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Industry 4.0: Data That Drives Decision!

Today’s futuristic manufacturing practice of exchange of data from machine to man will revolutionize the manufacturing of the future, termed as Industry 4.0. With Industry 4.0, exchange of data via network between machine and man, analysis and interpretation of data play pivotal role at various levels of manufacturing.

The information thus available from machine can significantly help in

  • Guiding business heads to know about machine out as negative, breakthrough, profit making.
  • The utilization of cutting parameters and individual tool utilization by application manager or floor manager.
  • Minimizing machine down time and easing predictive maintenance by maintenance manager.
  • Scheduling the tasks and activities on the machine by planning team.

Software and hardware are available for establishing the integrated network at the manufacturing floor for an effective exchange of data from machine to man and vice versa. Let us see how this data works at various levels:
If we consider above mentioned users of this data, the analysis provided in graphical and numerical form is very important.

Business Head
The data can be presented on shift/day/ week/month wise in predefined levels for negative, breakthrough, profit for individual machine (profit center).

Application Engineer
The individual cutting tool time and axis and spindle load data will help to optimize the machine and cutting tool parameters. The tooling also can be selected depending on the analysis of individual tool. The real time data is collected and presented in graphical and numerical form. This can have major impact on cutting tools cost, maximum utilization of machine capability in terms of axes and spindle load (can be presented as torque) by selecting best possible cutting tools available in the market.

Maintenance Manager
The machine status and alarm messages are sent via email and SMS to the assigned individuals. The corrective or preventive actions can be planned immediately. The threshold data of axis and spindle motor can be predefined. The gradual changes in the same can be monitored on periodic basis. This helps to decide the predictive maintenance activities on the machine at scheduled time to minimize sudden breakdowns.

Planning Team
The data of machine non cutting time due to various factors also can be tracked and documented. These activities such as availability of cutting tool, input material, program, material, tea /lunch breaks, operator non availability. The corrective measures can be implemented. These details can evaluate in real time.
HAAS, the worldwide leader in CNC and CNC Machines, also offers control solutions that enable Industry 4.0 at your factory floor. The HAAS Control – software and hardware – designed and built in-house, and optimized specifically for Haas machines.The Haas Next Generation Control has the ability to send Email and SMS text notifications about the operating status of your Haas machines. Besides, Haas machines provide specified parameters as MTConnect protocol which is an open-source, royalty-free, read-only, and XML-based protocol that allows data collection from manufacturing machines.

Shardul Itkalkar
PHILLIPS Machine Tools technical centres and regional locations throughout India have one or multiple sets of these tools/instruments. The qualification of the machine condition can be assured by a specific protocol and quantification of parameters for machine condition analysis during a preventive check. It is always advisable to qualify the machines from the certified agency/engineer. A record file of periodic check results should be maintained for every machine. The analysis of these records will provide a wear pattern of the components and help in predictive spare parts planning. The unpredictable machine breakdowns can be reduced considerably with this check, as well as it helps to control the spare parts inventory cost.

Our specialist, Shardul Itkalkar, heads the Engineered Products division of Phillips Machine Tools India Private Limited. With more than two decades of industry experience, he advocates the right maintenance for your machines. He can be reached at sitkalkar@phillipscorp.com

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