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Real-Time Data Collection in Manufacturing: Benefits and Techniques

Bhagyashri Kambale | January 12, 2022 | 540 views
REAL-TIME DATA COLLECTION
Real-time manufacturing analytics enables the manufacturing base to increase its efficiency and overall productivity in a variety of ways. Production data is an effective means of determining the factory's efficiency and identifying areas where it might be more productive.

“Without big data analytics, companies are blind and deaf, wandering out onto the web like deer on a freeway.”

– Geoffrey Moore, an American Management Consultant and Author

Creating a product-specific data collection may assist you in determining and visualizing what needs to be improved and what is doing well. In this article, we'll look at why manufacturing data collection is vital for your organization and how it may help you improve your operations. 

Why is Manufacturing Data Collection so Critical?

Visibility is the key benefit that every manufacturer gets from manufacturing data collection. By collecting real-time data, or what we refer to as "shop floor data," manufacturers better understand how to assess, comprehend, and improve their plant operations. Manufacturers can make informed decisions based on detailed shop floor data. This is why having precise, real-time production data is critical.

“According to Allied Market Research, the worldwide manufacturing analytics market was worth $5,950 million in 2018 and is expected to reach $28,443.7 million by 2026, rising at a 16.5% compound annual growth rate between 2019 and 2026.”

For modern manufacturers, the advantages of data collection in manufacturing are numerous. The manufacturing industry benefits from production data and data-driven strategy in the following ways.

Substantial reduction in downtime by identifying and addressing the root causes of downtime.
  • It increases manufacturing efficiency and productivity by minimizing production bottlenecks.
  • A more robust maintenance routine that is based on real-time alerts and machine circumstances.
  • Improvements in demand forecasting, supplier scoring, waste reduction, and warehouse optimization reduce supply chain costs.
  • Higher-quality goods that are more in line with customers' wishes and demands depending on how they are utilized in the current world.
So, after looking at some of the significant benefits of real-time manufacturing analytics, let’s see what type of data is collected from production data tracking.

What Sorts of Data May Be Collected for Production Tracking?

Downtime: Operators can record or track downtime for jams, cleaning, minor slowdowns, and stoppages, among other causes, with production tracking software. In the latter scenario, downtime accuracy is optimized by removing rounding, human error, and forgotten downtime occurrences. The software also lets you categorize different types of stops.

Changeovers: Changeovers can also be manually recorded. However, changeovers tracked by monitoring software provide valuable data points for analysis, considerably reducing the time required for new configurations.

Maintenance Failures: Similar to downtime classification, the program assists in tracking the types of maintenance breakdowns and service orders and their possible causes. This may result in cost savings and enable businesses to implement predictive or prescriptive maintenance strategies based on reliable real-time data.

Items of Good Quality: This is a fundamental component of production management. Companies can't fulfill requests for delivery on schedule unless they know what's created first quality. Real-time data collection guarantees that these numbers are accurate and orders are filled efficiently.

Scrap: For manufacturers, waste is a significant challenge. However, conventional techniques are prone to overlooking scrap parts or documenting them wrong. The production tracking system can record the number and type of errors, allowing for analysis and improvement. Additionally, it can capture rework, rework time, and associated activities.

WIP Inventory: Accurate inventory management is critical in production, yet a significant quantity of material may become "invisible" once it is distributed to the floor. Collecting data on the movement and state of work in progress is critical for determining overall efficiency.

Production Schedule: Accurate data collection is essential to managing manufacturing orders and assessing operational progress. Customers' requests may not be fulfilled within the specified lead time if out of stock. Shop floor data gathering provides accurate production histories and helps managers fulfill delivery deadlines.

Which Real-time Data Collection Techniques Do Manufacturers Employ?

Manufacturers frequently employ a wide range of data collection techniques due to the abundance of data sources. Manual data collection and automated data collection are two of the most common data collection methods. Here are a few examples from both methods:
  • IoT: To provide the appropriate information to the right people at the right time with the correct shop floor insight, IoT (Internet of Things) sensor integration is employed.
  • PLC: The integration of PLC (Programmable Logic Controller) is used to measure and regulate manufacturing operations.
  • HMI: It can provide human context to data by integrating line HMI (Human Machine Interface) systems (such as individual shop terminals like touch screens located on factory floor equipment).
  • SCADA: Overarching management of activities with SCADA (Supervisory Control and Data Acquisition) systems.

