Comprehensive Operator Support
Streamlining Production Operations with Smart RDM Event Handling
At ConnectPoint, we recognize the indispensable contribution of manufacturing machine operators in the manufacturing process. They require extensive knowledge of the equipment they handle, quick troubleshooting and resolution skills, and an unwavering commitment to safety. Moreover, they need to closely monitor the execution of production plans and order fulfillment status.
We have incorporated robust features into our Smart RDM platform to support machine operators in their day-to-day responsibilities. By recording data, we can generate comprehensive reports and summaries at various levels, such as per operator, machine, or production line. This can potentially lead to optimizing the overall production process.
Machines performance monitoring
The role of production operators in monitoring machines is critical for ensuring that the manufacturing process runs smoothly and efficiently. Operators are responsible for identifying issues and making necessary adjustments to prevent downtime or product defects. To do this effectively, operators must be able to recognize the signs of malfunction and be skilled in troubleshooting.
Smart RDM platform provides operators with the tools to monitor machines and processes in real-time. Smart RDM presents data from multiple sources in an intuitive dashboard, allowing operators to navigate the information quickly and easily. This function enables operators to monitor processes and operations more effectively, ensuring that any abnormalities are detected promptly.
Abnormal data patterns in Smart RDM could signal an event or problem, especially when thresholds that define normal behavior are exceeded. Once an abnormal pattern is detected, an event of a special or configured type, such as an alert, can be generated and assigned to the relevant personnel for further investigation. This ensures that issues are identified quickly and resolved before they cause significant damage or downtime.
Smart RDM technology is useful for monitoring machines and processes and can also be used to monitor the execution of production plans and order fulfillment status. This function ensures that operators can stay on top of production schedules and quickly identify any issues that may arise.
Smart RDM has two modules that support event handling: Events and CMMS.
Events
In modern industries, it is crucial to have a comprehensive system for capturing, storing, analyzing, and comparing data in real-time. The Smart RDM platform implemented on the top of AVEVA PI data structure is a powerful combination of features that help users achieve this objective. The system has various functionalities that enable it to automatically identify and record important events based on the specific conditions related to data values collected in real-time. Depending on the configuration, the system can cover downtimes, alarms, quality issues, failures, orders, the realisation of production plans, shift summaries, and more.
For example, for one of our clients, we configured events to record reasons for the downtime of production machines, exceeding key production parameters, changeovers of production machines, and orders assigned to the machine.
Two things are needed to generate an event in Smart RDM: raw data from devices collected in PI and an algorithm that defines the conditions for starting and closing the event. This approach provides the greatest flexibility for generating events because the system administrator can create events in any way they desire.
When generating an event, its type is determined, and the values of parameters defined in it are calculated. The event’s end date can be determined automatically by the algorithm or ended by an authorized user directly in Smart RDM. The functionality allows for real-time notifications about system conditions that require specific attention, user actions related to events handling according to the pre-defined workflow, event-related data editing, adding file attachments to the event, event division, and editing history.
CMMS
The efficient management of maintenance operations is crucial for industries and organizations, and it is vital to have a system that can track and manage maintenance events effectively. The Computerized Maintenance Management System (CMMS) module is designed to fulfill this objective. It is intended to track and manage user-defined events related to maintenance operations in industries and organizations. The primary goal of CMMS is to improve maintenance efficiency, reduce downtime and maintenance costs, and provide reliable data on equipment maintenance history.
Typical use cases of CMMS include tracking planned downtimes or tracking failures, faults, machine adjustments, and other downtimes entered into the system manually. However, it is also possible to follow different types of events, e.g., related to waste management or outage plan. The flexibility of the CMMS module ensures that it can accommodate a wide range of maintenance events, ensuring that all relevant data is captured.
The Smart RDM platform offers comprehensive functionality that covers notifications, user actions according to pre-defined workflow, event-related data editing, adding file attachments to the event, and access to the editing history. These features ensure that maintenance events are managed efficiently and accurately, reducing downtime and improving maintenance productivity.
Real-time notifications about system conditions requiring specific attention are crucial in quickly resolving maintenance issues. The user actions feature enables operators to act on events based on the pre-defined workflow immediately. Event-related data editing allows for the accurate capture of maintenance history. At the same time, the ability to add file attachments to the event ensures that all relevant documentation is available in one place. Event division and editing history enable operators to track changes and ensure that all data is accurate and up-to-date.
