Digital Factory:Digital Factory

Getting started with Datonis Digital Factory

Datonis Digital Factory is a cloud based application suite for digital transformation focused on a targeted set of users. This is used to bring the organizations (Plant) manufacturing related data together from many sources spreading across the multiple dimensions. Digital Factory is an enabler for IoT as well as not IoT systems which will help digitization as well as helps the manufacturer to look at various important elements. This gives a facility to use targeted app for targeted set of people. Digital factory helps in propagation of the information between systems / machines and various people (including shop floor operators). Following are the different aspects of Datonis Digital Factory.

Configuration with Datonis Digital Factory

We start with Configuration App. This is the space which is used to create the digital Twin of the Plant / Manufacturing Processes. This covers various onboarding activities like mentioned below:

• Organisational Data: To start with one can onboard the logical hierarchy of the manufacturing assets (Workcenter) under Department, Cell /Line. The workcenter is the logical entity which represents the digital twin of the physical machine connected under IIOT process.The workcenter configuration will have various settings in terms of Automatic Booking, Maintenance settings etc as shown below.

• Shift and Shift Plans: It will also allow to configure Shift and Shift Plans. Shift Plans are the calendar been created by the Shift Supervisor as per the Production Schedule.

• Productivity Master Data Configuration app will also allow the administrators and supervisors to load the masters for Productivity
  1. Loading the Part masters with using application user interface or by using the bulk uploads provided. Supervisors can also add the Routing masters providing the cycle time, operation code and operation name and default workcenter on which this operation can be performed.
  2. Another important masters are for Downtime Reason codes, Performance Reason Codes. The downtime Codes will be used while calculating the Availability. And Performance Reason codes will be used while measuring the Performance Loss.

• Alerts Configuration app will also allow the administrators to configure the alerts for various apps and types. Alerts configured can help the users to track the escalation around various activities happening in Plant.
  1. Productivity Alerts: These are the alerts intended to track various productivity aspects as mentioned below:
     1. To check if the Production is not happening and machines are in idle state
     2. To check the Production Rate
     3. To Check the KPI based alerts for e.g. Alert me if my Availability is below 70% for a workcenter or Alert me if OEE of the workcenter is below 60% etc
  2. Maintenance Alerts
     1. to track the maintenance parameters or condition based parameters of the machine to check the anomalies based on outlier.
     2. To track the maintenance of the workcenter if its due.

Productivity with Datonis Digital Factory

Productivity is the important aspect of Datonis Digital Factory. It is one of the important application which showcases various production activities. However, at the same time as productivity is seen as one of the most vital factors affecting a manufacturing company’s performance and other aspects. Productivity Application covers various aspects. This mainly covers

• Real Time monitoring of Production: Productivity app captures the real time monitoring of production which helps the supervisor and operators to track the production. We have different dashboards and analysis which will show what is happening in the Plant.
  1. Productivity KPIs: Productivity Application keeps an eye on computing various important productivity KPIs such as Availability, Performance, Quality and OEE.
  2. Realtime Timeline views tells the supervisor whats happening on the Cell or Line. Units can generally monitor this so that they can track the SKUs, their production and how good they are from their targets.
     1. Availability : This is very important KPI looked from Productivity. Datonis Digital Factory's Productivity Application give various aspects of Availability. While capturing Availability it takes into account Availability Losses, which includes any events that stop planned production for an appreciable length of time. There are various dashboards showing other details of availability. It also showcases the Planned and Unplanned Downtimes, Major and Minor Stoppages and Unbooked Downtimes. Productivity application also offers various reports like Downtime analysis and MTBF and MTTR Analysis at Cell and Workcenter levels.
     2. Performance
     3. Quality
• Actions : Productivity Application allows to perform various manual actions such as Production Booking, Downtime Booking.
• Dashboards and Reports:

Learn more about Quality workspace and its reports

Maintenance with Datonis Digital Factory

Condition Based Monitoring is the process of monitoring a parameter of condition in work center (vibration, temperature etc.), in order to identify a significant change which is indicative of a developing fault. Condition monitoring has a unique benefit in that conditions that would shorten normal lifespan can be addressed before they develop into a major failure. Datonis Manufacturing Intelligence has added a separate workspace in this release and will be having more advancements in this module in the upcoming releases. Although there are few master data configuration related changes for CBM module. Those will be covered in the Master Data Configuration Section. Various elements of Maintenance are

• Real time monitoring of various critical parameters of Workcenter. This will help monitoring the health of the workcenter and helps to capture the various capabilities over process like cp, cpk and other statistical capabilities.
• Looking at Total Preventive Maintenance (TPM) by using maintenance orders and maintenance records
• Inventory management of spare parts and consumables
• Digitisation of SOPs, Documents, covering various aspects of maintenance and Employee Health and Safety by using Checklists
• Alerts
• Dashboards and Reports