CNC and Other Machines: Integrating CNC and other machines (both new and older types) to keep tabs on production efficiency and machine well-being is a must these days.

Final Words

One of the most challenging aspects of shop floor management is determining what to measure and what to overlook. The National Institute of Standards and Technology recently conducted a study on assisting manufacturing operations in determining which data to collect from the shop floor.Additionally, you may utilize the manufacturing data set described above to obtain information from your manufacturing facility and use it strategically to improve operations, productivity, efficiency, and total business revenue in the long term.

FAQ


What is manufacturing analytics?

Manufacturing analytics uses operations and event data and technology in the manufacturing business to assure quality, improve performance and yield, lower costs, and optimize supply chains.

How is data collected in manufacturing?

Data collection from a manufacturing process can be done through manual methods, paperwork, or a production/process management software system.

Spotlight

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CORE Industrial Partners Portfolio Company Cadrex Manufacturing Solutions Acquires EPMP

CADREX | October 07, 2022

CORE Industrial Partners (“CORE”), a manufacturing, industrial technology, and industrial services-focused private equity firm, announced today the acquisition of E.P.M.P., Ltd. (“EPMP” or the “Company”), a precision sheet metal fabrication services provider, by CORE portfolio company Cadrex Manufacturing Solutions (“Cadrex”). The Cadrex platform was formed in 2021 and includes ten business units with approximately 1.5 million square feet of manufacturing space and more than 2,000 employees across ten states as well as Mexico. Founded in 1984, EPMP provides high-volume sheet metal punching, forming, welding and assembly capabilities utilizing a variety of different metals, including aluminum, copper and brass, as well as carbon, galvanized and stainless steel. The Company serves a nationwide customer base in the renewable energy, HVAC, food & beverage, and industrials end markets, among others, through an equipment fleet that includes press brakes, turret punches, fiber lasers, combination laser & punch machines and automated fabrication cells. Headquartered outside San Antonio in Seguin, Texas, EPMP operates an ISO 9001-certified facility with over 50,000 square feet of manufacturing space. “EPMP’s significant historical investments in automation-driving material handling systems and robotics augment Cadrex’s high-volume sheet metal fabrication capabilities and make EPMP a highly strategic fit with the platform.” -Matthew Puglisi, Partner at CORE. Clint Plant, President of EPMP, said, For almost 40 years, EPMP has been committed to manufacturing and service excellence, demonstrating that commitment throughout all aspects of our organization. We recognize and appreciate this same customer-centric orientation at Cadrex and we’re looking forward to collaborating with Cadrex and CORE to continue our strong momentum. ABOUT CORE INDUSTRIAL PARTNERS: CORE Industrial Partners is a private equity firm with $700 million of capital commitments investing in North American lower middle-market manufacturing, industrial technology, and industrial services businesses. CORE’s team is comprised of highly experienced former CEOs and investment professionals with shared beliefs, deep experience, and a demonstrated track record of building market-leading businesses. Through our capital, insight, and operational expertise, CORE partners with management teams and strives to build best-in-class companies. ABOUT CADREX MANUFACTURING SOLUTIONS: Cadrex is a leading provider of complex production parts, assemblies, and weldments for a variety of end markets, including information communication technology, aerospace & defense, energy transmission & distribution, food production & agriculture, medical, material handling and electronic gaming & kiosk. With locations in nine states and Mexico, Cadrex offers comprehensive in-house manufacturing capabilities, including laser cutting, sheet metal fabrication, injection molding, electromechanical assembly, CNC punching, CNC machining, robotic welding, stamping, fastener insertion, and tool and die manufacturing, to effectively serve customers with lights-out manufacturing capabilities from low- through high-volume production. ABOUT EPMP: EPMP is a precision sheet metal fabrication services provider for a variety of end markets, including renewable energy, HVAC, food & beverage, and industrials. The Company offers high-volume sheet metal punching, forming, welding and assembly capabilities from an ISO 9001-certified facility outside San Antonio in Seguin, Texas.

