Traditionally, manufacturing data management at the shop-floor level consists of machine controller data being transported, stored, and then analyzed on a central server for various key performance indicators. The raw data is transported using standard networking technologies like Profibus, Ethernet, Modbus, or RS-232. The method involves external data acquisition and analysis system, internal communication networks, appropriate network bandwidth, cables, and software resources. Today, machine tool controllers are getting more open and have separate systems for real-time motion control and human-machine interface. The data storage capability, computation power, and ability to exchange information in a standardized format between the motion control unit and PC are becoming robust in machine tool controller technology. In this paper, we examine a computer numeric control (CNC) integrated data collection methodology that effectively manages manufacturing data, process violations, alarm management, and quality control within the controller itself. The proposed methodology eliminates the need for an external device for data collection and has a potential to provide a platform for implementing user-defined alarms and customizable process violation alerts. The system architecture, implementation, benefits, limitations, and future work needed for the controller-integrated smart manufacturing control and information system is explained.
Reference: Deshpande A., Neidhart J. "Machine Controller Integrated Manufacturing Data Management." The Applied Systems Health Management Conference 2011, 10-12 May 2011, Virginia Beach, VA.
SaaS for Manufacturing: I/Link
Efficient manufacturing data management has become important in today’s globalized manufacturing environment having long supply chain and distributed facilities extending across political boundaries. Numerous manufacturers have begun searching for ways to improve system and equipment availability, traceability, and real-time production monitoring while reducing the cost of operations. A major contributor to increased cost, inferior quality, and reduced system utilization is unplanned outages, non-integrated processes, and redundant capital/infrastructure cost. There is a need for a real-time manufacturing data management system which is not only cost effective, but also flexible enough to accommodate various technical requirements and changing business processes. The manufacturing world is significantly lagging behind with respect to real-time manufacturing data management.
I/Link is a cloud computing based machine controller integrated data management system for manufacturing. It is implemented on an open architecture constant velocity Revolution MTI controller. I/Link enables efficient production monitoring and real time decision support system for process optimization and scrap reduction. All the data collection and cloud communication is accomplished by the Data Transportation Utility integrated within the Revolution controller. The I/Gear Data Transportation Utility (DTU) is a middleware software product that is designed to make integration easier by moving data between dissimilar devices and systems. The data is compressed & encrypted before sending it to the cloud. I/Link can be accessed from any internet browser with proper login credential. The software as a service (SaaS) paradigm decreases the cost exponentially.
Benefits to the Machine Tool vendor:
The development of an integrated production monitoring system, as a service, provides a huge after-sales market for the machine tool builder in addition to extended business opportunities and improved customer satisfaction. Machine tool builders will be able to monitor their machine performance, type of machining activity, alarms, and failures to make changes to improve the machine performance and reduce warranty cost. The after-sales market would include maintenance contracts and production monitoring offered as a service. By monitoring critical data parameters, the machine tool builder can inform the customer of impending service/maintenance requirements that minimize the machine downtime. Additionally, the data collected can drive business intelligence, create a competitive advantage, and provide leads to marketing and sales. For example, if a manufacturer has all of his machines running at full capacity, then the facility is positioned to add a new machine to balance the load.
Benefits to the end-user include:
• Calculation of utility consumption of machines
• Maintenance cost closely related to cause and effect
• Process compliance assurance
• Improved operator productivity
• Integrated approach to security that covers networks, machine, wireless and wired sensors, and data to protect critical operations
• Improved quality and higher factory throughput
• Flexible and hierarchy-customized alert management system
• Reduced cycle time and downtime
• Demand-driven manufacturing
• Better scheduling and resource management
• Faster problem resolution
• Support of Six Sigma, lean, and green initiatives with dependable information.
I/Link is a cloud computing based machine controller integrated data management system for manufacturing. It is implemented on an open architecture constant velocity Revolution MTI controller. I/Link enables efficient production monitoring and real time decision support system for process optimization and scrap reduction. All the data collection and cloud communication is accomplished by the Data Transportation Utility integrated within the Revolution controller. The I/Gear Data Transportation Utility (DTU) is a middleware software product that is designed to make integration easier by moving data between dissimilar devices and systems. The data is compressed & encrypted before sending it to the cloud. I/Link can be accessed from any internet browser with proper login credential. The software as a service (SaaS) paradigm decreases the cost exponentially.Benefits to the Machine Tool vendor:
The development of an integrated production monitoring system, as a service, provides a huge after-sales market for the machine tool builder in addition to extended business opportunities and improved customer satisfaction. Machine tool builders will be able to monitor their machine performance, type of machining activity, alarms, and failures to make changes to improve the machine performance and reduce warranty cost. The after-sales market would include maintenance contracts and production monitoring offered as a service. By monitoring critical data parameters, the machine tool builder can inform the customer of impending service/maintenance requirements that minimize the machine downtime. Additionally, the data collected can drive business intelligence, create a competitive advantage, and provide leads to marketing and sales. For example, if a manufacturer has all of his machines running at full capacity, then the facility is positioned to add a new machine to balance the load.
Benefits to the end-user include:
• Calculation of utility consumption of machines
• Maintenance cost closely related to cause and effect
• Process compliance assurance
• Improved operator productivity
• Integrated approach to security that covers networks, machine, wireless and wired sensors, and data to protect critical operations
• Improved quality and higher factory throughput
• Flexible and hierarchy-customized alert management system
• Reduced cycle time and downtime
• Demand-driven manufacturing
• Better scheduling and resource management
• Faster problem resolution
• Support of Six Sigma, lean, and green initiatives with dependable information.
The Use of Compiled CNC Program in Smart Machining
In many commercial and defense applications, the data contained within the part program can be very sensitive and must be protected at all times. To achieve this program security, many organizations have security cleared personnel load the part program into the control and then have to remove/delete the file immediately after the part program has completed machining the part. This is very cumbersome and an undesirable way to secure the part program data. Also this method is open to errors made by the operator who might change the machining parameters on the fly. Effective version control and program code management is nearly impossible. The recently launched GBI Revolution machine’s MTI control eliminates this current problem due to the fact that every time a new program is loaded it is compiled prior to machining. The computer industry might be going away from compiled programming languages to more interpreted language but the manufacturing industry is just embracing the idea of pre-compiled NC code. The compiled file is stored within the control and used to machine the part, but the actual raw data can not be accessed, edited or downloaded. The original program can be immediately deleted from the control leaving the compiled file within the control for as long as needed with no safety concerns for the raw part program data. This security feature will be immensely valuable to any commercial or defense manufacturer that is concerned with part program data security. It will ensure process compliance and assurance especially in case of subcontracting manufacturing to external organizations.
Business in India - The Implications of Mythology, Culture and Beliefs
Devdutt Pattanaik: East vs. West -- the myths that mystify | Video on TED.com
Devdutt Pattanaik takes an eye-opening look at the myths of India and of the West -- and shows how these two fundamentally different sets of beliefs about God, death and heaven help us consistently misunderstand one another.
Devdutt Pattanaik takes an eye-opening look at the myths of India and of the West -- and shows how these two fundamentally different sets of beliefs about God, death and heaven help us consistently misunderstand one another.
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