Operator context
Smart RDM is a dedicated application designed for a broad range of users at each level of the organisation that provides functionalities such as data visualisation, events monitoring, and reporting. However, to enhance its functionality for production operators, Smart RDM has a separate function that limits the information available to the user based on the selected resource(s). This function records the user’s name in the resource’s attributes, indicating the operator’s name and shift, which can later be used for reporting purposes.
The primary advantage of this functionality is the ability to assign an operator to a resource and add their name to any event. This feature helps perform summaries in reports per operator and identify those who have the worst results. By having this information, managers can focus on those operators and provide them with additional training or support to improve their performance. The operator’s name added to the event can also help trace the issue’s root cause.
Secondly, the operator context in Smart RDM is essential because it fills the gap that automation systems cannot cover. Automation systems are designed to handle repetitive tasks and data analysis, but they need the human factor necessary to understand the context of the situation. The operator function in Smart RDM provides that context by displaying the application on the machine, allowing operators to understand the situation better and take necessary actions to address any issues.
Moreover, the operator function in Smart RDM is also useful in enhancing the overall efficiency of the maintenance process. By assigning operators to specific resources, the application can provide relevant information to the operators based on their assigned tasks. This information can include data related to the specific resource, maintenance history, and other relevant information that can help operators perform their tasks efficiently.
Knowledge base
Access to accurate and up-to-date information is critical for success in today’s fast-paced world. This is particularly true in the context of manufacturing, where the performance of machines and equipment can significantly impact overall productivity and efficiency. A knowledge base is a centralized repository of information that can be used to provide this information and support to users, particularly operators in the manufacturing environment.
The Smart RDM reporting module is an example of a system that enables the creation of a reporting structure that reflects the real structure of assets in the factory. This structure can include information about machines, work instructions, and other relevant data. By making this information available to operators, the system can help them to quickly find the information they need to carry out their work effectively.
The business administrator of the application is responsible for maintaining the knowledge base and keeping the information in the system up-to-date. This involves updating the reporting structure and ensuring that the right parts are available to the right users.
The subscription functionality of the system is another important feature that enables operators to receive notifications when documents are updated in the system. This helps ensure operators always work with the most current information available. For example, if there is a change in a work instruction, operators can receive a notification and update their work accordingly, reducing the risk of errors or delays.
Reporting
Operator’s perspective
Smart RDM is a powerful tool that collects data related to events and the operator’s actions, providing valuable information for analysis and future decision-making. The data collected includes a wide range of information, such as KPIs, summaries, calculations, manually entered data, and more. This data is essential for understanding the performance of a system, identifying areas for improvement, and making informed decisions to increase efficiency and productivity.
One of the advantages of Smart RDM is that it allows operators to validate and change data collected by automation systems if necessary. This ensures that the data is more accurate and reliable for the specific purposes it is being used for. Operators have a unique understanding of the system they are working with and can provide valuable insight into the data collected. They can also manually enter data into the system, providing additional context and information that may not be captured by automation systems alone.
The ability to validate and change data is essential for ensuring the accuracy of KPIs and other metrics used to measure performance. When the data collected is inaccurate or unreliable, it can lead to incorrect conclusions being drawn, which can have serious consequences for the organization. By using Smart RDM, operators can help ensure that the data used to make decisions is as accurate and reliable as possible.
Management’s perspective
Smart RDM offers more than just accurate data; it provides valuable insights into operators’ actions. By tracking the actions of operators and the events they interact with, the system can identify patterns and trends that can help improve efficiency and identify areas for improvement. For example, if certain events consistently cause downtime, it may be necessary to take action to address the underlying issue.
However, the data collected by the machines offer an even broader perspective. This is because the assets in the factory are modeled in a way that refers to their context. Over time, the collected values of production and machine parameters can create a basis for preventive and predictive maintenance. This information can also be used to create investment plans and manage the spare parts warehouse more effectively.
By using this information, manufacturing plants can minimize the risk of equipment failure and increase the overall efficiency of their operations. In addition, monitoring and analyzing machine data in real-time can help organizations make more informed decisions about their operations and improve their bottom line.
Summary
In brief, ConnectPoint’s Smart RDM platform offers a range of robust features that optimize production operations for manufacturing machine operators. The platform facilitates machine performance monitoring, real-time tracking of production plans and order fulfillment status, event handling, and support for operators and their managers. Two modules bolster event handling: Events and CMMS, with the latter providing efficient maintenance operations management while the former automates event detection and handling. Smart RDM also incorporates an operator context function, which limits user access to information based on selected resources and tracks the user’s name in the resource’s attributes. This feature aids in generating operator-specific reports and identifying those with suboptimal performance. These capabilities enhance manufacturing processes, minimize downtime, and boost productivity.