Digital Factory:Digital Factory

Getting started with Datonis Digital Factory

Datonis Digital Factory is a cloud based application suite used to bring the organizations (Plant) manufacturing related data together from many sources spreading across the multiple dimensions. Many 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. Following are the different aspects of Datonis Manufacturing Intelligence.

• This includes Productivity, Quality, Energy, Work order.
• This is intended mainly for reporting, analysis, visual summaries, and passing data between enterprise level and plant floor systems.
• Datonis Manufacturing Intelligence greatly depicts the manufacturing process covering the different segments of Industrial manufacturing.
• Ability to present data in the context of the end user activities.

Datonis Manufacturing Intelligence is been structured in following main modules.

Productivity with Datonis Digital Factory Intelligence

Productivity is the 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 covers the Productivity at the Plant, Department, Cell/Line and at Work center level. A Cell is a logical un-ordered set of work centers where as Line is an ordered set of work centers. This means that there is a sequential work that happens when producing a part. The Line can be considered as subset of Cells.

• Productivity at Plant Level: Productivity workspace captures the productivity elements at all the Organization level. This includes Plant, Cell/Line and Work center. Under this workspace, Productivity at a Plant level is covered as a landing screen. This view gives the productivity at the selected Plant from the filter. This has broadly following sections:
  1. Cells: This shows the cell-wise distribution of Uptime, Down Time, Production Quantity for all the Work centers falling in each Cell.
  2. Lines: This shows the Line-level Uptime, Down Time, Production Quantity. This also shows if each line will be active or inactive.
  3. Work orders: Work order section depicts the status of all the work orders running in the plant. This essentially covers following aspects:
     1. This shows the overview of the Work orders that are finished , orders which are on target ,work orders which are lagging in the schedule and the number of work orders which need attention.
     2. This also gives the further drill down view of all the running work orders with the Part and its progress of production. This drill down view is helpful to see the information related to each work order to track its progress with the planned quantity and its actual quantity produced
     3. There is a link provided the further drill down of each of the work order if we hover on the Work order Number.
     4. There is also a link provided for the Part analysis if we hover on the Part name. This link shows the quality aspects of the selected part and its rejections as well. (Covered in detailed in the Quality section)
• Productivity at the Cell level : When user clicks on the VIEW LIVE link from the Cells/Lines, this shows the Time line chart of all the work centers under that Cell/Line. The Time line Cell level view is the Live Dashboard view showing the current status of each work center. This also shows the productive and idle slot in the current shift till the time. This also shows live production quantity, total uptime and down time of each work center. There is also a link provided on each work center on the live dashboard to drill down further at a work center level.
• Productivity at the Line level: From the productivity workspace if the Organization is comprised of the Line, the Line view will be shown. When the user clicks on the VIEW LIVE, this is actually showing th live dashboard of the selected line for which the VIEW LIVE link is clicked. The Live Dashboard of the selected Line will show the Highlights section. This shows the status of the Line. This will be the status of the last work center in the sequence configured in the Line definition. (Line configuration by design). This also shows the production of the last work center in the Line definition. There is also the Production Time line section which shows the time line (productive and idle) of the last work center configured under the Sequence Work center under Line configuration. Under the Work centers section individual work center performance (Production Quantity, Up Time, Planned Down Time, Availability, Performance, OEE, CU, Operator assigned on that work center) is bee shown. There is also a link provided if user clicks on the Work center. This is navigated to the Work center Analysis report.
• Drill down with Work center Level: Work center Analysis is the report showing the performance of the work center for the selected date and shift. This mainly depicts OEE, availability, performance, Quality. This also shows the Total Production, Capacity Utilization (CU), Up Time and Down Time. This also shows the Productive and Idle Time line view of the Work center. This report also shows the Parts per Hour distribution of the selected date for the selected shift. The Work center Analysis report can be also navigated from the Reports menu under the sub menu as Productivity.
• Reports (Productivity): There are different reports covered under this.

Learn more about Productivity reports

Quality Workspace with Datonis Manufacturing Intelligence

Quality is another important aspect of Datonis Manufacturing Intelligence. The continuous efforts to deliver the quality products while balancing optimal throughput is an important measure to help manage manufacturing processes. The effects of quality bottlenecks can be reflected across the entire line or cell. 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.

Learn more about Quality workspace and its reports

Condition Based Monitoring (CBM) Workspace with Datonis Manufacturing Intelligence

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.

Learn more about Condition based monitoring reports

Energy Workspace with Datonis Manufacturing Intelligence

Datonis Manufacturing Intelligence also covers the Energy workspace. This gives an overview of the Utilities configured in the Plant. There are 3 out of the box utilities that are targeted in this version of Datonis Manufacturing Intelligence. These include electricity,Compressed Air and Steam.

