In the last article, I took you to experience Industry 4.0 in practice, in the case of A, B, C, D dazzling, B is the best choice, the end of the editorial intentionally sold a shutdown, to be delivered in the next answer sheet. Do you remember? Now is the time to hand in the answer sheet, following the topic of the previous article, I continue to take you to experience Industry 4.0 in practice, to experience how intelligent workshops can help improve traditional manufacturing.
As we mentioned in the previous article, Bosch Automotive Diesel Systems faced many machine maintenance and management problems when improving production efficiency, and the Production Performance Management System (PPM), one of Bosch's Industry 4.0 software solutions, helped it solve these problems and achieve significant results.
Reduce manual data collection
Continuous, real-time monitoring of machine status
Improved data accuracy
2% increase in overall equipment efficiency OEE
Fast fault identification, 50% reduction in fault location time
Pre-determined faults, preventive maintenance
10% reduction in tool inventory
Annual savings of 1.6 million RMB
On the road to Industry 4.0
Bosch Automotive Diesel Systems collaborated with the Bosch Software Innovation Team, the Bosch MES development team and Bosch Rexroth to complete the collection of machine tool, tool, spindle and production data. By means of sensors and RFID chips connected to each product, information about the machine's status and performance is collected, combined with tool and production data, and transmitted to the production performance management system (PPM), thus providing near real-time analysis and visual monitoring, while the work order management module delivers information about various tasks to the relevant personnel and systems based on pre-defined rules.
The system not only allows Bosch Automotive Diesel Systems production to visualize the performance status of each machine tool, but also helps it gain insight into the production system and track every product that comes out of the assembly line.
Providing employees with the tools they need
Automation provides employees with the information they need to do their jobs better. Condition monitoring is now a real-time process that automatically and instantly flags when a machine is performing outside of its expected range and notifies the relevant maintenance personnel that it needs to be checked.
You can also see the machine vibration level, machine performance and other useful information," said Jinjun Ji, director of Bosch Automotive Diesel Systems Production Division.
The production performance management system (PPM) is a system that integrates information collection and evaluation management to promote smart production and intelligent processing of data. Its advantages also include reduced machine downtime, better control and control for planners, flexible configuration of daily requirements, real-time virtualization of models, and rapid integration with third-party systems with the help of open standards and interfaces.
But Bosch Automotive Diesel Systems understands that true business insight is based on information being interpreted deeply and its meaning understood. This project is not about replacing employees, but about providing them with better assistance so that they can better apply their expertise to solve core problems. With visual historical data, and a series of data mining and big data analysis such as trend analysis and threshold monitoring of these data, the software can quickly identify correlations between events and failures, thus shortening the time to locate failures, allowing machines to reduce unplanned downtime and quickly reset once problems occur, leaving people to do more creative and valuable work. People, says Jinjun Ji, "are still the key factor in the success of a project."
Transformation, still in progress
This system not only allows employees to find the root cause of problems and identify the cause of failure, but also to identify potential problems in time to prevent machine downtime early. With a deeper technical understanding of operations, the team can use benchmarking to achieve continuous improvement of the system. The result is increasing productivity and cost effectiveness.
Jinjun Ji sees this as a project still in progress and a potential new business model: "There is no end to the project, and once we have implemented the first step, new ideas will come pouring in." "Having this system in place has facilitated our equipment maintenance and management work," says Zhang Liang, Technical Support Specialist, "and we look forward to working together to obtain more equipment optimization in subsequent projects. "
The Connected CHIRON machine tool project is a technology test bed that demonstrates what is initially possible when humanity enters the era of Industry 4.0. Through the cross-divisional collaboration of the project, manufacturing and IT experts are constantly exchanging new sparks and generating innovative solutions that are excellent for Industry 4.0 practices. The Smart Factory helps operators increase productivity and reduce downtime while creating more flexible manufacturing methods and even bringing new business models to the table.
The first step to improving productivity is to collect data to understand the bottlenecks and barriers that exist. Bosch Automotive Diesel Systems now has visualization of shop floor conditions, which provides a favorable support for assessing shop floor conditions and making decisions based on facts rather than hunches. Each assessment and decision will help improve the equipment, not only solving the problems faced now, but also removing obstacles that may be faced in the future.
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Article adapted from Bosch Software Innovation