The latest Pro.Lean SCADA module from P4A is designed as an easy-to-use tool to boost OEE performance through measurement and analysis of efficiency, production, quality and downtime.
Automation systems that manage production processes can only be optimised if provided with the right information in real time. The Movicon Pro.Lean module from Products4Automation has been designed to help remove production inefficiencies by detecting the key performance indicators (KPIs) that enable reduced losses and increased profits.
By providing full access to real time production data, the Pro.Lean module enables users to detect and anticipate weak spots in production systems, and make the right decisions to increase productivity and boost efficiency. In an increasingly competitive manufacturing environment, it drives gains in quality with continuous and improved processes according to lean manufacturing principles, while also embracing the ideals of Industry 4.0.
It is reckoned that, on average, a well established manufacturing company performs at just 60% of its full potential performance capacity. This means that for every 100 approved goods produced in an ideal situation, only 60 are produced in reality. It is easy to imagine how improved production efficiency and an increase in the OEE value would create a noticeable increase in returns. But you can’t fix what you can’t measure: the Pro.Lean module automates the gathering and analysis of KPIs, enabling OEE values to be calculated to highlight actual plant production capacity.
The Pro.Lean module enables improvements in the four key areas of efficiency, downtime, production and quality. Improving local and global production efficiency will enable users to improve the productivity of existing machines by reducing rejects and downtimes. At the same time, downtime analysis enables users to eliminate anticipated and repetitive problems relating to production. By increasing efficiency and decreasing downtime events caused by production inactivity or malfunctioning, users can increase the effective production rate. Lastly, by analysing production data and the quantity of defective items produced, it will be easier to detect the causes and eliminate them.
Collected data is represented by the Pro.Lean module in real-time using attractive graphical dashboards to display indicators and operating statuses. Operators will be able to supervise and control all productivity processes anywhere, anytime, by using the web interface graphics. The dashboard interface has been designed with the latest ergonomic requirements in mind. It can also be customised and integrated with advanced supervision and control features to enable the module to function as a supervisor. This technology is open to all types of additional data visualisation and therefore accepts display screens of any type to visualise production plant data as required.
Reports are created automatically, providing efficient analysis that fully details production data. Those areas experiencing inefficiencies are highlighted, giving details on where and when production downtime occurred and the causes. These integrated reports can be completely customised to integrate any other production data type that needs analysing or cross-referencing with the data from other production assets.
Pro.Lean enables communications with any field device or system through open interfaces, making it easy to collect and record the maximum amount of information. Data can be collected from PLCs, CNCs, PACs, inverters, fieldbus devices, I/O, instrumentation and more. Communication drivers for all common control system protocols are included, and the technology is OPC UA compliant as both Client and Server. Communication drivers for IoT system integration is also offered, along with direct connection to management level systems.
All of this allows meaningful analysis of KIPs for the calculation of OEE. And by highlighting specific areas of action where users can improve productivity, Pro.Lean offers a rapid return on investment.