Tamaki worked with the Client in order to build an OEE and TEEP solution that was bespoke to their needs. PLCs, SCADA, Reporting Software, IT Network Design, Electrical Wiring Solutions and Operator Training were some of the elements that contributed to a successful solution built from the ground up.
ABP were looking for an all encompassing OEE and tracking system that could be scaled up to suit their needs. They were using paper tracking systems for downtimes which then had to be manually entered. Their previous system did not automatically look at the line or the schedule in order to automatically determine start/stop and downtimes.
Tamaki and site were looking to build a solution from the ground up. The main hinderance in the current system was that each machine and conveyor was installed as a stand-alone unit. In order to achieve the end result, we had to start monitoring each machine and conveyor for their status.
Tamaki installed an Allen Bradley PLC for the site electricians to tie into the line. Every machine and conveyor consisted of different signals that could be read and written to. Tamaki worked with the electricians and adjusted the PLC programming accordingly in order to accommodate for the various types. Proximities were installed on the line to count product and determine line speeds.
Now that we had every machine connected to one central system we could start to determine line stoppages, line speed issues, quality issues etc.
The next hurdle was context; we knew when the line stopped and started but we didn't know why and we therefore could not categorise these stoppages. Tamaki and site took a two pronged approach to this problem. The first more obvious solution is to try and connect to any machines on the line that were Ethernet capable. On this line we connected to the main piece of equipment and were able to bring back downtimes and their reasons to our central system. You will often see on machines you purchase, a standard HMI with alarms. These alarms are generally stuck to the HMI screen and bringing these messages automatically back into the end report was a key deliverable.
For conveyors and machines that did not have an Ethernet connection, Tamaki deployed 2 physical HMI screens on the line. The HMI's showed the line status, gave the operator control over the start and stop functions of the line but also displayed any line stoppages. Operators were then able to enter a reason for that downtime in a 3 click operation per downtime. Screens were designed minimalistic with simple navigation, keeping in mind that the less time an Operator is looking at the screen, the more time they have for the end product.
The end result was a 10 page report that went out to management staff at the end of each shift. With all the data collected, it was our job to connect and present contextual information in a neat and meaningful way. The bespoke end result also adhered to elements from ABP's own OEE and TEEP philosophies.