1. Energy Dashboard: This is the Plant level utilities consumption view. This covers the Highlights covering all the configured Utilities. It shows Kilowatt Hour consumption (Kwh) for Electricity, amount of compressed air for Compress Air and Steam consumed (Kg). This report also shows the Cell Summary which is nothing but the utilization of these metrics in each cell. There is a link provided for the further drill down on the Cell.
2. Cell Analysis: This report shows the utilities consumption for Electricity, Steam and Compressed Air for a Cell under Highlights. There is also a detailed section showing this data for the each work center for that Cell. There are out of the box three utilities supported in Datonis Manufacturing Intelligence. One can configure it from these. The cell analysis also shows the work center level resource consumed and we can get the details of it by further clicking on the link provided on the work center name.
3. Workcenter Analysis: This shows the overview of configured utilities consumed under the Highlights Section. This also shows the hourly electricity Consumption, Hourly Compressed Consumption and Hourly Steam consumption in a bar chart.
4. Energy Configuration: Datonis Manufacturing Intelligence has introduced the Energy as a separate workspace capturing the utilities consumption. We can configure these utilities for the Workcenter under Configure Workcenter Parameters. Here we can add a Parameter and map into a metric from the Thing associated to that Workcenter on Datonis. When we select the metric and map it to thing, we can map it to the type of Energy from Electricity, Steam etc. Selecting the Parameter Type as Energy allows it to select it from the Utilities supported in Datonis Manufacturing Intelligence.

Workorder with Datonis Manufacturing Intelligence

A Work order is another workspace added in Datonis Manufacturing Intelligence. This captures the overall production happened for a Part for the planned work order. This workspace gives the detailed view of the work order progress. Datonis Manufacturing Intelligence also allows to create the Work order entities for a Plant and for a Part. This basically describes the deliverables planned for the given time-frame. Work order also maintains its life cycle in terms of when it is planned vs when it is completed and other aspects of it.

• Work order Configuration: Under the Actions there is a Work order option to create the Work order. The Work order can be created for the selected Part. There has to be planned quantity to be added in the Work order. The work order also has the time duration for which this work order is planned. When the production user is making the production booking he will be able to associate this work order with the actual production done in that time. Apart from creating the work orders, this is also used to get the overall insight of all the work orders in that plant for the selected time/date frame. This gives a tabular view of the production done for each of the work order. This gives the insight of Planned Start and Planned End along with the Actual Start and Actual End based on the Production booking done. This view also allows certain operations/actions which can be performed on each work order. This includes deleting a Work order, Marking the work order as a finished work order.

• Workorders Dashboard:This view shows a detailed insight of a work order in a Plant. This mainly captures following:
• Planned vs Completed Quantity : This gives the pictorial view of each work order and its planned/completed count. Planned vs Actual time line: This view gives the details of how each work oder is performing. This is helpful to check which are the lagging work orders in their completion and which are on track work orders. The gantt chart representation helps to track this.
• There is also a tabular view of each of the work order showing its performance. This gives a detailed insight of each work order. There is also a link provided to get into further details of the Workorder Analysis.
• Workorder Analysis: This view shows the Planned vs Completed count of each work order.

Learn more about Workorders reports

Actions

The Bookings are added under the Actions menu. There are two kinds of Bookings.

1. The Production Booking allows to associate the Part, Operation from the Routing to the actual Parts produced from the slots. This also allows to associate the Work order to the batch/lot produced in actual data which is represented in Time line. The Production booking is an important process which is required to be followed when to need to see the Planned vs actual production. The steps for the Production booking are captured in the video.

Learn how to perform Production Booking

1. The Loss Code booking can be also done under the Production menu from the Bookings option. Here also we need to select the slots for which the down time reason code is required to be added. For an operator this an important booking which will calculate the availability in the OEE calculations. The steps for this are captured in the video.

Learn how to perform Loss Code Booking

1. Rejection Booking: The Rejection Booking at the Shift level can be done. There is a setting which we need to apply at a Shift level while creating a Workcenter. If this is set at Shift level and we have done the Production booking for time frame , we can do the quality booking of it and associate the Rejection Code and Rejected Quantity for same. If a Slot level configuration setting is been provided for a workcenter option for booking the rejection at the Shift level under this menu is not possible.

Learn how to perform Rejection Booking

1. Failure Mode:The manner in which an equipment or machine failure can occur. The typical failure modes can be premature operation, failure to operate at the prescribed time, failure to cease operation at the prescribed time, failure during operation. The CBM failure modes which are added in Datonis Manufacturing Intelligence can be booked under this. We can take a look at the CBM parameters data for the time period for which this Failure Mode is been booked. This helps to look at the consequences of the failures and the parameters causing those.

Do It Yourself ReportsIntegration for Analytics with Datonis Manufacturing Intelligence

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.