• Various Personas that are involved in this app are:
  1. Maintenance Manager – Responsible for overall maintenance of operations. Responsible for running TPM program, responsible for key metrics like OEE, MTBF, cost of spares, etc. Responsible for maintenance budget and expenses.
  2. Maintenance Engineers/Supervisors – Typically working on field and responsible for actual operations.
  3. Production Operators and Supervisors - These are the team members who can raise a request for problems on the machines / tools they are working on.
• Workcenter maintenance Workflow--This will include regularly scheduled service, routine checks, and both scheduled and emergency repairs. It also includes replacement or realignment of parts that are worn, damaged, or misaligned. Machine maintenance can be done either in advance of failure or after failure occurs. Typically, an engineer / operator will be working on the machine for his day-to-day work. The maintenance department is responsible for the continuous operation of all machinery and systems necessary for a manufacturing facility.
  1. The first consists of planned shutdowns for maintenance and/or upgrades to the systems.
  2. Suddenly some breakdown occurs in the machine and the operator is seeking help from the maintenance department to correct it.
  3. The Maintenance Department will have their regular guidelines / SOPs / TPM checks to work upon in order to keep the machines health and productivity as expected.
  4. For the sudden or unplanned breakdowns the maintenance engineer has to work on it to find the issue and take corrective actions against it.
  5. Maintenance Order is all the information about a maintenance task and outlines a process for completing that task. A work request is used by non-maintenance staff to make the maintenance team aware of a task. At times the maintenance department team will also create this as part of his job card.
• Maintenance Request :A maintenance request is a request for maintenance, possibly raised by an operator, or a supervisor. Maintenance requests can be created for an asset (Workcenter / Tool) by specifying the description of the issue/problem. A maintenance supervisor has an ability to convert a maintenance request to maintenance order. Else, the requests can also be deleted. Maintenance App provides the option to create the maintenance Request from the Maintenance Dashboard. Operators can create maintenance request from console app. Supervisors can also raise the requests from Production Timeline from Productivity app.A maintenance request can have following information
  1. Maintenance Of : Workcenter or a tool for which Operator / Supervisor is finding a problem and wants to raise a request.
  2. Description : enter additional description of the maintenance request.
  3. Priority : Allows users to assign priority of the request (High/Medium/Low).
  4. Status : status of maintenance order (Open/In Progress/Closed).
• Maintenance Order :A maintenance order is a directive to perform maintenance of one asset. Maintenance order specifies the asset of which the maintenance is to be carried out, maintenance description along with additional information such as scheduled start/end time, priority, status, order number, type etc. The purpose of a maintenance order is to create a plan along with its schedule to ensure that timely maintenance of target assets is initiated and tracked. Maintenance Supervisor may initiate a new maintenance order in following cases:
• Upon receiving a maintenance request from an operator (from operator dashboard).
• Asset health is low as per the defined maintenance threshold.
• Planned maintenance of an asset.
• Emergency maintenance in cases such as machine breakdown.

A maintenance order is consisted of:

1. Order Number - This is an auto-generated number. The number will be generated on creation of any new maintenance order. Format is OD-n, where n is a number greater by 1 than the last maintenance order. Order number is not displayed while creating the maintenance order, but is visible while editing the order.
2. Maintenance Of : The user will select the asset type (Workcenter OR Tool). Based on this selection, users should be able to select one Workcenter, or one Tool.
3. Description : Additional description of the maintenance order.
4. Maintenance Type :Allow users to check if the maintenance is Planned or Unplanned.
5. Scheduled Start : Planned start time of maintenance.
6. Scheduled End : Planned end time of maintenance.
7. Priority : Allows users to assign priority to the order (High/Medium/Low).
8. Status : status of maintenance order (Open/In Progress/Closed).
9. Created By : Email id of the user who has created the maintenance order.
10. Created At : Datetime at which the order has been created.
11. Assigned To : Email id of the user to whom the order has been assigned.

