers have this function built into them.
Griffy
RE: Automated machine downtime
I've also found these guys from a different forum:
http://www.enetdnc.com/
Exactly what I was looking for.
If you have a look, let me know if you are aware of any similar company.
Thanks again,
Maxbreizh.
RE: Automated machine downtime
Veryintersting question. Do you mind me asking if your company is high volume or a job shop? What are you expecting to do w/ the data?
RE: Automated machine downtime
The company is Innovative Controls Inc @ htt
they use Sixnet h
RE: Automated machine downtime
It's high volume if you like because they could process 1000 piece orders.
I'm running KANBAN on Kaizen cells and I need the data to determine the causes for cycle failures.
Well, the data is very useful for many reasons... cycle times, unplanned maintenance ratios, process optimization, CAPEX requirements (type of machine mostly needed), training of the operators, etc.
This data is crucial if you wish implement lean manufacturing in your work environment, particularly KANBAN.
Maxbreizh.
RE: Automated machine downtime
Where/ How can I get more information about your system?
Can you be my contact for that or should I use the web link on your website?
I need a quote for this system, installed in our premises.
Thanks!
Max Breizh
RE: Automated machine downtime
RE: Automated machine downtime
Thanks.
I went to the GE website and I looked at the product offered, particularly:
"Proficy Shop Floor SPC - a complete statistical process control solution for the collection, monitoring and analysis of plant floor quality data"
I am worried that this is too powerful a system (therefore expensive) for what I am trying to do. Do you remember how much you paid for this system (give me an approximate per machine is great!).
Thanks,
MaxBreizh
RE: Automated machine downtime
It seems to me that you have a good opportunity here if you work on this one without front end software. What I propose is that you make a daily half-hour trip to this area and, if a machine is not running, stop and ask the operator why.
This does several things.
First, it allows you to build credibility with your operators. Second, it allows you to make the call on the actual cause. Third it will improve morale. Fourth, your discussions with your management team will have more conviction from first hand knowledge as opposed to statistics. Fifth, it allows education of the operators both in operation and in analysis.
When you are satisfied that they understand what you are looking for, step back and take another look. You may not need the software at all.
Griffy
RE: Automated machine downtime
Sorry not much help here with cost. We had Cimplicity running so it was just a matter of paying local Fanuc whizz to get a screen made and then hooking it up to our server as the machine tool had the front end loaded when purchased. Look at this site it is a screen capture of our reporting and the homepage of the team that did the connection and screen.
http://
RE: Automated machine downtime
What is you makes perfect sense to me.
The purpose of the software is not to determine how good the operators are at running their machines. I trust them at doing their job perfectly well, if not the issue is training and not punishment. I'm 200% behind what you say.
The main reason why this is done is to determine the ratio between planned and unplanned maintenance (curative and preventative) ; this is particularly difficult right now because the machines run according to a particular cycle time that does not necessarily require each and all machine to run at all times. For example I may thread and mill with 2 different machines, but it takes 3 times longer to thread so the milling is in standby 2/3 of the time and that's okay, but I do not have any way to measure it accurately ; so I need this software _
Bugnut,
Okay. Now I understand. I looked at the wrong website! Control Installation is indeed much simpler than Innovative Solutions. I'll call them tomorrow-
Thanks!
Max Breizh
RE: Automated machine downtime
If you didn't want to purchse software right away you could collect valuable data to evaluate the process by monitoring the logic of the machine. this would provide you with exact times run, buttons pushed, change over times, up & down times plus any other combination you can think of.
Depending on the controllers in use, such as an Allen Bradley SLC series, you could program in a logic program with a few cascaded RTO functions. Also the programing of TOD clock circuit would give you all the data you need with the time of day logged without adding a lot of cost. The MSG function is an invaluable tool. These are options available at practically no cost except time to program.
rlgauto
RE: Automated machine downtime
I have tried to dertemine some of the causes like mantainance, please give me some ideas how to solve this problem.
RE: Automated machine downtime
What are the failure causes when the machine goes down? Take a look at the usage and failure history if available, and see if there are patterns. At the very least you could create a pareto and go after the most prevalent failure type first. Six to Seven breakdowns in a 4.5 hour run should give you quite a bit of data in just a few days.
Some Categories for failures in no particular order:
Improper run setup
Feedstock Problems
Program Problems (timing etc)
Maintenance
Facility (poor quality power, air, etc)
Package design inappropriate for machine or tooling
Regards,
RE: Automated machine downtime
One of the greatest analytical tool around is the graph. I suggest plotting the breakdowns over the elapsed time. Look for clusters and/or spacing. All early in the run, llok at set up. Evenly spacer would cause me to look at operator issues and late clusters might point to variation in the feedstock. Not absolutes but they may save time in the long run.
Griffy
RE: Automated machine downtime
I have looked at the failures: I have found that it has to do with Feedstock promblems the pills get stack in the feeder now I don't know how to solve that, because I thought by changing the brushes it will be ok but it is still happening.
RE: Automated machine downtime
How does the problem normally get "fixed" when the machine goes down? See if there is a way you can build or add this fix (or something similar) to run at the same time the machine is in operation.
Regards,