Streamlining Production Operations with Smart RDM: Event Handling and Support for Operators and their Managers – Part 1
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.
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.
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.