News

Back

OEE is Key

Apr 24, 2014

The traditional approach for optimizing a packaging line consists of using a PLC-based model from a single-source automation supplier, an approach focused heavily on maintenance in an attempt to limit downtime. But there’s an alternative approach, one based on a motion-centric solution with a focus on productive outcome.

“The key is to not only focus on keeping the machine running, which directly affects the OEE Machine Availability variable,” explains Scott Carlberg, servo product marketing manager for Yaskawa America, Inc., Waukegan, Ill., “but rather address all OEE variables with a motion-centric solution flexible enough to allow for new packaging innovations.”

Yaskawa provides a means to gather that kind of data and improve packaging line performance via a number of features contained in its motion control solution. For example, significant improvements in machine throughput can be achieved with the advanced servo algorithms incorporated into the company’s Sigma-5 series of servo amplifiers.

“These algorithms assist in decreasing settling time of discrete machine movements,” Carlberg says. “Even a small decrease in the settling time of each discrete machine movement in a production cycle can result in a significant reduction in overall production cycle time. Ultimately this leads to more units being shipped per hour and a lower overall cost per unit.”

In addition, application toolboxes ranging from recipe management to complex kinematics have been developed for use with Yaskawa’s MPiec machine controllers. The onboard OPC server can be used to stream large data arrays for thousands of individual recipes to the MPiec controller via HTTP communications, allowing a CPG manufacturer to effectively manage thousands of product SKUs. These large data arrays, each consisting of thousands of cam points, are managed by camming and kinematic toolboxes specific to typical packaging applications.

“These toolboxes streamline the implementation of complex machine move profiles with a resultant motion path that is extremely smooth and efficient,” Carlberg says. “The resulting higher throughput and reduced wear on mechanical components contributes to both the overall quality of the packaged product, and decreased overall per-unit cost.”

Consistent monitoring of all OEE variables can sometimes be as important as the work done to improve the manufacturing process itself. It’s an area where PackML architecture shines, and where Yaskawa’s PackML toolbox can help packaging system owners manage and measure the effectiveness of their lines. The toolbox includes a project template and core code for using the PackML machine state diagram.

“Using this globally standardized machine code architecture helps reduce the amount of time and expense involved in integrating machines from different suppliers into a cohesive production line,” Carlberg says.