Electricity + Control July 2018

IIOT + INDUSTRY 4.0

How remote monitoring improves machine maintenance Brandon Topham, RET Automation

A flashing red light on the plant floor often signals a problem on a production line or in a work cell. It’s a familiar scene in lean manufacturing environments, where these Andon signals help plant workers identify problems before they lead to excessive downtime.

Key attributes of this system include the following: Portability. Less maintenance. Increased data analysis. Take Note!

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T he Industrial Internet of Things (IIoT) is transforming the way manufacturers identi- fy problems on the plant floor as the latest wireless solutions address integration challenges. Beyond the plant floor, traditional Andon alerts do not provide much information about the cause of disruptions or maintenance trends. But manu- facturers can now leverage the IIoT to expand the capabilities of existing maintenance monitoring systems, such as Andon signals. IIoT eliminates data silos, so device-level data is accessible to the entire operations team. It provides valuable insights intomachine performance, process inefficiencies and other potential risks. In this smart environment, wireless sensors enable real-time remote monitoring of machine performance and manufacturers can use the information to increase overall equipment effectiveness (OEE), which is a calculation of manufacturing process efficiency.

How IIoT improves machine monitoring In today’s mobile world, wireless networks are everywhere. The advantages are clear: By elim- inating the wire limitations in conventional sys- tems, wireless networks improve data logging and process monitoring and control, while maintaining high levels of security and integrity. Whereas in the past, wireless systems were difficult to install and maintain, today, many re- mote monitoring solutions can be integrated into a single, inexpensive unit. Some of the key attrib- utes of this integrated system include: • Portability: I/O devices that manufacturers can easily install and then uninstall andmove to a new location as monitoring requirements change. • Less maintenance:The radio, I/O terminals and LCD screen are included within a single hous- ing. This means fewer mechanical and wiring issues need to be incorporated into a mainte- nance schedule. • Increased data analysis: A single wireless I/O device can collect both digital and analogue sensor readings and forward this data to a cen- tral collection point for analysis. In addition, mul- tiple sensor readings can be aggregated into a single gateway device before being forwarded to a host-controlled system for analysis. These days manufacturers can make device-level data accessible to operators and plant managers, providing valuable insights into OEE. The three primary factors included in an OEE calculation are availability, performance and quality. The results of this calculation provide actionable insights into the critical sources of waste in a man- ufacturing operation. This is where access to data from sensors and indicator lights becomes impor-

26 Electricity + Control

JULY 2018