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ADDITIVE MANUFACTURING

Amnovis Selects 3D Systems’ Dual Laser Direct Metal Printing Solution to Advance High-Reliability Applications

3D Systems | October 06, 2022

3D Systems (NYSE:DDD) announced that Amnovis, an additive manufacturing production and engineering company based in Aarschot, Belgium, has incorporated 3D Systems’ DMP Flex 350 Dual into its contract manufacturing workflow. This next-generation technology includes two lasers, which enables Amnovis to produce high-quality, highly reliable end-use parts for a variety of industrial and medical device applications. As a result of employing the DMP Flex 350 Dual solution, Amnovis is realizing enhanced productivity – at least 50% more as compared to the single laser DMP Flex 350 – and lower costs. Amnovis’ founders were among the first to employ laser powder bed fusion (LPBF) technology to additively manufacture Titanium medical devices such as orthopedic and spinal implants. Incorporating the DMP Flex 350 Dual printer into its manufacturing workflow is allowing Amnovis to expand its potential for stock and patient-specific medical device innovation. This unique innovation ecosystem is also enabling Amnovis to introduce product and process enhancements that can also be utilized for highly regulated industrial applications including aerospace and high tech. The DMP Flex 350 Dual is the most recent addition to 3D Systems’ Direct Metal Printing (DMP) portfolio. This dual-laser configuration maintains the benefits of the single-laser configuration including flexible application use and quick-swap build modules, and a central server to manage print jobs, materials, settings, and maintenance for 24/7 productivity. Additionally, the company’s unique vacuum chamber significantly reduces argon gas consumption while delivering best-in-class oxygen purity (<30 ppm). The printer also includes Oqton’s 3DXpert — the all-in-one software for industrial additive manufacturing that enables efficient preparation, optimization, and 3D printing of high-quality parts by streamlining the workflow from design to printing. The DMP Flex 350 Dual is designed to help accelerate innovation for a variety of applications including medical devices, aerospace, turbomachinery, semiconductors, and automotive & motorsports. “For us, innovation benefits from material and process enhancements, as well as the ability to increase productivity, We’ve experienced a tremendous leap in 3D printing efficiency by integrating 3D Systems’ DMP Flex 350 Dual into our workflow. By scaling our high-end parts manufacturing for quality-critical applications in medical, high tech, and other industries, we ensure faster delivery at lower cost, while maintaining our high-quality standards." -Ruben Wauthle, CEO and co-founder, Amnovis. In order for our service bureau customers to gain a competitive advantage, they need to differentiate the services they provide while becoming increasingly responsive to customer requirements, said Scott Anderson, vice president, segment leader, 3D Systems. Our collaboration with Amnovis is yet another example of how we can apply our application development expertise and a broad range of integrated additive manufacturing solutions to help maximize productivity, reliability, uptime, and yield. By integrating the DMP Flex 350 Dual into its solution portfolio, Amnovis is delivering high-quality parts to their customers while realizing exceptional total cost of ownership. About 3D Systems: More than 35 years ago, 3D Systems brought the innovation of 3D printing to the manufacturing industry. Today, as the leading additive manufacturing solutions partner, we bring innovation, performance, and reliability to every interaction - empowering our customers to create products and business models never before possible. Thanks to our unique offering of hardware, software, materials, and services, each application-specific solution is powered by the expertise of our application engineers who collaborate with customers to transform how they deliver their products and services. 3D Systems’ solutions address a variety of advanced applications in healthcare and industrial markets such as medical and dental, aerospace & defense, automotive, and durable goods. About Amnovis: Amnovis, based in Aarschot, Belgium, is a manufacturing and engineering company that uses innovative additive manufacturing (AM) technologies and materials for high-end applications such as medical devices. As an ISO 13485 certified contract manufacturer, Amnovis offers best-in-class AM technologies and expertise and paves the way for emerging AM technologies and materials. Digital process automation provides the traceability and repeatability to flexibly scale up manufacturing of products that comply with customer and regulatory requirements.

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