Use Cases Manufacturing System Automation

Manufacturing System Automation

Manufacturing system automation integrates software and machinery so that manufacturing processes are run autonomously through computer programming. The goal of manufacturing system automation is to minimize the amount of human assistance needed in the manufacturing process. These systems provide constant feedback loops and adjust controlling parameteres in response to feedback from PLCs and smart sensors installed on machinery. Sensors are commonly embedded in new equipment or can be installed on legacy equipment. Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices and computers, usually in combination. The benefit of automation includes a reduction of costs related to labor, electricity, water, gas, and scrap, as well as improvements to quality, accuracy, and precision. Manufacturing system automation can also reduce changeovertimes, thereby enabling small batch size production and mass customization.
Read More
Improving Production Line Efficiency with Ethernet Micro RTU Controller
Improving Production Line Efficiency with Ethernet Micro RTU Controller
Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations
IIC Smart Manufacturing Connectivity for Brown-field Sensors
IIC Smart Manufacturing Connectivity for Brown-field Sensors
The discrete manufacturing domain is characterized by a strictly hierarchical structure of the automation systems, commonly referred to as the automation pyramid. Data acquired by a sensor typically flows through an IO-module into a Programmable Logic Controller (PLC) which manages the local real-time control system. As all process data are concentrated in the PLC, re-programming the PLC and thus, implementing interfaces to access these data appear to be the natural choice to transfer them to the IT system. However, for brownfield installations this choice has proven impracticable for the following two reasons:In brownfield facilities, PLC usually operate within a once-specified environment and are rarely re-programmed. That is why the active staff is often not familiar with the code and lacks of the competence to modify the existing implementation in a reasonable amount of time.Furthermore, for cost reasons, any PLC was selected to exactly match the requirements of the environment within which it was intended to operate. That is why it cannot be assumed that a PLC will be able to support additional tasks such as communicating data through additional interfaces.
Maintenance efficiency – automated
Maintenance efficiency – automated
Egger Ltd at Hexham, Northumberland, UK, manufactures chip board and associated products on highly automated production lines. The programs within numerous manufacturing systems and controllers are vital to the resulting OEE of the company and require frequent back up, version control and automatic administration. Egger standardised on Versiondog software from SolutionsPT to undertake and manage this task.

The global Smart Manufacturing Market is set for rapid growth and is expected to reach around USD 479.01 billion by 2023.

Source: Zion Market Research

What is the business value of this IoT use case and how is it measured?
Your Answer

How do automated manufacturing systems provide business value?

● Safer for Employees
● Increased Productivity (24/7 runtime)
● Improved Product Quality
● Higher Yields
● More Accurate Data Collection

Not only do automated industrial systems increase production capacity, but the quality of that production is improved, along with greater safety for the employees operating the equipment. These systems can also be configured to provide more accurate data to optimize weak points and greatly decrease product defects due to human error.

What are the benefits of MIcrogrids?

Provides power quality, reliability, and security  for end users and operators of the grid

Enhances the integration of distributed and renewable energy sources

Cost competitive and efficient

Enables smart grid technology integration

Locally controlled power quality

Minimize carbon footprint and greenhouse gas emissions by maximizing clean local energy generation

Increased customer (end-user) participation

 

Which technologies are used in a system and what are the critical technology?
Your Answer

What are the latest trends in manufacturing technology?

New manufacturing technologies are continually emerging. Some of the biggest trends in recent years include:

  • 3D printing: enabling the creation of almost any component using metal, plastic and other materials, reducing lead time and streamlining the design-to-production process
  • Cloud services: enabling virtual sharing of data and services from any location quickly and efficiently
  • The Internet of Things (IoT): transforming not just the consumer market, but the maintenance and upkeep of electronic devices used in manufacturing processes as well
  • Nanotechnology: enabling things like faster computer processing, longer product lifecycles and super-precision manufacturing, and pioneering advancements in sectors such as space engineering and biotechnology
  • Advanced data analytics and predictive technologies: enabling better process control, prevention of defects and quicker response times in manufacturing
  • Industrial robotics: offering ways to increase productivity, improve quality and reduce cost by automating difficult or monotonous tasks.
What business, integration, or regulatory challenges could impact deployment?
Your Answer

What is the biggest challenge face Manufacturing System Automation?

● Cost of Initial Investment

There’s only one real downside to implementing automated manufacturing systems, which is the initial cost. This includes the costs of machinery and implementing automated programming as well as training of employees to manage these new systems. However, ROI on this investment generally pays for itself within a few years.

 

Download PDF Version
test test