heat treat lean cell
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Heat Treat Lean Cell. Optimizing Maintenance Processes Tony Haynes – Program Manager. Preface. Unique depot manufacturing environment Low volume, high mix with frequent priority interruptions Focused on repair rather than new parts manufacturing - PowerPoint PPT PresentationTRANSCRIPT
1 – Commercial Technologies for Maintenance Activities
Heat Treat Lean CellHeat Treat Lean Cell
Optimizing Maintenance Processes
Tony Haynes – Program Manager
– Commercial Technologies for Maintenance Activities
PrefacePreface
Unique depot manufacturing environment Low volume, high mix with frequent priority
interruptions Focused on repair rather than new parts
manufacturing Factory equipment networks usually “islands”
disconnected from factory Intranet Few depots implement formal manufacturing
execution systems
– Commercial Technologies for Maintenance Activities
Lean TransformationLean Transformation
Lean tenets focus on removing everything that does not add value to the product Minimize material handling
Reduce manufacturing process footprint Physical arrangements that minimize WIP movement
Synchronize operations Use WIP buffers to compensate
Eliminate process redundancy All depots are undergoing Lean
Transformation
– Commercial Technologies for Maintenance Activities
OOPS!OOPS!So what do you do when your equipment footprint is large, when equipment reliability is uncertain, when incoming workload is largely unpredictable, and the only way you can gather data is by dispatching an engineer to collect it? In short – the normal situation for depot manufacturing.
– Commercial Technologies for Maintenance Activities
The Problem AreasThe Problem Areas
Heat treat, thermal spray, and metal removal Large footprint Difficult to forecast daily work load Frequent priority jobs Complex machines – significant down time
Little or no automated data collection from depot equipment or processes
Down time often seems excessive but data is of questionable reliability
– Commercial Technologies for Maintenance Activities
Focus – “Islands” of Factory NetworksFocus – “Islands” of Factory Networks Two drivers
Fear of infection by malicious software Very real need to separate factory floor networks from
office IT systems Solutions exist that can isolate factory nets but still
make historian data available The Smart Machines Pilot Project, Phase II, is
interested in piloting a solution Example architecture from Canadian National
Infrastructure Security Coordination Centre Additional information available from NIST’s
Process Control Security Requirements Forum, ISA’s SP99 committee, and from www.pcsf.org
– Commercial Technologies for Maintenance Activities
Securing Plant Control NetworksSecuring Plant Control Networks
– Commercial Technologies for Maintenance Activities
Focus –Data CollectionFocus –Data Collection
Large amounts of useful data exist in equipment control systems but is transient
Process health and effectiveness usually requires the addition of sensors that have nothing to do with control
Data historians collect and store data from both
Any process data that requires human entry is of questionable reliability
The Smart Machines Pilot Project is focused on exactly this domain
Technology, Speed, Flexibility, Service
First 24 Hours on the Mold 5 Machine
View shows steam heat applied to upper and lower
platens, and temperature rise of the mold cavity in between.
Technology, Speed, Flexibility, Service
A Part Cycle Without Faults on Monday Dec. 27th
Time line data is masked here. Production cycle time is CAT confidential.
Technology, Speed, Flexibility, Service
The Next Part Cycle With Faults on Monday Dec. 27th
Time line data is masked here. Production cycle time is CAT confidential.
Technology, Speed, Flexibility, Service
Typical results from Thursday April 7th.
Note similarityof the vibration
signatures during multiple runs.
– Commercial Technologies for Maintenance Activities
Focus – Unpredictable WorkloadFocus – Unpredictable Workload
Traditional scheduling systems don’t work well in environments such as depots
But optimizing equipment loading could have major beneficial effect on energy costs
The emergent behavior property of agent-based systems was long ago shown to be effective (NCMS’ Shop Floor Agents project)
– Commercial Technologies for Maintenance Activities
Focus - FootprintFocus - Footprint
No solution identified
– Commercial Technologies for Maintenance Activities
SummarySummary
Issues with installations such as these are pervasive
Common root problems appear No single solution but elements of the
common issues can be addressed
