Many companies have invested in sophisticated technology, such as human machine interface (HMI) and supervisory control and data acquisition (SCADA) packages, specifically to better visualise and control manufacturing processes. None of these systems inherently store the historical data needed to troubleshoot faults, machine failures and process issues. Although these systems efficiently show real-time data, their trending capability is often too cumbersome and complex to use every day.As a result,many fly almost blind, with very less information about how their equipment is performing. Seeing the forest Besides a way to monitor and store machine and process parameters continuously, companies need a method to generate fast, efficient and in-depth analysis. In short, critical process information that is stored in databases should be readily available for analysis so that one sees to forest in integrity and does not miss to woods for the trees.
Unlike traditional data collection and data historian systems, factory intelligence application is designed for plant maintenance and engineering personnel.The software gathers information by linking to each HMI, PLC, I/O module and existing process control system—in any combination—to monitor and track critical process information. It can even gather data from legacy equipment. Factory intelligence application monitors, records and stores machine and process parameters continuously from every production line on the factory floor. When the line is down Machines break down regardless of how much preventive maintenance they receive. A plant can have the most sophisticated software, but if it cannot monitor critical manufacturing parameters, it is powerless to correct or prevent downtime. A factory intelligence system, on the other and, monitors data points continuously, recording the information for troubleshooting a failure.
Tools for PM Since the factory intelligence application tracks and stores every piece of historical data, it can be used in conjunction with computerised maintenance management software (CMMS) to trigger advisory or emergency work orders. At the touch of a button, you can review ‘out of specification’ alarms at will to determine potential problem areas and identify periods when proactive maintenance shutdowns should be scheduled.
Improved efficiency Storing historical manufacturing data improves operator efficiency by clearly showing the relationship between operator activity and production results. It explains cause and effect, and can instruct personnel about ways to improve production performance.
Today, high-performance business intelligence software solutions quickly deliver in-depth analysis capability and superior reporting, as a result of their technological capabilities. Currently, industry benchmarking BI technology is easy to use, and is the first to combine hierarchical, relational and multidimensional database technologies. In doing so, it provides users with unparalleled decision-making power, giving organisations the power they need to maximise the efficiency of their processes. The author is the Director - Marketing, Altair |
