Digitization of Cycle Time

Digitization of Cycle Time

INTRODUCTIONPresent Status:- Total Number of assembly machines =42. Yield output= Lag of Plan. The daily output as per plan is not fulfilled. The data shows that appx. 50% on average of the target is

fullfilled. This directly effect the routing, indirectly overhead costs. There is manual procedure for counting, high possibility mistake.

Issue:- The cycle time depends not only the machining but also many

different factors. There need to be proper Analysis about machine cycle time,

component placement, loading and unloading, rejection, breakdown & manpower.

Need to be specific which factor is more effecting the cycle time, need statistical data like instantaneous time, average cycle time.

Objective-Project

To monitor 42 machines and obtain real time data analysis. To make overhead costs reduction with increasing productivity by means of

needfull manpower and using integrated industrial automation. It is necessary to find out where we are lagging. It is necessary to award/reward the more productive manpower for motivation.

System Block Diagram

RE CComputer

ControlUnit

S= IR Sensor.E= End Device:- Controller Atmega 8R=RouterC=Co-ordinator.

S

Machine Control Unit Master Control Unit(CPU)

Machine Control Unit

DS-1307Timer Module

Sample Data

1-19030-12:502-1390-1:093-240-1:104-240-1:105-870-1:116-6150-1:177-770-1:188-430-1:189-3340-1:2210-780-1:22

MCU-Internal Circuit

Master Control Unit

It Consist of an 802.11.15a module (RF) acting as a co-ordinator connected to remote PC.

The PC is installed with Matlab and Xctu software as a communication link.

ComputerControl

Unit

R/FInterfacing module

XbeeCo-ordinator

Rx

Tx

Vcc

Gnd

USBDisplayMonitor

WiFi-Internet

Detail Component List

S. No. Product Name Quantity Cost(₹)

1 Atmega16L Development Board 1 250

2 ATmega16L 1 150

3 Xbee Board 2 2400

4XBee / ZigBee Adapter board with USB

interface3 700

5 Female to Female Cable 20 100

6 AVR-USB-ASP Programmer 1 399

Detail Component List

S. No. Product Name Quantity Cost(₹)

7 RTC DS1307 Module 1 120

8 LCD 16x2 Module 1 250

9 USB-TTL Module 1 270

10IR Sensor Module

1 150

Project Equipment Cost(Appx) 4789

Detail Software Tool

Eltima – USB Network Gate MS Excel- Macro Enable PLX-DAQ

AVR Studio:-6Khazama A.V.R Programmer

Model- Prototype

Receiver Module Transmitter Module

Sensor Device

Production data proto 27/11/15- reveting M/c

0

50

100

150

200

250

300

350

1 28 55 82 109 136 163 190 217 244 271 298

Piece

P…

Future Proposal

• Implementation of IR sensor on all 42 machine.• Data to be connected and controlled with server.• LED for monitoring the data in real time.• Need to purchase licenced software • A dedicated system is required for this task.