Factory Efficiency Analysis
Factory Performance Analysis and Continuous Improvement data capture
Factory performance analysis systems are evolving fast. Most of our products can provide data for archiving in a cloud-based database, which can be shared with you on displays, smartphones, etc.
This is otherwise known as IIoT – the Industrial Internet of Things.
You can access this data from wherever you are, and analyse KPI trends such as OEE, downtime, maintenance management schedules etc. which are important to your process. You don’t need any special software to view the reports, just a web browser.
All the analysis packages we offer are customised for you, so that your reports focus on the most important data automatically, such as OEE, reasons for down time, Takt time, quality, scrappage ratio etc.
Reports can be presented in any form you prefer, from line graphs, pie charts, gantt charts, pareto charts, dials, .csv files etc.
We are here to help you to develop your Continuous Improvement system, we have many years of experience helping companies like yours to automatically capture, analyse and share real-time performance data and graphs.
OEE and KPI system for a vegetable processing factory
The touch screen provides a secure cloud-based interface for the processing team to select jobs, staffing levels and to start/stop jobs…
Various live reports are available to the team and management, helping them to keep on track with planned performance levels…
Large real-time text displays along the processing line help to keep everyone informed of how the day’s production is progressing…
Mobile real-time production data collection systems
We can also produce mobile production analysis systems for applications such as concrete batching, waste collection systems, borehole drilling etc.
Here is an example of a system we produced for NewMix concrete.
One of our batch counting digital panel meter controllers, model INT4-C, can be seen on the panel, sealed to IP67. It transfers its data to an embedded computer making https secure posts to the cloud based database.
This the provides the management with a graphical display of dates, times and amounts of each delivery for each vehicle.
It could include loaction information as well, to show exactly where the offloads were made.
This system constantly relays the real time batching and deliveries made to customers, allowing the management team to keep an eye on a real-time audit of deliveries.
All data is stored to a cloud database and includes tamper detection, helping to ensure that the chances of theft from the lorries is minimised.
SMS and email messaging can form an important part of the system, so that appropriate engineers can be automatically alerted to a problem.
Ruggedised tablets are ideal in food processing environments, with buttons sized to be easy for gloved hands to operate.
Analysis can be easily broken into shifts and shifts can be set and altered intuitively with our user-friendly shift planner.
Line Logger module for event and count capture
Pulse inputs can be fed to our compact LineLogger, where they are timestamped, totalised, and passed on to be saved in a cloud-based SQL database.
The line logger is only 22.5mm wide and DIN rail mounts, with detachable screw terminals. The LineLogger forms the first part of the link between your production process and the database, accepting NPN, PNP, contact closures, 24V pulses etc from optical sensors, proximity sensors, limit switches, PLCs etc.
What makes us different, when it comes to process monitoring and OEE systems?
We create production monitoring systems tailored to your exact needs. We start with a blank sheet of paper, we listen carefully to what you want and we design an efficient, easy to use system which perfectly fits your requirements.
This makes it easy to use, easy to learn and easy to upgrade. Everything is expressed in your terms, not some generic techo speak.
You have access to the system as it develops, so you can let us know if you need any changes.
In addition, our cloud based systems are hosted on secure servers over https secure link. Your access is through high security one-way encrypted passwords which you can administer.
On our cloud-based systems any software updates are administered by us and you don’t need to re-install anything.
Simple, efficient, cost effective, secure, tailored to your exact needs – what a winning formula!
A typical web-enabled production line dashboard showing live data.
Try this simple example…
Open this on your PC:- [Main Display]
This would normally go on something like a 55″ screen.
Press F11 button to go full screen.
It also views well on a small vertical phone or tablet screen.
It updates live as soon as you press an andon button on the remotes. The time is in Melbourne by the way.
The SmartPhone Remote Pushbutton station for hoist 5 is available [Here]
This would normally be viewed on a phone, acting as a remote 3 pushbutton module. AMOLED display phones like the economical Samsung J3 work great for this.
In the real world, we would have this all password accessed to prevent malicious access.
Notice how the phone updates the screen almost instantly.
A count is registered whenever the button goes from red to green or amber to green.
Click the yellow bar charts icon in the top right of the main screen.
Notice how the barchart updates in real time too (Hoist 5)
Notice also how we matched the corporate look of ACM Parts, the client in Melbourne for whom we developed this demo
Notice also that you haven’t needed to install any apps or software, this is an example of SaaS (software as a service).
If you have any questions, just click the Ask Me button on the right and we will do what we can to help.
Factory Energy consumption analysis
Factory energy consumption analysis is another area where a cloud based system is ideal.
Our power monitoring units can post data to a cloud database, and you can access the reports from desktop, mobile phone, laptop etc.