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Production Performance Monitoring
Challenge: Identify and correct the source of reduced output in one of multiple production lines.
A water bottling operation had five steps in its bottling process: Cleaning, Filling, Capping, Labeling, and Packaging. One of the plant’s production lines had a recurring problem of lower output than the other lines. The production manager wanted to identify the step, causing bottling constraints and quantify losses in the underperforming line in order to determine how to bring output up to that of the other lines. The bottling machine in question was older and had no way to monitor throughput.
Solution: Production Performance Monitoring (PPM) Kit
The production manager installed a Banner Production Performance Monitoring (PPM) Kit, and sensors were placed at each stage of production to determine what was limiting throughput. By monitoring each step in the process, the production manager learned that during the capping process, the cap was frequently not sealing properly, and bottles were being rejected at a higher rate than the other lines, reducing output. The facility made a service call to the machine manufacturer, who was able to quickly make adjustments to the machine to bring the process back into specification.
Key Benefits
Increases process awareness
Banner’s PPM Kit analyzes machine performance and availability by measuring individual line speeds and part counts and then comparing real data to ideal run conditions. The PPM Kit uses Banner wireless all-in-one photoelectric sensors or pre-existing sensors with wireless nodes to aggregate performance data, which is then sent to Banner’s DXM Controller. The controller then routes the performance data to Banner’s Cloud Data Services platform for automatic dashboard creation and simple visualization.
Helps identify which line upgrades will give the best ROI
By measuring and analyzing machine performance, the PPM Kit provides a standardized method for performance tracking to set process benchmarks. The kit gives immediate feedback on process states and error conditions, offering insights into machine performance to help optimize throughput. Performance metrics can be used to identify system bottlenecks, make personnel scheduling decisions, and determine which line upgrades offer the best ROI.
Installs easily and is compatible with new & legacy machinery
Banner’s PPM Kit is a stand-alone, add-on solution that is compatible with new and existing production machinery without the need for modifications. Facilities may upgrade existing equipment’s sensors with wireless communications using a TL70 Node and Banner’s S15 Adapters or install Banner’s wireless D-cell Q45 Photoelectric sensors for a fast installation. The PPM Kit setup requires simple settings configuration via the LCD display of the DXM controller, all without the need for software. Wireless communication between the all-in-one sensors and DXM controller allows for sensor mounting in virtually any location.
Wireless PPM Kits
Production Performance Monitoring (PPM) Kit is a self-contained, wireless throughput monitoring application kit.