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.

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:

• 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.
• Maintenance Engineers/Supervisors – Typically working on field and responsible for actual operations.
• 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.

The first consists of planned shutdowns for maintenance and/or upgrades to the systems. Suddenly some breakdown occurs in the machine and the operator is seeking help from the maintenance department to correct it. 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. For the sudden or unplanned breakdowns the maintenance engineer has to work on it to find the issue and take corrective actions against it. 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 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)

• 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

Framework for enabling TPM, TQM, Quality Control Plans, EHS improvement initiatives • Capabilities to integrate photos, videos, documents, symbols • Defining, booking of policies • Compliance • Ability to define improvement

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.