Consumer goods industry benefits from integrated B&R Edge solutions
The FMCG industry continues to propel its growth by embracing the latest technologies. The industry is highly dynamic, with consumer demands changing rapidly and factories looking at adopting new production practices to meet these demands. The industry is highly competitive, with factories looking at continuous product and packaging innovations.
With personalization and brand-to-order gaining momentum, production lines often come under force per unit area to operate and contribute to changing demands. Therefore, it becomes significant for factories to have reliable production processes that produce quality products with shorter time to marketplace.
Re-shaping procedure requires understanding the procedure
As the manufacture prepares itself to re-shape production processes, it must evaluate and understand the exact chapters of production lines. The entities within the factory, such as inventory, design, manufacturing, quality, end-of-line, and logistics, need to marshal with each other and operate with transparency. Connectivity in lines with Information technology systems becomes essential to have seamless information commutation for supporting controlling. Mill automation solutions are necessary to support factory operators in optimizing the process and improve productivity.
The demands of consumers are increasing and becoming more than quality centered. The consumers pay attention to diverse factors such as greenish packaging of products, tailor-fabricated merchandise, transparency, and convenience in commitment. These demands are not only evident in food products but likewise in fashion, beverages, households, and personal intendance.
Overall Equipment Effectiveness calculation
Therefore, factories are slap-up to devise and implement flexible manufacturing practices. To achieve a competitive level of production efficiency, factories need to monitor operation at the product level. One of the well-nigh followed methods to monitor performance is past calculating OEE (Overall Equipment Effectiveness) of the production line. OEE is analyzed by measuring 3 disquisitional components: automobile or line availability, productivity, and product quality. These parameters give factory managers visibility of the number of products manufactured defect-complimentary against the production line'southward capacity. It has go 1 of the most critical KPIs for factories to appraise line performance.
OEE calculations for the production line is implemented with ease using Edge Controller. Edge Controller is a powerful factory automation solution from B&R that enables factories to monitor, assess, and optimize the production procedure. Information technology has several core components that provide an ideal foundation for data management. In add-on to OEE measurement, PDA (Process Data Acquisition), an integral chemical element of Edge Controller, supports factories in acquiring and archiving process data in real-time. It is easy to configure, blueprint reports, and customize OEE calculations best suited for the process. The Edge Controller can also integrate energy monitoring and condition monitoring in the same system.
Due to the volatility of demand in the marketplace, factories are under pressure level to introduce new products with innovative and bonny packaging. For instance, skincare products might be introduced based on demography or information virtually the crumbling of consumers. The aforementioned make must manufacture multiple models and varieties of products using the same production line. This tin disrupt the production menstruum and the complete supply chain. Therefore, it is vital to have an integrated system that connects all supply chain elements and provides transparency using all available data.
Process data acquisition is congenital-in with set to utilise modules that can integrate data from design, production, inventory, logistics, and service. Edge Controller provides the framework for a manufacturing execution system and offers critical operation data to optimize processes. With intuitive dashboards, graphs and reports can be generated, giving a clear overview of the production process and supply chain.
Efficient status monitoring of the product line
Some other primal focus in factories manufacturing consumer goods is to reduce line stoppages. Whatsoever product line heats up while performing continuous operations and producing products in large volumes. Production lines typically have conveyors transporting products to the filling station, inspection, sorting, packaging, and distribution systems. The complete process involves mechanical linkages and movement components.
When lines are running for long hours, vibrations, rut, and wear and tear of moving parts increment continually. These ultimately lead to breakdowns bringing the entire product line to a standstill. Prevention of line stoppages has a pregnant result on OEE and operational operation. Well-nigh production facilities have a preventive maintenance organisation in place for a long time. The maintenance activities are planned according to running hours and, in some cases, done only afterwards a failure. Loss of production because of unplanned stoppages inevitably leads to additional costs. Efficient maintenance exercise that can sense or anticipate failure in a product line well in advance helps to have corrective action to avert stoppages.
B&R'due south status monitoring solution ConMon enables manufacturing plant managers and operators in the prevention of line failures. The arrangement analyzes vibration data from critical points in real-time, providing detailed reports and warnings. The measured information and reports help line managers identify abnormal patterns with the system predicting issues before they happen. ConMon, as a role of the Edge Controller, allows monitoring asset health, optimizing maintenance activity, and provides maintenance squad real-time alerts to operational risks. The data is made available in reports as well every bit graphs for maintenance personnel to perform root cause analysis. It ultimately helps manufacturers lower maintenance costs, maximizes uptime, and better production throughput. An effective maintenance strategy supported by intelligent condition-based monitoring ensures equipment reliability and increases line availability for mass production.
In improver to line maintenance, manufacturers are peachy to identify the sources of significant energy consumption in factories. Production processes account for energy consumption in the form of electricity to natural gas, water, steam, boilers, chillers, and residual water. Finding a source of unnecessary energy consumption can be a substantial cost saving for any manufactory. With EnMon, B&R supports factories in implementing innovative free energy monitoring solutions to proceed continuous runway of consumption in individual machines and lines. The EnMon system is an integral function of the Edge Controller. It offers excellent insights into the energy used at the facility and aids factories in devising practical energy-saving deportment.
Cease to end shop floor interoperability
Seamless connectivity in a factory needs an effortless exchange of data. With the integration of IT systems with production, data generated in lines need to be shared in existent-time with the enterprise to support decision-making. Nonetheless, the challenge in product lines is the presence of machines from different vendors without interoperability. Openness can ensure that machines from different vendors communicate with each other and with the IT system seamlessly.
With open up communication protocols such as OPC UA and MQTT, it becomes possible for production lines to connect and share data mutually with IT systems in a unified manner. OPC UA, a well-known open up protocol, allows the commutation data independent of the equipment's vendor. The protocol is platform-contained and features built-in security mechanisms.
OPC UA has been designed for scalability and supports a wide range of application domains, ranging from field level to enterprise direction support. With seamless connectivity from Operational Technology (OT) to It (Information technology), across lines and supply chains, information technology enables factories to accomplish a gainful business organisation model.
The road for a smarter tomorrow
Factories manufacturing consumer goods are on a road of revolutionary alter in the way they operate. Applied science has been a meaning disruptor in the sector, with factories looking to leverage the latest factory automation solutions to boost functioning across process chains and stay competitive. With data having a meaning stake in decision-making, Border Controller solutions from B&R enable factory operators to accept easy access to operational data. This data can be analyzed and used to optimize the functioning of the procedure and meliorate the product line's health. B&R helps mill operators with scalable hardware and powerful software to go efficient, smarter, and serve speedily changing consumer demands.
Source: https://packagingsouthasia.com/consumables/flexible-films-and-laminates/consumer-goods-industry-benefits-from-integrated-br-edge-solutions/
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