How Connectivity of Devices Enhances OEE

For manufacturing plants to experience maximum overall equipment effectiveness (OEE), the connectivity of devices is crucial for gathering accurate data. To enhance the availability, performance, and quality metrics of machinery—the three components that constitute OEE—plants now have various connectivity solutions at their disposal to capture valuable data for enhancing production.

Comprehensive Solutions

OEE holds significant authority as it encapsulates a wealth of information in a single figure; therefore, it is widely utilized as a benchmark for optimizing production processes within factory settings. By adopting a three-pronged strategy that delves into the availability, performance, and quality metrics of machines, factory managers can gain a deeper insight into areas that require adjustments in their manufacturing processes to attain peak efficiency. Once areas of concern have been pinpointed, new technologies can be sought after to rectify deficiencies in manufacturing processes.

Enhancement Strategies for Machine Availability

Monitoring the operational status of machines on the factory floor continuously is vital for minimizing downtime and enhancing network uptime. Real-time data is therefore essential to implement predictive maintenance procedures. Different types of machine status data including machine vibration, motor current, tool levels, coolant levels, among others, can be generated during production. With this data, machine maintenance specialists can proactively schedule maintenance activities in advance (predictive maintenance) to prevent unexpected machine downtimes. However, this data manifests in different formats. One form is streaming data, which is transmitted in large volumes necessitating preprocessing before transmission to a backend system. Another form is status data, transmitted in small volumes and through a transparent method without preprocessing. Hence, distinct data collection techniques are warranted.

For streaming data, the optimal approach involves utilizing front-end data processing to reduce the volume of data transmitted, ensuring that only valuable data is relayed to the backend system.

Techniques to Enhance Machine Performance

In a mixed-model production environment, a programmable controller that supports a multitude of functions and interfaces, such as serial, DI/O, and AI/O, proves to be immensely valuable. The controller aids in categorizing production tasks by automatically retrieving task sequences from a manufacturing execution system (MES). For instance, tools identified by RFID tags trigger the controller to fetch corresponding production methods from the MES via RESTful API, subsequently notifying all relevant machines using an industrial protocol like EtherNet/IP, PROFIBUS, or Modbus. Production information can be acquired through an IT protocol such as RESTful API.

Strategies for Enhancing Output Quality

Attaining flawless production hinges on zero defects, with production data once again playing a pivotal role in achieving this objective. Two varieties of data are relevant: stable data (on/off status) and transient data (generated over short intervals and requiring comprehensive recording without omissions). Upon generating the latter, an immediate alert should be dispatched to operators signaling an ongoing interruption. As the precision of production quality lies in this transient data, the critical task is to precisely capture and record this data. A robust IIoT controller designed to withstand harsh environments can accurately collect data to ensure line managers are constantly updated about the status of all on-field devices.

Moxa’s Cutting-Edge Solutions

In addition to the aforementioned solutions, there exists a plethora of options available for manufacturing plants to elevate their production technology and enhance their OEE efficiency. For further information on these solutions, refer to our whitepaper: Device Connectivity Is the Key to Optimal OEE in Industry 4.0.