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Technology
Enabling Live Manufacturing
Through integrating the WebLink-2059 with B2D software, an automotive
supplier was able to use live information from 35 different pieces of
production equipment at their plant in Mexico to improve throughput
and quality.
Introduction
As if maximizing productivity wasn't difficult enough, one manufacturing
company was faced with finding a cost-effective way to relay critical
operating information across international borders. A supplier of automotive
electrical components recently implemented a new production line in
their factory in Mexico. Faced with tremendous pressure to produce top-quality
parts and meet promised delivery schedules, the company needed a way
to create and deliver live information to its key managers in Mexico
and at their headquarters in Indiana.
B2D Solutions Inc., a leading provider of live manufacturing systems,
saw this as an opportunity to combine their software platform, B2Di,
with Advantech's line of wireless remote data acquisition products.
B2Di utilizes Advantech's WebLink-2059
with integrated AStudio software to easily communicate to the wide variety
specialized equipment protocols that were needed in this application
including RS-232/422/485, Ethernet or fieldbus communication. Advantech
even developed a Society of Plastics Institute (SPI) driver for this
project that enables communication to all injection molding machines.
The end product was an Internet-based live information management system,
providing instant access to vital information such as availability,
productivity, quality and critical process data. The B2Di allows companies
to use this information to measure performance against standards and
make faster, fully informed operating and business decisions.
System Requirements
This automotive supplier looked to B2D to aggregate live data from 35
different pieces of production equipment at the plant in Mexico. The
factory included an array of equipment from injection molding, solder
and assembly machines to winders, testers, and quality control audit
stations. Using the WebLink-2059, the B2Di solution provided a means
for each equipment operator to create the information necessary to improve
productivity and quality. The WebLink extracts real-time data from plant-floor
systems and wirelessly transmits that data to the B2Di server using
an XML based protocol called the B2D-API. B2Di then transforms this
data into usable business information and distributes it to appropriate
users through a standard web browser. B2Di monitors this information
and provides alerts that are transmitted via email, pagers, PDAs and
cell phones. The information is provided to various personnel - line
supervisors, QC managers, production engineering, and maintenance -
so they can quickly determine the status of the plant floor, refine
their process parameters, and respond to issues as they occur.
System
Description
The system is comprised of 35 WebLink-2059's that are integrated into
a self-contained 15" flat panel operator interface called a Graphical
Device Module (GDM). B2D's GDMs convert the proprietary protocol of
each piece of equipment into an open web-based protocol for communication
with the rest of the system. Each GDM communicates wirelessly to the
B2Di system through multiple access points using 802.11b communication
technology. The B2DiQ server located in Mexico collects the data and
delivers applications such as real-time SPC, productivity, scrap counts
and alerts/alarms to the production floor. Data from the factory floor
in Mexico is transmitted to company headquarters via pagers, PDAs, cell
phones and the desktop browsers. A redundant server located in Indiana
is used primarily to with open, flexible technologies that make it easy
to configure and use.
Conclusion
B2D's unique live manufacturing technology platform enables companies
- of any size or sophistication - to easily and cost-effectively share
and use live information to create a low cost, high velocity, performance
driven operation. Advantech's WebLink enables equipment and operators
to integrate with the B2Di platform.
Since
deployment of the B2Di system in Mexico, scrap at the plant has decreased,
downtime has been reduced and process knowledge is being feed directly
into improved control plans. Quality spills have been eliminated and
machine availability improved 20%. B2Di has also freed up resources
to focus on other issues rather than spend time looking for problems.
The
above mentioned application was designed and implemented by B2D Solutions,
Inc., Cleveland, OH. B2D solutions Inc. is a leading provider of live
manufacturing technologies and systems. The B2Di platform gives companies
live visibility of their operations across their extended enterprise,
enabling them to improve quality and productivity, more efficiently
utilize resources, leverage strategic relationships, and rapidly respond
to changing conditions. To date, B2D Solutions Inc. has licensed B2Di
to industry-leading customers in manufacturing and are now expanding
into the telecommunication and utility/energy industries. For more information
on B2D Solutions Inc., call 216-561-0069 or visit them on the web at
www.b2dsolutions.com
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