MES Sigma Develops a System in Peru to Add Overall Equipment Effectiveness Monitoring to Machines
MES Sigma’s solution calculates OEE productivity rates to optimize production (OEE), monitors the status of variables that influence the final product (SPC), and monitors energy consumption to conclude the energy savings of optimization.
InduSoft Web Studio offered a robust feature set for OEE dashboard capabilities, over 250 native communication protocols, patented integration with SQL databases, and affordability.
MES Sigma reports that in every installation, companies have been able to increase their OEE index.
Figure 1: OEE is an index that is calculated by measuring Key Performance Indicators, as seen in this production monitoring screen.
OEE, or Overall Equipment Effectiveness is a valuable set of metrics that explain how well a machine, process, or a plant is operating. OEE is an index that is calculated by measuring Key Performance Indicators (KPI). These indicators include metrics such as Availability, Performance, and Quality. Availability measures how often a machine is online and producing. Performance measures the rate or speed of production. Quality is a measure of how many nonconforming units are produced during production.
Tools such as Statistical Process Control (SPC) can be used to monitor and improve the variables involved in production and help ensure a better quality of product, or measure and monitor energy use and waste. The combination of monitoring KPIs and adding automated SPC can dramatically increase productivity for a machine, reduce energy expenditures, and improve business competitiveness.
While implementing OEE tools for machines in his home country of Peru, Javier Donayre, Manager of MES Sigma noticed that very few manufacturing businesses were taking advantage of OEE solutions, which caused an enormous amount of waste and lost machine efficiency. Those who did implement solutions often used manual recording procedures, making the process slow and prone to human error. To fill this gap in the market for overall equipment effectiveness solutions, MES Sigma began developing a series of OEE solutions that could be customized for each machine or operation and bring OEE capabilities to new machines or retrofit older installations.
Figure 2: The production analysis screen shows a pareto chart to track possible outcomes based on production variables.
Few companies in Peru currently employ Total Productive Maintenance (TPM) tools. Occasionally businesses will record some metrics manually, but manual records were prone to errors and were often taken at times that were not representative of normal production cycles. This meant that plant managers and machine operators were often planning production, setting schedules, and ordering materials based on incorrect data that skewed decision-making. Current practices were inefficient, and machines could be optimized fairly easily by implementing automated solutions that could help improve machine performance over time.
To solve this problem, MES Sigma began developing customizable SCADA solutions for these businesses that would automate the monitoring and recording of machine and process efficiency data and allow operators to better understand and improve their production capabilities.
As MES Sigma began looking for the ideal platform for a customizable SCADA that could provide intuitive OEE dashboards, they examined their requirements. The SCADA software chosen would have to allow communication with a DCSs, PACs, and multiple PLCs. It needed to include as many communication protocols as possible to allow the system to be individualized for each customer, but the most critical protocols were ModBus, Ethernet, ProfiBus, and OPC.
Once communication capabilities were established, MES Sigma needed a SCADA software solution that could easily write information to different databases and generate Excel reports. Finally, affordability meant choosing a solution that would allow them to offer all the features of a SCADA system at a price point that would not be prohibitive for the majority of their clients, and would offer scalability to grow with the business.
InduSoft Web Studio offered the perfect solution, thanks to the robust feature set for OEE dashboard capabilities, over 250 native communication protocols, patented integration with SQL databases, and affordability compared to every other commercially available SCADA software option on the market.
MES Sigma solutions can be used for nearly any machine that manufactures a product or a good. Solutions have been designed for the manufacture of welding electrodes, packaging machines, printing presses, textile machines, and many others. The SCADA solution that powers these OEE dashboards can be integrated easily into the enterprise network or work as a standalone system.
Figure 3: Statistical process control (SPC) is a method of quality control which uses statistical methods.
MES Sigma’s solution calculates OEE productivity rates to optimize production (OEE), monitors the status of variables that influence the final product (SPC), and monitors energy consumption to conclude the energy savings of optimization. Competing OEE solutions offer many of the same features, but are not competitive in terms of pricing or the ability to add new capabilities as the scope of projects expands.
Over the years MES Sigma has used many different versions of InduSoft Web Studio as necessary for their solutions. With the guaranteed compatibility of the newest versions of InduSoft Web Studio with older applications, it’s always possible to work on the latest version of the SCADA software and still support older applications. The OEE solutions integrate with PACs, PLCs, and DCSs primarily though Ethernet and Modbus.
Over the past few years, MES Sigma has noticed that data increasingly needs to be available among different areas of the plant and throughout the business structure. They are increasing the capabilities of their solution to work with Cloud technology and are currently adding functionality that makes OEE data available on smartphones and tablets.
The biggest benefit to an OEE solution is the ability to measure improvement in machine productivity, which makes it relatively easy to quantify an ROI. MES Sigma reports that in every installation, companies have been able to increase their OEE index. For example, one company reported an increase of 15% in equipment effectiveness in only two months after installing the new system, and many companies intend to add more installations on other machines within their plants.
MES Sigma is currently offering advice and training to entrepreneurs to recognize the value in implementing these solutions, as there is a large, untapped market in Latin America for improved efficiency and equipment effectiveness. Meanwhile MES Sigma is constantly evolving their offering to support new customer demands, such as remote connectivity, cloud-based applications, and the ability to monitor machines and processes from anywhere via smartphone and tablet.
Figure 4: Better production analysis offers companies the ability to make real-time business decisions based on OEE and SPC data.
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