An application that can provide OEE calculation analysis from the multiplication of Availability (A), Performance (P), and Quality (Q) to determine the percentage of a machine’s effectiveness when operating on the production floor in real time using LabVIEW and DSC Module Software.
– Haliatech
CHALLENGE :
Develop an application that can perform real-time OEE calculations on machines operating in a food and beverage industry.
SOLUTION :
Design a communication program with the machine using LabVIEW and DSC Module to access all parameter data required for OEE calculations.
One of the industrial sectors that is beginning to move towards Industry 4.0 is the food and beverage industry. They are utilizing the latest technology to support their business development. The implementation of the OEE system to improve efficiency during the production process is a step towards Industry 4.0. For this reason, we have developed an application that can monitor production conditions in the field and provide OEE analysis from real-time machine monitoring results.
One of the machines that plays an important role in supporting production is the packaging machine. This machine is involved in sorting suitable products and packaging them. By applying OEE to this machine, we can determine the effectiveness of the use and utilization of machines, equipment, time, and materials in an operating system on the production floor. OEE directly defines the difference between actual performance (current operational and production status) and ideal performance (targets to be achieved). OEE qualifies the quality level of manufacturing unit performance, related to the quantity of products during the scheduled production period.
System Design
We designed this system using the following components:
- LabVIEW Environment
- LabVIEW Datalogging Supervisory Control (DSC) Module
We use the Client-Server method for communication/data exchange. On the Client side, data is retrieved for each parameter from the machine using OPC technology. OPC can be obtained when installing the DSC Module software. OPC enables the LabVIEW application to access data sources with the same and consistent protocol on the Packaging machine.
LabVIEW as a graphics-based programming language allows us to focus solely on the visual flow of the application, because its simple syntax makes it easy to understand what the program is doing. In this case, LabVIEW is used as programming for an OPC Client that only needs to know the unique address of each parameter from the OPC Data Source (OPC Server). The OPC Server is developed by the relevant machine vendor, so we only need to build our own OPC Client application to access it.
The data obtained from the readings by LabVIEW (OPC Client) is then implemented in the OEE formula. The following variables are used:
- Availability: measures loss/wasted time in production due to downtime, which falls into two categories: breakdowns and setup/adjustments.
- Performance: measures losses due to processes that are slower than they should be. This is due to two factors: decreased machine speed, and minor stops and idle time on the machine.
- Quality: measures losses due to goods that do not meet production standards. This is due to two factors: defects & rework, and startup & yield loss.
Loading time = a –b
Operating time = loading time – c
Desc:
a = available time
b = planned downtime
c = unplanned downtime
Each variable in the calculation is determined through parameter data contained in the Packaging machine. Each parameter has a unique address that can be read using OPC.
We display the calculation results in the form of Real-Time and Percentage graphs that can be accessed using a local web. This allows users to monitor anywhere using smart devices such as laptops, smartphones, etc.
If you have any questions about this application or general solutions for using NI products, please contact us at sales@haliatech.com.
AUTHOR INFORMATION:
Muhammad Nurul Fikri
Haliatech, Alliance Partner of National Instruments
Bekasi – Indonesia
(+6221) 85508561
