PROBLEMS IN THE WIRE & CABLE INDUSTRY
Some common problems in the Wire & Cable industry are strongly related with the fact that many factories still use paper as their main data-recording method. Some common errors such as misreading, misspelling and transfer loss happen quite frequently when using paper, which causes mistakes or missed information when organizing the data.
To deal with the problems derived from paper-recording, Pioneer Machinery has developed various Pioneer SmartFA models which are able to build comprehensive digital manufacturing processes and smart factories for our clients. And here is where Pioneer SmartFA OEE system model comes into play.
Pioneer OEE system allows clients to customize their
own user interface, deciding which information should
be shown on the UI and thus building an effective
production system that fits into their work habits.
Information such as status of running, malfunctioning
and standbying among others, can be clearly displayed
on the OEE system.
With the card-control system, once the line stops due to an alarm on the production, the operator will have to key in the HMI the reason for the alarm and the corresponding intervention before resuming to start the line. This way we prevent employees from forgetting to report the events of the machine at the end of the day.
Therefore, the card-control system is a valid and efficient tool to help decision makers understand the status of the whole factory in real time.
Besides showing the real-time status of the machine on the interface, the OEE system is capable of automatically generating reports in just a few seconds, which solves common problems associated with manual transcription or memory error due to a delay on the task.
Data analytics and production optimization
Organizing the data via Pioneer OEE system and trying to figure out the trend with statistical analytics give process engineers a big hand on process optimization. Information such as total running time of the machines, failure rate, standby status and so on, are reliable references on re-checking the overall plan and decreasing the failure rate.
Automatic data collection
The OEE system collects the data and supervises the machine automatically which drastically decreases the need of an operator waiting besides the production line. With a much higher collective frequency than humans, the OEE system can collect huge amounts of data which can be useful for further database building and data analytics through artificial intelligence models.
The time required by an operator to generate a report would usually take 30 to 60 minutes for data collection, reorganization, etc, while a report automatically generated would take only 1 to 2 minutes.
The OEE system decreases the need for manpower per product line, thus giving more elasticity to the employee distribution.
Uploading all of the information onto the Pioneer SmartFA platform allows the managers to figure out the situation of the machines at any time and place.