High-tech monitoring devices are giving processors insights into their machines, molds and production, allowing them to boost efficiency.
SMART ATTEND
Smart Attend’s system for real-time manufacturing monitoring, Smart Attend Pro, is getting an update to its Smart Scheduling software module this summer.
The upgraded module will collect production data such as cycle times, productivity and scrap generation, and automatically reschedule jobs based on machine or
The module boosts the capabilities of Smart Attend Pro, which, in addition to real-time monitoring, stores and tracks production data, generates reports and helps users identify inefficiencies.
The device features a distinctive machine-mounted light tower with 150 LEDs and a 100-decibel speaker that alert operators to process issues.
The tower displays different colors to signal problems: Green means no complications; red means a machine is down; yellow is caution; purple or orange indicate low material. Recorded messages announce problems over the speaker.
The device’s process-monitoring software, available through a web-access portal, records signals that are critical to injection molding machine, extruder and auxiliary equipment operation, and compiles a data stream for real-time or historic analysis. Three years of process data can be stored with the system, either on the company’s cloud server or a plant server, GM Max Preston said.
The device’s dashboard displays cycle times, part counts, machine status, alarm reports and scrap levels by machine, as well as overall equipment effectiveness rates. The dashboard is accessible on plant and personal computers as well as through a smartphone app for Android and Mac systems.
A benefit of the dashboard, Preston said, is immediate awareness of the production status of machines and jobs, along with notification of downtime, excess scrap and other problems. The software, which was developed by the company, is customizable.
With the information that Smart Attend Pro gathers, processors can develop metrics that show how efficiently plants operate. Preston said it is not unusual for processors to reduce downtime by 65 percent in the first six months of system use.
Preston said the company is launching a rebranding campaign this month at Amerimold in Rosemont, Ill.
RED E INNOVATIONS
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The device can be programmed to monitor mold performance, including how many molding cycles it has performed in a job or overall; cycle times; and how long it has been in use or in storage, said Jim Stuart, president and owner.
The monitor incorporates a GPS so molds can be tracked. In many cases, he said, the mold owner is an OEM that ships molds to a Tier 1 or secondary contractor. GPS lets the owner track where the mold has been, where it is and receive an alert if it isn’t returned on time.
The monitor also can send an email or text message when a mold completes a certain number of cycles, which aids predictive maintenance.
Stuart described the MAD monitor as a “next-generation” product for his company that incorporates sophisticated technology. Because it is wireless, workers don’t need to connect or disconnect it when moving molds. Its aluminum body has an IP67 waterproof rating, which also protects it from solvents and other liquids. Its powerful signal passes through walls and isn’t blocked by the metal in shops. It can measure cycle times as fast as 0.3 second.
Pat Toensmeier, correspondent
Contact:
Red E Innovations,
Troy, Mich., 888-789-1415, www.redevault.com
Smart Attend,
Aurora, Ontario, 866-210-9630, www.smartattend.com
