Remote control of technological processes

Functions performed and benefits obtained:

  1. Remotely switch devices on/off. The system controls who can work on the devices and when, only then is the device activated. This allows to assign the working time of the machine to the production of specific parts, to eliminate unauthorised use of the machine (not for company business), to analyse the efficiency of the employees (to minimise downtime).
  2. Remote measurement of process parameters (power, current or other parameters used). This allows to monitor their compliance with technological requirements, automatically report deviations and warn of possible faults
  3. Remote metering of power consumption and employee logging allows the energy consumed by the plant to be allocated to specific projects or processes, thus cleaning up their cost

These solutions perfectly complement the functionality of a modern ERP programme and ensure the control of production equipment via workstation-based industrial computers and specialised controllers.

The algorithm is as follows:

  1. ERP prepares work tasks and sends them to workstation computers
  2. The worker selects a job on the computer and starts the job by holding the worker’s badge to the computer.
  3. The computer commands the machines to start the operation, sends a message to the ERP “Employee XYZ has started operation ABC on machine tool KLN”
  4. The computer checks that the machine is up and running. If not, it generates an audio-visual message to the employee and transmits it to the ERP.
  5. When the machine finishes its work, it records the time, the electricity consumed and transmits the info to the ERP.
  6. Additional analysis of the power consumption curve compared to the normal operating mode (excessive deviation may be a sign of impending failure)
  7. Next, the worker selects the next job on the computer and starts it by holding the worker’s certificate to the computer, the algorithm repeats from page 4.

Employees are identified using contactless e-cards, which also provide access control and automatic tabulation.

 

This will allow the quality control system to record who has carried out which production operations when. This will provide a basis for economic analyses of the actual duration of production operations and for calculating the wages of employees.