Modern Machine Shop

NOV 2018

Modern Machine Shop is focused on all aspects of metalworking technology - Providing the new product technologies; process solutions; supplier listings; business management; networking; and event information that companies need to be competitive.

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Page 94 of 155

Lights-Out Machining Modern Machine Shop 93 operator attention, shed light on precisely how long it takes to complete a job in addition to the actual machining time. Common variables have been set up to track the status of each job. Part count is handled by G code and increases by one each time a part cycle is completed. Other variables require operator input. These include run target (the machine will pause when the part count reaches that value), job number (this is listed on the job traveler) and production-log code (this shows when production status has changed). The production log helps identify processes that lend themselves to lights-out operation. If a machine set up to run all night is not getting close to the 15.5 available hours, then it might be that this job is not well suited for running overnight. Or, if one machine runs all night and another runs half the night, perhaps it makes sense to push the job that ran only half the night to a different machine and replace it with work from the other, longer-running machine to achieve higher utiliza- tion. The production log also serves as a diary of sorts, because it is used to document issues such as tool breakage or bar-feeder malfunctions that caused machines to fall short of targeted produc- tion values. Soon, no one will need to visit machines each hour to collect and enter data for the production log. This is thanks to an automated data-collection and reporting system Gillen is developing that uses a web-based, Industrial Internet of Things (IIoT) platform to pull data from machines that have agents for the open-source MTConnect communi- cation protocol as well as the company's Jobboss enterprise resource planning (ERP) software. The platform is Devicewise for Factory from Telit, a company that offers IIoT modules, software and connectivity services and software. Gillen says the benefits of this system are that it interfaces with a variety of controllers and no custom programming is needed for data collec- tion. It is configured to automatically pull all data that was previously collected manually from the machine (part count, machine code and more) as well as ERP data ( job number, job description, order date, order quantity, delivery date, etc.) and stores it in the cloud. Data is accessible via a web dashboard. Reports then can be created to more graphically show what was previously available in the production-log spreadsheet. The system has been collecting data every 20 minutes since early June 2018 without missing an entry for a machine that was running. Three turning centers and one mill are currently connected. Another mill still requires an MTConnect agent to be installed before it can be connected. The automated data-gathering system collects production information from machines every 20 minutes. It also pulls job data from the shop's ERP software. Reports can then be created to more graphically show production log information. TABLE 1. Production log codes. Code Status 00 Available 10 Production 15 Stolen time 20 Setup 25 Re-work 30 Wait: Material 40 Wait: Set up 50 Wait: Operator 60 Wait: Tooling 70 Wait: Engineering 80 Maintenance 85 Machine down

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