Visualization in the Production Plant – Andon Board

Visualization in the Production Plant – Andon Board
Machine Eye – Toolkit for Process Optimization
and Lean Production: Visualization on the Production Line – Andon Board
A Bird’s-Eye View
The following information can be
displayed for each machine:
• Current status of the machine
• Shift productivity (OEE)
• Availability, performance and quality rate
• Current production rate
• Target and actual number
of products made
• Current order with quantity
balance and remaining time
• Most recent stoppages of
the machine
• OEE trend of the last few days
and weeks
People who are concentrating on their work can easily lose sight of the big picture. Machine
Eye reminds machine operators, shift leaders and managers of the current status of the
whole process – on big screens and mobile devices.
Better Informed, Better Motivated
Toyota pioneered the trend of involving workers in the overall process success, and introduced Andon boards: displays on the production lines that showed targets, performance
results and current machine status. This information motivates the workers and gives them
all a greater feeling of responsibility for the whole process and for quality.
Problems must be solved quickly, because only immediate responses can prevent further
losses. Visualizing problem situations directly on the shop floor helps everyone to concentrate on the critical issues and is a big step towards optimized productivity and lean production
culture. Thanks to affordable large LCD screens and mobile devices, this is now an economic
proposition even in small businesses.
Customizable Visualization
Machine Eye supplies the information for such displays. The source of data for the shopfloor
displays is the database of the OEE Analyser. External data sources can also be integrated.
A standardised set of parameters is displayed for each machine. Multiple machines can be
shown on one display; cycling of the display through several machines or machine groups is
also possible. The contents of the visualization can be expanded at any time at the request
of the customer.
Visualization on big screens …
... and on smartphones – shift productivity, production rate, OEE trends
and more.
System Configuration
Lightweight system:
• Data via HTTP interface
• With or without web server
• Space-saving and economical
• Customizable and ready to use
• Affordable even for
small companies
The ASP.NET Web API extracts the data from the OEE database and delivers them via a HTTP
interface. A web server supplies the HTML layout file, which can be any lightweight model.
If the system is set up without a webserver, the HTML file has to be installed on every display
processor. In this case, changes to the HTML file also have to be copied onto each individual
display computer.
The display computer for the big screen should have a graphics card with the same resolution as the screen. The visualization of the data in the browser does not need much computing power, so that economical and space-saving computers such as single-board PCs with
embedded Linux are suitable. Any normal, commercially available LCD screen can be used.
Successful in Practice
Many companies have implemented project-specific visualization solutions and have achieved impressive results with them. For example, Böhler Edelstahl installed a display of realtime performance data in the control room and achieved a productivity jump of over 10%.
Machine Eye is a moderately priced, customizable and ready-to-use solution that makes the
advantages of visualization affordable for small companies.
System Configuration
Web-Server
OEE Database
Web-ABI
WLAN
Internet VPN
Touchpad
LAN
Customizable Information Set
PC, Notebook
Big Screen with
Video Processor
© Thomas Topf
“Machine Eye visualizes the
status of the machines and our
progress towards the targets.
That improves efficiency.”
Justine Pisjak, Magna Powertrain AG,
Assistant Manufacturing Manager
Success Story: MAGNA Powertrain Uses Machine
Eye to Visualize Production
MAGNA Powertrain is a leading global supplier for the automotive industry, specializing in
design, development, testing and manufacturing of powertrain systems and components,
and especially in the integration of complete systems.
The company’s innovations focus on reduction of fuel consumption, improved vehicle safety
and increasingly on electronic control technologies that improve performance and reduce
emissions. The plant in Lannach, near Graz, was built in 1999 and employs around 1000
people in manufacturing of 4WD/AWD systems and axle drives.
“At the moment we have four Machine Eye displays in operation”, explains Justine Pisjak,
Assistant Manufacturing Manager at MAGNA Powertrain. “Visual production management
means a lot to the OEE experts in the plant: they rely on it for analyzing current status, for
weighting deviations, and for monitoring whether changes have the intended effect.”
The production workers are also very happy with the “information at a glance” function:
they find the instant overview of the status of the machines very useful. It helps them to
act on the basis of facts. As Justine Pisjak says, “Machine Eye is a heads-up tool”: it alerts
the workers to anything unusual. “When we notice something going wrong, it’s down to
our organization to solve the problem. We need good procedures that the workers follow
instinctively. But these all depend on the starting point – and that is the real-time analysis.
Of course, the visualization also leads to efficiency gains all by itself.”
Machine Eye:
• Facilitates real-time status analysis
• Weights deviations
• Shows progress towards targets
• Informs at a glance
• Raises efficiency
KVP Guide
Planning, Control and Evaluation of Improvements
Visual DataXplorer
Discovery of Errors and Quality Problems in the Production Process
PM Steel
Manufacturing Execution System for Steel Plants
Process Master
Control and Quality Management according to ISO/TS 16949
IPC
TPM and Maintenance Management
OEE Analyser
Analysis and Performance Parameters of Machines
Machine Eye
Visualization in the Production Plant – Andon Board
Contact person for Machine Eye:
Dr. Christian Schindler
Phone: +43 (0) 316 27 86 60 – 30
E-mail: [email protected]
GAMED
Gesellschaft für Angewandte Mathematik und EDV m.b.H.
Harter Straße 48,
8053 Graz, Austria
Phone: +43 (0) 316 27 86 60
Telefax: +43 (0) 316 27 86 60 - 10
Internet: www.gamed.com
Registration Number: FN 50094v
Commercial Court of Registration:
Commercial Court of Graz