Real time production performance monitoring system a production aid for all industries (original) (raw)

The Production Performance Monitoring System

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To ensure efficient running of production line a production performance monitoring system (PMS) is necessary. Such a system could relay data to monitoring office where decisions can be made to improve production. The data should be true and it should be relayed without human intervention. Such unadulterated data would be interpreted and analyzed to spur actions from the management. A production line is normally operated in a combination of automation or semi automation machineries using programmable logic controller (PLC), sensors and display panel. All this builds the entire networking of the PMS. With the help of this monitoring system the management will be able to monitor both the workers and machine performance. This performance will directly reflect towards the production output. To ensure the performance is always sustainable a real time PMS is required to capture the information's from the production lines and distributes them into understandable production data. The data available should be interpreted accurately in order to identify the various faults at production level and to immediately rectify them to improve efficiency. An accurate data management and monitoring system is equally important in improving production. Faults due to improper monitoring are a down turn to the management whereby it will result in less productivity. Devices designed should be capable of working as individual units or working together with multiple terminal links such as automated machineries, robotic systems and manual process line. This system can be used in any production line to monitor the line performance and helps to improve line efficiency. By implementing such a system will result towards a better line efficiency and this will help the company to generate higher revenue.

Automated Monitoring and Measuring Improvement of Production System Performance

Overall equipment effectiveness OEE represents a set of key characteristics that allows monitoring the efficiency and productivity of the manufacturing processes. The main purpose of any OEE initiative is to become the most efficient, most effective manufacturer within a market, minimizing the main losses. Overall line effectiveness OLE is another OEE related to measure productivity of production line. It is a powerful metric of manufacturing performance incorporating measures of the availability, performance efficiency, and quality of a given processes along the manufacturing line. There are many methods exist by which productivity could be analyzed and improved, such simulation software that allows users to monitor and identify the problems faced for improving the productivity of the company. In the present paper a simulation program (OLE analyzer program) developed to monitor production system and identify the line based on OLE. The methodology depends on developing the OLE metrics to be more accurate and suitable for implementing on a production line that all involving number of machine arranged in series and parallel. It deals with each machine in the production line with its actual performance. The proposed methodology was applied to a case study where the OLE metric were 46.84% related to the six big losses (breakdown, setup, idle time, reduced speed, time loss, reject on startup, and production reject), and low development of losses improvement were assessed. The study suggested the area of weakness suffer from lack of learning orientation that is ought to be improved and at the same time, a variety of specific recommendations are provided. After implement the computer software methodology, the improvements plan the OLE value increased to 68.94%. Keywords: Overall equipment effectiveness – overall line effectiveness – OLE analyzer program.

PRODUCTIVITY ENHANCEMENT THROUGH PRODUCTION MONITORING SYSTEM

A production monitoring system uses the real time data while production is online. The real time production monitoring systems are designed as means of auto data to collection and monitoring the data via display boards. This study focuses on analysing the real time production monitoring systems through trend analysis in production and over consumption of raw material controlling the over consumptions in a pen manufacturing industry. Methodology followed is through process flow diagram, collection of data, analysis of data. Pre and post analysis was conducted to identify the factors responsible for over consumption and causal factors responsible for the over consumption were identified to reduce the cost of consumption by 58% with introduction of production monitoring system.

Improvement of Performance Measurement Systems Using Production Management Dashboards

The issue of performance measurement has been increasingly discussed by the academic community and professionals of most industries. The large amount of publications about this theme indicates its importance for business management and also the existence of gaps in knowledge. In Brazil, there has been an increasing interest from construction companies in improving their performance measurement systems. However, the characteristics of this industry make the development and implementation of performance measurement systems a relatively complex task. Previous research has pointed out the need for improving the use of performance measurement for decision making, by properly processing and analyzing existing data. One way of improving performance measurement systems is the development of performance dashboards, which allow a set of performance indicators to be monitored through a single interface. This paper proposes a set of guidelines for the conception and assessment of production management dashboards, as a mechanism for improving performance measurement systems for production management in construction. It is based on two action research empirical studies, which involved the development and implementation of production management dashboards in two different construction companies. The main contributions of this research study are: (a) criteria to assess the effectiveness of dashboards; (b) mechanisms for involving different management levels on the use of dashboards; and (c) guidelines for implementing dashboards.

Real time production monitoring system in SME

Estonian Journal of Engineering, 2013

Real time production monitoring systems (PMSs) is an alternative to manual data collection and captures most of the required production data without human intervention. The general objective of the current study is to analyse PMSs and to offer particular solutions for small and medium sized enterprises (SMEs). The subtasks to be solved in the case of each particular PMS include determining relevant parameters, designing PMS and development of the data analysis and prognosis model for short term and long term planning. The selection of suitable PMS components and relevant parameters and the development of lathe cutting unit measuring system are described in the case study. Defendec Inc. and National Instruments Corporation wireless components were adopted to implement a part of the PMS.

