EFFICIENCY MONITORING SYSTEM - Indas Automation

Reduce losses and increase efficiency on filling lines using real-time line OEE analytics. Eliminate guesswork and discover the real downtime reasons.

In the food and beverage processing industry, efficient and flexible packaging and filling of different types of products contribute significantly to the success of the companies.

With the increase in the number of new mixed beverages and foods, packaging materials, and packaging formats, operators are also facing the problem of responding quickly and flexibly to new challenges. It requires not only more efficient working practices but also carefully planned logistics to ensure the proper handling of products and packaging materials.

In a value-added chain of production, filling and packaging are the final and most cost-intensive steps. Availability of filling and packaging lines is between 50 and 80 percent. Unavailability of the filling line means a loss. Even the shortest downtime, so-called micro-stops, if accumulated, will significantly reduce line efficiency. Therefore, the causes of downtime should be identified.

Despite of all machines upstream and downstream of the filler have greater nominal output, there is always a possibility that these machines could cause a filler stop.

Efficiency Monitoring System (EMS) from INDAS Automation was developed using COPA-DATA software tools while keeping all the above issues in mind.
INDAS Automation is a Silver COPA-DATA Partner.

Efficiency Monitoring System (EMS) is connected via ethernet with all machine control systems, collecting alarms, warnings, states, and defined values in order to provide online analytics like OEE (Overall Equipment Effectiveness). The root cause algorithm is developed to identify the cause of filler stops and to help operators to manage lines more efficiently.
EMS also supports manual entries for cases where it is not possible to automatically detect the causes of the filler stop. Predefined causes can be selected via operator panel but there is also a possibility for the supervisor to change the cause later, if necessary.

All collected data are stored in a historical database for later analysis and reporting. EMS is web-based and can be accessed locally or remotely, providing mobile access anytime, anywhere.

EMS Key Functionalities

Easy scalable to new lines in food or beverage production plants
High connectivity with machines and production facilities, including the Weihenstephan Standards communication protocol
Plant and production line overview, with the status of every machine and conveyors
Recording of the root cause that occurs before the bottle/can speed on the filler drops

The EMS has the possibility to interconnect with the energy management system and SAP. Additionally, the EMS is responsible for automatically acquiring all data necessary for efficient real-time supervision and analysis, whereas, for the data that cannot be acquired automatically, it grants a possibility for the machine operator to enter downtime causes manually. The operator is also provided with different kinds of reports, such as alarm and event statistics, messaging via SMS or E-mail, Gantt charts for the evolution of machine states, trend curves of major process parameters for every machine, extended production reports for filling teams, as well as the capability of archiving data. EMS possesses OEE indicators for current shift of production batch, along with OEE analysis according to the performance concept.

Benefits

Accurate tracking of machine issues
Elimination of guesswork and discovery of real downtime reasons
Instantaneous access to production status and data
Effective responsiveness to critical issues
Remote monitoring of line conditions
Production increase

Some other benefits are reflected in identification of bottlenecks and the increased ability to comment on machine stops and specific events, reducing downtime with root cause analysis and focused corrective actions, close monitoring of machine KPIs and reducing time for KPI analysis, as well as effective data sharing and reporting that helps supervisors at their daily meetings, easier planning of capital investments in filling lines and improved awareness of machine impact on the line flow.

EMS Reports

RAW Data Report
List of identified and stored states of the line.

DDS Report
List of grouped faults for filter. The report is based on the root cause, stored for filter.

State Loss Tree Report
Quantification of losses from planned downtime, unplanned downtime, target rate losses, and quality losses, organized in Loss Tree.