Machine monitoring morphs

The ability to remotely access monitoring data on machine tools was initially a means of discerning machine status, problems, downtime and other factors in near real time, enabling them to be quickly addressed. Basic monitoring systems remain a valuable option for individual shops, while machine monitoring on a larger scale, such as across multiple sites, requires a more comprehensive approach, typically involving an equipment monitoring system coupled with enterprise manufacturing intelligence. These systems work autonomously to continually monitor and provide visibility to equipment performance. This information can then be converted into intelligence that is fed continuously into a comprehensive enterprise resource planning (ERP) system to track overall company performance.

The advances that have melded multiple discrete systems, including monitoring and management of tools, raw materials and maintenance, have led to a growing number of offerings, from the basic to the highly complex. The challenge, however, is identifying the right system or collection of systems for an operation.

The rapid growth of these systems is due to a number of factors, including advances in Wi-Fi and radio frequency technology, sensor systems and standards such as MTConnect that facilitate connectivity between machine controls and reporting networks.

No-Frills Monitoring

As monitoring systems began to come online, Productivity Inc., Minneapolis, saw a marketing opportunity. “We realized that the little guy needs a monitoring system the most,” said Don Engles, manager of the machine tool distributor’s automation group. Productivity created Uptime-Pro, which manages monitoring from an operational and a business perspective.

The system is a real-time dashboard capable of remotely monitoring a machine and reporting such transition states as in use, loading/unloading or down. Using network connectible devices, the on/off function can detect an emergency stop or nonresponse.

“Uptime-PRO is basic production management in its simplest form,” Engles said. “You don’t need an IT specialist to keep track of things. We also realized that many of our customers operate with legacy machines—older units with less-sophisticated controls. Uptime-PRO can handle these machines, as well as the newest configurations.”

Uptime-PRO is priced like a service. “Subscribers pay a monthly fee and, for that, they can add as many machines as they wish, up to its 50-machine limit,” Engles said.

The lack of frills have not detracted from the system’s monitoring capabilities, according to Engles. “As our customers grow or expand, the system can easily work with them. We are monitoring machines for companies with plants in Ireland, as well as several Canadian facilities.”

Although the system can be accessed through a smartphone, most users employ tablets or office PCs for readability and connectivity considerations. “One of the main reasons for tighter monitoring is that mobile data is not closed-loop,” he said. “In effect, you’re dependent on your service provider, and you can encounter periods when service is down or you can travel to areas where it’s poor or nonexistent.”

The role of MTConnect is growing in the system, but, at present, only a small percentage of the market takes advantage of it, according to Engles. “This is especially true among small shops. Most of our customers are just seeking basic monitoring and regular report generation at a reasonable price.”

Courtesy of Olympic Steel

Curt Olsen of Olympic Steel (right) with an operator at a machine tool using Uptime-PRO.

Curt Olsen, operations project manager at steel service center Olympic Steel Inc., Minneapolis, agrees. “We like all of the features of Uptime-PRO, but certainly the best part is the price.”

Olympic Steel installed Uptime-PRO 2 years ago to monitor and improve performance in six machining centers hard-wired together. The most important benefit is Uptime-PRO’s reporting capability. “We don’t have that many machines, so if something goes wrong, one of our people will notice it right away,” Olsen said. “We generate reports every 24 hours, which have helped us analyze information and find the reasons for delays causing lost running time. This has given us a better understanding of our business. Uptime-PRO is now a key component of a Six Sigma project I’m working on.”

Learning to interpret the reports is vital. “We had one report that showed just 15 percent machine efficiency, which really put our people on edge,” Olsen said. “But the reality is that spindle running time is only part of the equation. In this case, we were dealing with two 2,400-lb. parts per run that take half an hour to load and another half hour to unload. As a result, the machine was not running for more than an hour. What’s important to us is discovering why the machine isn’t operating and what the team can do to minimize the downtime.”

Olsen would like to see a feature requiring the operator to enter an incident report explaining any lapse in run time of more than 60 minutes before the machine could be started again.

Midsize Monitoring

In 2002, CNC Computer Integration LLC was founded to develop wireless programmable logic controllers for older machines. This required software to monitor machine performance that, in turn, evolved into a system with multiple tracking capabilities, including machine parts, fixtures and ancillary equipment.

The initial challenge was developing a wireless capability that would be affected by electrical interference on the shop floor, according to John Carpenter, founder and president of the Somers, Conn.-based company, which created the WireFreeCNC system. Today, the system monitors machine status and performance, provides remote diagnostics and cycle monitoring, detects emergency situations and determines operator and equipment efficiency and work-in-process time. It can also track and locate manufacturing accessories, including fixtures, tools, gages and maintenance items.

Two new features, G-Time Saver and G-Edit allow users to optimize NC data and simulate G code remotely or at the machine.

The primary market for WireFreeCNC is medium-sized shops. The wireless feature allows rearrangement of the shop floor, which would be difficult with a hard-wired network. Pricing is typically from $2,000 to $4,000 per machine. Real-time reporting and records maintenance allows shop managers to cost-justify improvements, including new machine purchases, according to Carpenter. The monitoring system is accessible through mobile devices.

When Brett Wilkinson, engineering manager for Ballco Manufacturing Inc., began searching for a monitoring system, he established specific parameters. The Aurora, Ill.-based company was searching for a way to track data, rather than just monitor machines. “We knew that no ‘out-of-the-box’ system would have the specialized applications that we needed,” he said. The answer was a system developed by WireFreeCNC that integrates with JobBOSS, Ballco’s ERP system.

A manufacturer of valve components ranging from ½ ” to 60 ” (12.7mm to 1,524mm), Ballco operates 75 CNC machines. The plant layout changes frequently, making the wireless feature essential. The company installed WireFreeCNC 3 years ago as part of an overall equipment efficiency program.

“We were looking for metrics that could assist us in tracking and defining trends, rather than just measuring machine performance,” Wilkinson said. “The system helps us define our workflow in both a macro and micro sense.”

When raw material arrives at the plant, it is identified on a bar code with an inventory control number and printed large enough to be scanned from a distance by a forklift operator. When the material is needed, it moves to the first operation and is checked onto the machine via the bar code. The time and setup details appear on the operator’s tablet when he logs in. Once setup is completed, all aspects are measured and inspected before the job is run. If necessary, the material is moved to another machine for subsequent operations. At the end of the shift, the operator and the system have a complete record of all the parts that have been processed.

Courtesy of Ballco Manufacturing

A forklift operator in Ballco Manufacturing’s plant in Aurora, Ill., uses a bar code scanner to identify stock in inventory, as well as work-in-process, using WireFreeCNC.

A key metric is the exception report. Each part processed must meet a predetermined profit margin and reports are reviewed daily. Any part that misses its profit goal is examined to determine the reason. “The problem often comes from the job being estimated some time ago, and prices for materials or other inputs have changed,” Wilkinson said. “In that case, the customer is informed of the price increase. If the customer disagrees, we drop the part.” Another report goes to the toolcrib to monitor the cost of the tooling for any particular job.

The Web-based system is accessible via smartphones and tablets. While mobile devices frequently identify jobs and materials within the shop (often through custom apps), they are rarely used from external locales because of the in-house capabilities.

“Thanks to the comprehensive near real-time metrics that we receive, the system gives us a clear vision for improvement,” Wilkinson said. “When we started, our overall equipment efficiency level was roughly 32.5 percent. Since then, we’ve managed to double it, and we’re working upward from there.”