TPM – Total Productive Maintenance is an approach that is based on the guidelines of the Japanese Institute of JIPM

TPM, Total Productive Maintenance, assumes an equal share of operators and mechanics from maintenance services in troubleshooting and maintenance of machines. The assumption is based on the fact that an employee who works at the machine eight hours a day, five days a week knows her job better than a branch manager, or a maintenance worker with several dozen machines in its care. This is the first operator to hear too loudly, larger than usual machine shake or spills. Basically TPM is based on 8 pillars, like;

  • focus on improvement,
  • self-maintenance,
  • planning technical reviews,
  • training and education,
  • early management,
  • quality assurance
  • office kaizen,
  • BHP,

The second pillar of TPM is autonomous traffic maintenance. Again there is no question of repairing machines. What is an autonomous word? It is the involvement of each employee in the process of servicing the current machines. Based on this pillar, we assume that an employee who works eight hours a day, five days a week knows her work better than a branch manager, or a maintenance worker with several dozen machines. This is the first operator to hear too loudly, larger than usual machine shake or spills. For the machine to serve him and us, just let him comment on the problems that arise. Autonomous maintenance of the traffic can be said when all operators are involved in the monitoring of machinery in accordance with standards. Device control standards are defined by the crew selected for the TPM workshop as part of the subsequent deployment steps. The third pillar of TPM is the planned maintenance of traffic. Knowing machine behavior and workpiece replacement times (work hours), you can predict how your components will be consumed in the future, and make planned maintenance and repairs. The Maintenance Department has clearly defined machine operation dates. Production and Maintenance Managers work together to achieve the highest OPE and OEE. Scheduled machine maintenance is just as important as the production of an assumed quantity of a product. If a plant seriously implements the TPM, it treats equally tensions between maintenance services and production – inter alia by changing the premium or changing the organizational structure. Most of all, it is based on the next TPM pillar and systematically implements training and training at all levels of the crew. The above approach is possible if we know the real number of machine hours, ie we monitor their work.

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OEE factor

In the modern machinery, automotive and aerospace industries, where we have a large share of computer-controlled machines, we have long tried to analyze processes and work on their measurements. As a result, OEE – Overall Equipment Effectiveness co-ordinated. It determines the total efficiency of machines and production lines and its value is calculated on the basis of three other component indicators, such as:

Availability – the ratio of scheduled time to task completion to the actual time in which the task can be performed. Availability is reduced by failures and according to the adopted method by setting up and setting up machines;
use (efficiency) – the ratio of time available to actual work. Use (performance) is understated by speed losses in performing the operation;
quality – the ratio of the number of good and defective products.
This indicator is calculated according to the following formula: OEE = Availability x Usage x Quality

Availability: 90,0%
Yield: 95,0%
Quality: 99.9%
The average OEE value for most modern manufacturing plants is approximately. The pursuit of continuous performance improvement in this way, measured by the OEE gauge, makes many plants depart from the manual form of recording and calculating manual performance factors for the use of specialized computerized production monitoring systems. The processing of signals automatically taken from the manufacturing process (eg from PLCs) of the current state of the machines, their performance, causes of downtime or micro-disruption, influences the credibility of OEE and other KPIs. This makes it possible to monitor the effectiveness of real-time machines and production processes and report them for any length of time and in any context (eg line, machine, product, change, employee). This makes it easier to understand the so-called. Deadly moves that eat time instead of using it productively. The implementation of OEE and machine monitoring is a better understanding of our best practices and technologies and increased production.

If you have more questions please contact us ….

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Why You Should Connect Your Machines To A Teleinformatics Network.

Modern computer numerical control machines called CNCs, allow you to connect to a teleinformatics network or as most prefer a computer. The most common question we receive is what is a teleinformatics network used for?

A teleinformatics network saves time and avoids a number of unnecessary and time-consuming activities. Here’s a list of all of the benefits to connecting your machines tools to a network:

  • The network allows you to remotely transfer technology from the server to the individual components. The server also allows you to manage digital versions and thus track their changes.
  • Using a network is faster, more reliable, and prevents damage to or destruction of a control program transferred from a device such as a pen drive.
  • You can have electronic delivery of production orders such as an MRP or MES.
  • You can monitor a machine’s working time.

The teleinformatics network on the production floor is not a computer network you would use at home to which we would connect a printer, scanner, or perhaps even TV set. Its proper design and topology should take into account the goals to be achieved (transferring programs, monitoring, etc.) as well as security of access and use. It is a myth that the connection of a CNC machine’s tools allows them to be accessed from anywhere on the Internet. However, it does depend on the topology design, applied solutions, and security used.

So, once again, the teleinformatics network on the production floor is not a home or office network. Exploitations and different environmental requirements also affect the way it is designed and built. So, what should characterize the network?

  • Resistance to currents straying.

    Especially if cables are placed in ducts where a CNC machine’s power supple cables run. This prevention can be achieved through the use of shielded cables or constructing a fiber optic network. (Complete resistance to drive and wiring, as well as wandering currents with a Fiber network is only 20% more expensive.)

  • Connectivity stability and the ability to remotely monitor the entire infrastructure.

    Let’s not forget that an IT network includes many other things including switches and hubs, routers, and firewalls.

  • Adequate bandwidth and access times.

    Because there are not large amounts of data being sent over the network, the industrial network does not need to have the highest data transfer rates. It should be noted, however, that depending on the network’s topology and expected response times, relatively new (and therefore expensive) solutions are usually used. Additional, this network is built “for the future” and not simply just for the here and right now.

Most importantly, most modern CNC systems are equipped with network cards as standard; older versions, however, may require the purchase of an additional expansion card or license for it such as a Siemens Sinumerik.

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The IoT in Practice

Our solutions can be broadly understood as the monitoring of equipment through IT networks, which is now understood the IoT (Internet of Things). Virtually any controller or control unit can be connected to an IT network to control and monitor its operation as well as track the use of time and operating parameters. We create our own connectors and write dedicated integrations. Contact us if you would like to learn more.

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Production Support

We create software that directly supports production management by monitoring the work of CNC machines and devices. By presenting automated reports on the percentage of capacity utilization of individual machines tools, we provide your management staff with new tools to help optimize your production. We have proprietary solutions that allow you to connect to most of the control systems and software used in your organization such as an ERP, MRP, etc.

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Why Monitoring Your CNC Machine Tools is Worth It

The point is of course, rhetorical in principle because machine tool monitoring allows you to generate automated information about which machines work most efficiently, which are most often serviced, and which are repaired too often. In addition, monitoring allows you to anticipate the required technical inspections based upon actual operating hour and not operator estimations. Precise supervision raises not only disciplined use of machinery, but also allows for optimal planning of production and introduction of changes between shifts. If we add the opportunity to integrate with the cost center, the advantages become obvious. Employees work well because they are well supervised!

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