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How to monitor and control automated assembly production line?
With the advent of Industry 4.0, broadly defined automation of production lines has become a standard, without which it is difficult to imagine a modern
Make sure you have all information you need to make a smart decision. With Smart Machine’s fully integrated line management and control solutions, decision-making has never been easier. With dozens of build-in analytical and diagnostic functions, it supports the operator in detecting bottlenecks, increasing uptime, reducing scrap and improve line performance and efficiency. The system provides full production traceability, SPC analysis, operator guidance throughout the changeover process and provide a support function for line control.
Smart Machine is a complete line control system supporting all operations and operators’ activities dedicated for automated assembly lines. System provides automated changeovers on-the-fly together with advanced line control of all WPCs on each station. System ensures uninterrupted operation of the assembly line and timely execution of production and quality. That guarantees the highest OEE as well predictable line’s work, every shift and every day.
System is fully embedded with basic automation. Thanks to standardized and predefined communication can be easy connected with any PLC and any line’s supplier. A standard PLC library with a transparent telegram structure and a user-friendly interface allow a fast and easy integration with the Smart machine.
System is design to ensure smooth operation, configuration, maintenance the line and to support operators in correct problem-solving.
Smart Machine covers special processes like clearing the line, golden (dummy) parts and SPC checks.
Modular architecture of our system, gives unlimited possibilities for free configuration of the system, so that our product can be tailored to any requirements set by our customers.
Smart Machine will help your business in a daily management and production execution by effectively collecting, visualizing and analyzing data across your entire supply chain.
Machine Connectivity is responsible for communication with the machine’s PLC and devices. Thanks to the standardized and predefined communication protocols, telegrams structures can be easily implemented with any PLC. A standard PLC library with a transparent telegram structure and a user-friendly interface allow fast and easy integration with the Smart machine.
The module responsible for controlling and validation of product proceed through the line. Each piece is checked and the system decides where to transfer the product after each operation, validates quality criteria and decides whether a product is OK/NOK based on an analysis of the results obtained from the PLC compared to the set quality limits.
Production Execution let operators execute orders and operations according to plan and technology. It validates and supports different types of production processes during which the operator can report production and machine states. The system displays current production, its status and progress. Operators can monitor production in real-time.
The system guides the operator step by step on what to do in the next step, starting from scanning the BOMs, sending recipes to PLCs, starting dummy tests (golden parts) or accepting the newest documentation. Additionally, the instructions for the production or changeover are enriched with images or movies.
The system automatically records all defects, place/operation of occurrence and its type reported by PLC or by Operator. With Reworks Management it is possible to create a dedicated production flow based on the type of defect. The new route is saved to the WPC’s RFID chip and the WPC is going to the expected station for rework. ANT’s Master Control logic decides about bypassing unnecessary stations.
With Traceability tracking and tracing of the finished good, semi-finished goods and raw materials is possible. Ongoing production is being matched with S/N, batches of components and containers. The system validates processes and confirms scanned resources. The labelling and marking process is done automatically in any step of production. With Traceability, it is possible to find raw material based on scanned finished goods.
The module registers each, even the shortest stop of the individual stations and its reason from PLC. Build-in algorithms assign responsible machines for a line stoppage. It helps to automatically identify bottlenecks and each machines’ status.
Built-in set of tools for statistical analysis of the process, such as histogram, control cards and more. Allows detailed analysis of data collected at each stage of production in terms of stability and deviation from planned limits of each production process. The tool allows you to quickly detect even the smallest deviations in the process and react before product quality discrepancies appear.
System monitors constantly the number of OK parts – reported at each station separately, number of NOK parts – reported at different places. Production counters are gathered in real-time giving you information about current production progress, number of products on the line and already produced.
Online Visualization displays current production on TVs that are installed on the shop floor. Visualization includes production data with current OEE, production progress and machine states for ongoing production shift. It helps in production transparency and faster reaction times.
Dashboards & Reports is a complex analytic platform with ready reports. More than a dozen reports analyzing production, quality, trends and targets. Reports can be viewed in the perspective of line, machine (station) and in different time ranges.
OEE Analysis calculation in real-time. The module is responsible for displaying KPI together with availability, performance and quality. Managers are able to set individual OEE calculation methods dedicated for the line. The OEE let users check the current line’s health.
System integration is responsible for receiving inbound data and for sending outbound data to any other external system. It works in real-time. Different integration ways are supported like web services, intermediate databases or flat files. The module is compatible with any ERP, MES or BI systems.
With the advent of Industry 4.0, broadly defined automation of production lines has become a standard, without which it is difficult to imagine a modern
SPC, or statistical process control, is one of the most interesting tools in the context of quality management. Nowadays, this method is widely used
It’s no secret that every step of the pharmaceutical manufacturing process must be documented. However, managing paper documentation can be extremely time-consuming for pharmaceutical manufacturers,
Machine changeover, or machine conversion, is a process in which an operator uses instructions to change the settings of a machine in order to produce a different type of product or make changes to the machine.
An efficiently executed changeover can help increase a company’s production, reduce labor costs and increase quality.
Reducing changeover time can be done in two ways. The first is, to provide the operator or maintenance department with appropriate instructions in digital form, preferably illustrated step by step, which will guide them through the successive stages of changeover. The second way is to invest in machines and implement advanced solutions that automate changeover processes, which can automate some tasks on the fly as needed, or reduce changeover to a few basic steps.
The fraction of industrial processes that are becoming automated is growing. To optimize them and achieve better results, it is necessary to implement more and more advanced systems. Modern production companies are eager to take advantage of the opportunities offered by advanced management software. One of them is Smart Machine – a complete line management system.
Smart Machine from ANT Solutions is a software dedicated to production management. The system is supporting all operations and operators in the automated production line, which allows monitoring process, its status and realizing production in real time. All operators can execute orders according to plan and technology thanks to instructions displayed directly on the operator panel.
The system communicates with machines by a PLC. Thanks to that, the software collects data, including all parameters needed to make a batch (or single one) of products. This data allows for making an analysis, comparing historical and real-time ratios. But that is not all there is to it.
Collecting data is just the beginning. Smart machine’s connection with the system ensures the most effective operations and support for operators. The software minimizes human error, and diagnostic tools let reduce downtime and micro-stops. A real-time activity allows for ultra-fast communication, sending alerts directly to an operator, and taking an action at the right moment. Anticipating failures, preventing them, and gaining precious seconds – it is exactly what manufacturing industry is striving for, isn’t it?
Smart Machine is a system created for the efficient operation of the entire supply chain. What are the characteristics of the components determining its effectiveness?
Smart manufacturing means producing components with the highest quality factor at the lowest possible cost. How is this possible? An important component for operational success is repeatability. A human task is always affected by the human factor. With the same semi-finished products and using the same equipment, there is a risk of error that can occur due to fatigue, lack of accuracy, or other human error. Smart machine eliminate this risk.
Implementation of our system in the automatized production line has a lot of positive results. One of the most important benefits is achieving maximal line capacity in less time. Every second can mean large gains or losses, depending on the efficiency with which it will be used. Advanced software allows reducing waste and increases profits thanks to real-time production processes tracking.
Another important method that provides savings in the produce industry is minimizing defects. It is possible with Smart Machine tools to diagnose threats and prevent them. Furthermore, using advanced software minimizes human error and provides repeatable processes.
Less downtime – more effectiveness.
Less micro-stops – more availability.
Less defects – more high-quality.
This is what Smart Machine mean for nowadays production industries.
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