Integrated Platform for Real-Time Control and Production and Productivity Monitoring and Analysis

Romanian Review Precision Mechanics, Optics and Mechatronics

In this paper is proposed the IndustSystems, which is an integrated platform that aims at controlling and monitoring of production and evaluation of productivity in real time, via web access, using hybrid and scheduling algorithms that allow management and optimized use of production resources and perfect synchronization of production flows.

Design of an automatic production monitoring system on job shop manufacturing

Every production process requires monitoring system, so the desired efficiency and productivity can be monitored at any time. This system is also needed in the job shop type of manufacturing which is mainly influenced by the manufacturing lead time. Processing time is one of the factors that affect the manufacturing lead time. In a conventional company, the recording of processing time is done manually by the operator on a sheet of paper. This method is prone to errors. This paper aims to overcome this problem by creating a system which is able to record and monitor the processing time automatically. The solution is realized by utilizing electric current sensor, barcode, RFID, wireless network and windows-based application. An automatic monitoring device is attached to the production machine. It is equipped with a touch screen-LCD so that the operator can use it easily. Operator identity is recorded through RFID which is embedded in his ID card. The workpiece data are collected from the database by scanning the barcode listed on its monitoring sheet. A sensor is mounted on the machine to measure the actual machining time. The system's outputs are actual processing time and machine's capacity information. This system is connected wirelessly to a workshop planning application belongs to the firm. Test results indicated that all functions of the system can run properly. This system successfully enables supervisors, PPIC or higher level management staffs to monitor the processing time quickly with a better accuracy.

An integrated production performance measurement system

Industrial Management & Data Systems, 1997

Presents an original integrated production performance measurement system (IP2MS) based on a model able to examine simultaneously several production performances of different operation centres of a firm. The need for an integrated examination of the performances is of crucial importance for today’s manufacturers in order to achieve a competitive advantage. Obtains a quantitative and homogeneous appraisal of the production performances; furthermore, identifies activities responsible for the major differences between actual and desired levels of performance. The proposed model has been empirically tested in some significant medium‐large enterprises of Northern Italy.

System performance improvement by dynamic monitoring

2016 International Conference on Control, Decision and Information Technologies (CoDIT), 2016

Overall equipment effectiveness OEE represents a set of key characteristics that allows monitoring the efficiency and productivity of the manufacturing processes. The main purpose of any OEE initiative is to become the most efficient, most effective manufacturer within a market, minimizing the main losses. Overall line effectiveness OLE is another OEE related to measure productivity of production line. It is a powerful metric of manufacturing performance incorporating measures of the availability, performance efficiency, and quality of a given processes along the manufacturing line. There are many methods exist by which productivity could be analyzed and improved, such simulation software that allows users to monitor and identify the problems faced for improving the productivity of the company. In the present paper a simulation program (OLE analyzer program) developed to monitor production system and identify the line based on OLE. The methodology depends on developing the OLE metrics to be more accurate and suitable for implementing on a production line that all involving number of machine arranged in series and parallel. It deals with each machine in the production line with its actual performance. The proposed methodology was applied to a case study where the OLE metric were 46.84% related to the six big losses (breakdown, setup, idle time, reduced speed, time loss, reject on startup, and production reject), and low development of losses improvement were assessed. The study suggested the area of weakness suffer from lack of learning orientation that is ought to be improved and at the same time, a variety of specific recommendations are provided. After implement the computer software methodology, the improvements plan the OLE value increased to 68.94%.

Flexible Production Data Generator for Manufacturing Companies

Procedia Manufacturing, 2020

Advances in technology over last decades have been followed by many challenges of industrial competitiveness at different levels. Production planning and control generally demand too much time to data capture, and it makes it difficult to understand the analysis of the process flow and to obtain satisfactory results. These results can help operations managers make the best decisions and implement them. Companies that do not have tracking systems to automatically capture data from their machines, spend a lot of time trying to achieve a visual correlation which is consistent with the reality of their processes and goals. Companies without this technology can use data generator systems to simulate data variables in different sizes and previously identify suitable graphical correlations. Current's data generators work with several variables for a lot of situations. On the other hand, it can become confusing and error-prone due to excess of information. However, there is no automated data generator focused on process-flow data which has usability enough to meet the manufacturing company's needs. This study proposes a flexible production-oriented data generator for different physical arrangements in manufacturing companies, along with graphical correlations of production parameters to aid planning and decision making.