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Calculating Machine Run Time
Challenge
During normal operation, operators load welding machines with frame components to be welded. The loaded parts enter a robot welding cell and a completed frame exits. Operators unload the completed frame and load more components in preparation for the next welding cycle.
If production goals are not being met, it's important to know if machine downtime or operator inefficiencies are the problem. To determine where the source, facilities need to accurately measure and report machine run time back to a control location.
Solution
PLC logic added to the welding machine can turn on an output when the allocated process time is exceeded. This output is wired to an input of a DX80 Node. The Node’s input is transmitted back to a DX80 Gateway connected to an HMI that logs overage time. Accumulated overage time is totaled for each shift and operator.
Accurate work time is gathered at the welding machine and wirelessly transmitted back to a central control location for logging without running new data wires.
Based on real-time data collection, facility managers are able to accurately verify when the delays are the result of machine down time and when the delays are the result of operator inefficiency.