• Maintenance Record : A maintenance record captures the actual maintenance work performed against the maintenance order. A maintenance record may fulfil multiple maintenance orders. Following information must be recorded.
  1. Record Number This is an auto-generated number. The number will be generated on creation of any new maintenance record. Format is MR-n, where n is a number greater by 1 than the last maintenance record.
  2. Associated Maintenance Orders : Users should be able to associate one or more maintenance orders with the maintenance record. When multiple orders are selected, those must belong to the same asset. Users should be allowed to select any of the open maintenance orders. Additionally, users should also be able to create and associate a new maintenance order. Table of associated orders should be displayed with following columns:
     1. Order Number
     2. Description
     3. Maintenance Of
     4. Maintenance Type
     5. Scheduled Start
     6. Scheduled End
     7. Priority
     8. Actions [edit, delete]

1. Observations : Maintenance engineers may enter observations, if any.

• 1. Work items: user (maintenance engineer) can record work items, if any. Work items are added as text. Table of work items should be displayed with following columns:
     1. Sr No
     2. Work Item
     3. Actions [edit, delete] to edit or delete the Work Item
  2. Spare Parts Used : List of spare parts used along with quantity,Table of spare parts used should be displayed with following *## columns:
     1. Sr No
     2. Spare Part Code
     3. Description
     4. Quantity (values displayed shall be appended with unit of measure)
  3. Consumables Used :List of consumables used along with quantity, if any. Users shall be able to select a consumable from a dropdown list (searchable list, displayed in format ‘<consumable_code>-<description>’.Table of consumables used should be displayed with following columns:
     1. Sr No
     2. Consumable Code
     3. Description
     4. Quantity (values displayed shall be appended with unit of measure)
  4. Maintenance Start Time : Actual start time of maintenance.
  5. Maintenance EndTime :Actual end time of maintenance.
  6. Status : Status of maintenance record (Open/In Progress/Closed). On change, status of associated maintenance orders shall also get changed to the new value.
  7. Reset Maintenance Threshold : If set to True, resets the maintenance threshold of the asset for which maintenance has been performed. NOTE: maintenance is reset only when the status is changed to ‘Closed’. It should not get reset on save, when previous as well as the current status is ‘Closed’.
  8. Created By : Email id of the user who has created the maintenance record.
  9. Created At :Date and time at which the record has been created.

Maintenance App Elements

• Master data for Maintenance App: We can add master data for maintenance app like Spare part inventory and Consumables. Various maintenance parameters and checklists at different levels of assets and components. Administrative users (Production and Maintenance Managers/ Supervisors) can configure operating limits, critical parameter specifications (UCL, LCL, expected value)
  1. Spare Parts- Maintenance activity may require replacement of spare parts. As a Maintenance Manager/Maintenance Engineer one should be able to maintain a list of Spare Parts which are needed in the asset maintenance. While creating a maintenance record, the user should be able to add the quantity of spare parts used, if any.Maintenance Supervisors will be able to track the inventory of spare parts used and cost associated with it in the maintenance activity.
  2. Consumables- Maintenance work may require consumption of Consumables, such as oil, grease, gas, etc. As a Maintenance Manager/Maintenance Engineer one should be able to maintain a list of Consumables which are needed in the asset maintenance. While creating a maintenance record, the user should be able to add the quantity of Consumables used, if any. Consumables master can be added / uploaded in Datonis Maintenance App of Digital Factory.

• Real Time monitoring of Critical Parameters: Maintenance app allows to monitor the various critical parameters of the Workcenter. App provides various reports and Dashboards.
• Maintenance Request: Maintenance app allows to monitor the various critical parameters of the Workcenter. App provides various reports and Dashboards.

Learn more about Condition based monitoring reports

Checklist with Datonis Digital Factory

This is a framework for enabling TPM, TQM, Quality Control Plans, EHS improvement initiatives. Framework for enabling paperless operations. This helps in Covering digitization of TPM, TQM, Quality Control Plans, Maintenance & EHS improvement initiatives.Some of the features provided by Checklist are:

• This framework helps in Defining policies / Checklist templates.
• This enables the users to record the readings for these policies or logbooks for the defined Checklist Templates. Calendaring of policies by user so as to track the adherence and discipline in reporting on entered data / compliance.
• Provides capabilities to integrate variety of media like photos, videos,documents, symbols

BI

MInt supports the analytics application with the reports which the user can create on their own. This helps to show the descriptive analytical reports covering the Productivity Workspace from MInt. This helps in creating a rich set of data visualizations. It also provides an easy-to-use interface for exploring and visualizing data. This allows to create and share dashboards to the users. This is the DIY framework (Do It with Yourself) which will allow the user to create their own reports. There are out of the box following reports created:

• Production Insight By Workcenter : This will show the Production KPIs like Uptime, Down Time, Availability, Performance, Quality , OEE, Planned vs Unplanned Time for each workcenter.
• Production Trend : This report will show the Production trend across the days for all the Workcenters in the Organization.
• Loss Insight : Loss Insight report will help to see the details about the losses happened. This helps to see which are the Losses having more time booked and also helps to see the losses per workcenter.
• MTBF and MTTR : For the selected Loss/ Reason code this reports shows the Mean Time Between Failure and Mean Time To Recover.