How to Increase Machining Efficiency through Machine Monitoring

Machine efficiency is the machine’s ability to convert inputs to outputs efficiently without wastage. The machine efficiency is the ratio of output work to input work multiplied by 100 percent. The common machine efficiency terms which Industries refer are energy consumption, power consumption, productivity consumption.

Ways to measure effectiveness and efficiency of your equipment

While assessing the effectiveness and efficiency of your equipment, the following parameters are considered.

Machine Efficiency

  • Availability

How often a machine is available for use in production is an important factor when we are talking about availability. Availability is calculated by dividing machine’s operating time by planned production time of the machine.

  • Performance

Performance is measured by comparing production per hour with the ideal production rate. The ideal production is the production when the machine ran at its maximum rated speed for all time.

  • Quality

Material wastage and quality shortfalls are other examples of the poor performance of the machine. Rejected materials need to be reproduced, which means extra work by the machine, affects the machine’s performance.

  • Losses

Machine efficiency is reduced by many factors directly or indirectly like planned downtime, Breakdowns, Minor stops, Speed loss, Production rejects.

  • Overall equipment effectiveness

Based on availability, performance, and quality score, Overall Equipment Effectiveness (OEE) is determined. For an OEE of 100 percent, a machine needs to be free of defects, run at rated speed, and have no unplanned outages.

A single-digit OEE score indicates that a machine can do better. For optimizing productivity, it is important to calculate OEE regularly and analyzing the trends for individual equipment and the plant.

Target OEEs vary between plants and application categories, so owners and plant operators need to determine the appropriate benchmark for their operations.

Best Practices to Improve Machine Efficiency

From a business point of view, less waste equals more efficient production. Optimizing all the components within the factory is vital. The following parameters can be implemented for optimum results.

Planned Maintenance

A proper planned or scheduled maintenance is required for smooth production. It is best practice to carry out maintenance during night shifts or over weekends. It allows the main production shift to operate without disruption. For implementing this, it is important to keep the machines in the best working condition and maintaining up a time to an absolute maximum.

System Parameter Optimization

It is important to optimize the overall system parameters based on machine settings, the material processing settings, and the tool settings to generate the parts as quickly and as efficiently as possible. Once the overall system is optimized, the produced parts will be as per specification and quality standards.

It is beneficial to have a record of all the parameter settings for each job.  It will minimize the set-up and start-up times to a minimum. The use of set-up experts in a team will keep the machine uptime to a maximum.

Staff Training

Tools, equipment, and machinery need regular and frequent care and maintenance. Equipment needs to be assembled from the constituent after which they are installed appropriately so that they can operate effectively. Training the employees provides them the necessary and important skills and technical ability to install and monitor maintenance to all the systems while at the same time providing service regularly. The technician will handle the more complex tasks, but most of the workers will be able to handle most of the assembling and installation tasks.

Impact of Best Practice Implementation

Implementing best practices within the shop floors allows the machine to run longer and more efficiently. There will be more production at an acceptable quality standard. The overall outcome is that the industry runs more efficiently. Production is within schedule and to the desired quality levels.

Improving reliability, performance, and safety are among the top priorities for industrial organizations and businesses today. They are focusing efforts and resources on controlling costs and maximizing value from existing investments.

Importance of Predictive maintenance

Predictive maintenance helps to determine the condition of running equipment. It estimates the maintenance requirement and schedule.

Predictive maintenance uses condition monitoring as the base. Condition monitoring is the process that considers parameters of the condition in the machine (vibration, temperature, etc.) to identify a notable change in the condition which is an indication of a developing fault.

Condition Monitoring is a maintenance approach that monitors the actual condition of equipment, extracting information to know the actual wear and tear, degradation, and if a significant change has occurred. The data collected is used to establish trends, predict failure, and calculate the remaining life of an asset.

The maintenance engineer’s job is to prevent any disruption in the manufacturing process. With help of predictive maintenance, the maintenance team can plan effectively for the replacement timeline and make the necessary workarounds until new equipment is installed.

The use of new smart sensors enables you to move from reactive to predictive. These smart sensors are very handy and can be installed on legacy equipment without any hassle. New smart sensors are equipped with software data analytics mobile apps and a convenient dashboard. Now the user can configure the sensor easily and have all the data at fingertips. The sensor collects the data from machines and with help of modern technologies, this data is used to predict faults and improve maintenance processes, and improves plant efficiency. Machines can be monitored 24×7 remotely effortlessly using dashboard and mobile, action to prevent the failure can be taken before it is too late.

For predictive maintenance, there are multiple solutions in the market. Infinite Uptime is one of the best one-stop solutions for the smart sensor.

Infinite Uptime is a global industrial edge solution provider for mechanical predictive maintenance in the engineering and process industries.

Infinite Uptime’s Industrial Data Enabler (IDE), patented edge-computing Vibration monitoring system for predictive analytics and maintenance remotely gathers tri-axial vibrations, noise, and temperature of any mechanical rotating equipment in real-time. It empowers the Maintenance team to monitor the machine uptime, reduce unplanned downtime, and combat impending equipment damage in advance.

Moreover, the end-to-end solution with visual indicators ensures maximum machine-availability, decreased inventory of spares and maintenance costs, and complies with the guidelines on safety and physical distancing directed by the Government.  Not only does it help reduce maintenance fixed costs at a time where a reduction in costs and manpower is a dire need, but it also enhances social distancing by allowing remote monitoring of a plant without physical intervention.

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