Getting a Handle on Shop-Floor Information

By: Process Technologies Group, Inc.
Topics: Downtime Analysis, Data Collection, Uptime & Downtime, IMPAX TSS

Advanced technology identifies process problems before they become costly

The overall demands for quality product placed on today's fastener manufacturers by their customer base are increasing at an alarming rate, and it is suspected that doing business with any client will become more demanding in the future. One strategy being adapted by some companies to counteract these tough demands is to install new technology that will automatically provide accurate and meaningful information about current production and identify problem areas. Forward thinking companies that choose to use this new technology will reap the rewards.

One crucial identified area in need of significant improvement is shop-floor data collection. Today, much of the shop floor production data and downtime information is hand written on a sheet of paper by an operator and then manually entered by another individual into a computer system, or an operator may be required to walk to an input terminal and enter the data himself. A report is then generated for the manager that in most cases is both inaccurate and untimely.

Managers seem to only have information about what happened in their plant yesterday or last week, but they do not have the systems in place to determine what is happening in their plant at the present time. Therein lies the dilemma. Customers, clients, or other managers ask questions that demand immediate information, but managers only have information about what happened in the past. It is apparent that manufacturers who automate and collect accurate real time data, process that data, and act quickly and effectively in response to the information they gather will dominate the future-manufacturing marketplace.

Advanced Monitoring Made Simple

Process Technologies Group, Inc. has recently introduced a new system that specifically addresses many of the current shop floor data collection inadequacies, the new IMPAX TSS System for Downtime Analysis & Production Monitoring.

The IMPAX TSS System combines state-of-the art touch screen technology with powerful software utilities to create one of the most flexible stand-alone shop floor systems available in the industry. Its enhanced display makes all of its advanced features easy to access and use. With just a few keystrokes, an operator or manager can either input data or navigate the system to view uptime and downtime minutes by shift, the exact number of times a downtime code has been entered and the accumulated minutes recorded for each downtime code. Production data, tool life counters, and maintenance indicators are also available in the unit. Finally, the TSS unit tracks operator response time to a machine stoppage. Most information is available in a daily, weekly, monthly, and yearly reporting format.

The IMPAX TSS System applies a proprietary set of software modules that analyze input signals from sensors or machine controllers to determine the status and speed of any process. The system will analyze and then display process-critical information pertaining to machine run condition, speed, productivity, and efficiency based on actual part production.

In the event of a machine/process stop condition, the IMPAX TSS automatically converts from production monitoring mode to a downtime entry and analysis mode. The operator will be required to select from displayed downtime reasons and enter those chosen via the icons on the touch screen. Failure to do so will prevent the operator from starting the machine: this guarantees that all downtime information is logged and accurate.

IMPAX monitors on a thread roller at ITW
IMPAX TSS System for downtime analysis & production monitoring (top),
and IMPAX-SK process force monitor (bottom)

A Testimonial

Process Technologies Group recently spent some time with ITW Shakeproof Plant Manager Rocky Turner, who is in charge of a manufacturing facility in Oconomowoc, Wisconsin. Three IMPAX TSS Systems were installed on critical thread rolling machines at the end of manufacturing cells. We asked Turner what he felt was one of the main benefits of the IMPAX TSS. "The TSS gives us the ability to identify inefficiencies quickly and to document interruptions in production without putting unnecessary burdens on the machine operator."

We also asked Turner if the IMPAX TSS system has helped his Plant operate more efficiently. "Most definitely, by reviewing our data on a regular basis we were able to determine our leading cause of downtime. Once we determined the cause we immediately addressed the situation and instituted the proper corrective action. Simply put our production increased and our downtime decreased."

IMPAX TSS touch-screen interface
Showing downtime code entry screen

Unequaled System Flexibility

The system is capable of collecting critical process data from virtually any machine that runs in manual or automatic mode. This includes cold headers, thread rollers, stamping presses, screw machines, multi-slides, spring coilers, forging presses, assembly/insertion machines, drills/taps, saws, etc.

Data collection and analysis is also made easy with the IMPAX TSS. Stand-alone TSS units collect the data on the plant floor and can be viewed by an operator, supervisor, or manager at any time. If the IMPAX TSS units are networked, data is automatically transferred into a PC database for viewing purposes or further analysis and report generation. Numbers of IMPAX TSS Systems can be daisy chained in a network configuration. In addition, limited information can be sent from a PC to an IMPAX TSS System.

Process Technologies Group is well aware of today's business environment. Once a company is successful in their quoting process and receives a purchase order, it is seldom allowed a price increase throughout the life of the part. While you can't raise your price, the IMPAX TSS can raise your level of awareness. The IMPAX TSS system will help your company identify problem areas and stay competitive and profitable for many years to come. Take advantage of this new technology today. To learn more about the IMPAX TSS and other PTG products, call them or visit them on the web at www.impaxptg.com.

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