Datonis Manufacturing Intelligence Beta

Getting Started

About Datonis Manufacturing Intelligence (MInt)

Datonis Manufacturing Intelligence (MInt) is a cloud-based software which transforms the organizations (Plant) manufacturing related data from heterogeneous sources to depict a comprehensive 360-degree view of the plant. Today’s BI tools are very mature in data presentation and flexible in adaptation, but this doesn’t help those working on the shop floors that need to contextualize their analysis of data with the actions they are performing. Propagation of the information between systems and people (including shop floor operators) is the real need of the manufacturing industry.

Different Aspects of MInt

The following are Datonis Manufacturing Intelligence (MInt) key characteristics:

• Datonis Manufacturing Intelligence completely depicts the end-to-end manufacturing process
• A single portal which transforms and displays data with various angles like Productivity, Quality, Energy and Work order
• Preventive Maintenence with condition-based monitoring (CBM).
• Act with real-time insight: Passing data between enterprise-level and plant floor systems to display reports, analysis, visual summaries so that from a floor manager to the plant management can take informed decisions.
• On-Demand Monitoring: Datonis Manufacturing Intelligence has a fluid design and adapts to the target device screen, so you can monitor machines and access reports literally on the go.

Basic Concepts

Key Definitions

1) OEE - Overall equipment effectiveness (OEE) is a measure of how well a manufacturing operation is utilized (facilities, time and material) compared to its full potential, during the periods when it is scheduled to run.

• Overall Equipment Effectiveness (OEE) = Availability * Performance * Quality
• Availability = Operating Time / Scheduled Time
• Performance = (No. of parts * Ideal cycle time ) / Operating Time
• Quality = (No. of good parts / Total parts produced ) * 100

2) CU - Capacity Utilization (CU) is the extent to which an enterprise or a nation uses its installed productive capacity.

• Capacity Utilisation (CU) = (EWT – Planned Shut Down Time - No Demand) / EWT
• Effective Working Time (EWT) = Total available time - Planned maintenance

3) EU - Effective Utilization = Overall equipment effectiveness (OEE) * Capacity Utilization (CU)

4) Cycle Time - Cycle Time is the total time from the beginning to the end of your process including loading, processing and unloading. A Cycle is used to calculate throughput time and mostly used in discrete manufacturing.

• Cycle Time = Loading Time + Machine Auto Cycle + Unloading Timeline

5) Downtime - Total time for which machine was stopped or the product is not getting produced for a selected shift or a day

6) Planned Downtime - Downtime is caused by planned maintenance, operator leave or a holiday.

MInt Hierarchy

To translate the present organization structure into an IIOT enabled formation; The Datonis MInt application has the following hierarchy.

1. Department (Plant)
2. Cell or Line (under a plant)
3. Workcenter(s) (i.e. machines under a cell or a line)

Management Dashboard

This workspace captures the productivity elements at all the Organization level. The dashboard shows summarized insights for the key KPIs like OEE, Production Quantity, CBM Alerts and Quality Alerts. This dashboard gives a bird’s eye view to the key plant stakeholders as well as executive management.

This has the following sections:

• Cells: This shows the combined KPIs OEE, Production Quantity, CBM Alerts and Quality Alerts.
• Lines: This shows the Line-level OEE, Production Quantity, CBM Alerts and Quality Alerts KPI.

Productivity

Productivity is an important aspect of Datonis Manufacturing Intelligence. It is one of the basic variables governing economic production activities. However, at the same time as productivity is seen as one of the most vital factors affecting a manufacturing company’s competitiveness.

Datonis Manufacturing Intelligence portraits productivity in the following manner:

Bookings (User Actions):

The Bookings are added under the Actions menu. The user can perform the following actions under the productivity module:

• Downtime Booking
• Production Booking
• Book Performance Loss

Productivity Reports:

• Productivity Dashboard-This is a live dashboard which shows key productivity KPIs like OEE, Production Quantity, Stoppages, Hourly Production and Top Losses for the selected Cell or Line.

• Productivity at Workcenter- The reports displays productivity KPIs like OEE, Production Quantity, Stoppages, Hourly Production and Top Losses for the selected workcenter.
• Production Timeline- This dashboard shows the production timeline (Gantt Chart) since the beginning of the current shift.
• Productivity Analysis - The Productivity Analysis report plots the key KPIs in the form of a trend. This report is available at cell/line level as well as at a workcenter level.
• Loss Analysis - This dashboard shows an analysis of the planned and unplanned losses over the selected period. This report is available at cell/line level as well as at a workcenter level.

<<Add Video of te Reports >>

CBM

Condition Based Monitoring (CBM) plays a crucial role in preventive maintenance. 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 Based 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 a separate workspace for Condition Based Monitoring (CBM).

Although there are few master data configuration-related changes for CBM module. Those have been covered in the MInt Configuration Section.

Quality

Quality is another important aspect of production and so as of Datonis Manufacturing Intelligence. The effects of quality bottlenecks can be reflected across the entire line or cell. The continuous efforts to deliver quality products while balancing optimal throughput is an important measure to help manage manufacturing processes. Datonis Manufacturing Intelligence tries to cover the quality aspects of it from the rejection bookings and its impact can be also represented in the application in its reports.

Energy

Datonis Manufacturing Intelligence also covers the Energy workspace with two out of the box utilities i.e. electricity and Compressed Air. If a plant uses more utilities, there is a provision to add them. This gives an overview of the Utilities configured in the Plant.

Workorder

The Work order is another workspace in Datonis Manufacturing Intelligence. This captures the overall production happened for a Part for the planned work order. This provides a detailed view of the work order progress. Datonis Manufacturing Intelligence also allows creating the Workorder for a Part. Work order also maintains its life cycle in terms of when it is planned vs when it is completed and other aspects of it.