Lights out factory11/11/2023 But a step-by-step transition is precisely the achievable path forward that we at Siemens are helping our customers realize. In some cases, bulldozing and starting from scratch may seem more realistic than transitioning the existing operation. On the other hand, it’s hard for many manufacturers to look around an existing facility and imagine that it could one day be transformed into a factory of the future – whether lights-out or otherwise data-intensive – to reach new production efficiencies and quality of output. This success raises speculation that a completely self-sufficient factory may be on the horizon – a facility for which placing orders and receiving finished products comprise the only human interactions necessary. The most well-known lights-out factory may be the FANUC factory in Japan, where robots are building robots and no human workers are needed onsite reportedly for a month or more. Also called dark factories, these operations enjoy the high efficiencies one might expect of fully automated processes, as well as the boost in quality brought about by machine precision. On the one hand, many manufacturers are inspired by the recent success of a few lights-out factories – facilities that can literally operate in the dark because there are no humans on the shop floor. However, if one is “here,” the path to “there” may be obscure and potentially fraught with difficulties.Īt Siemens Digital Industries Software, we sense both these emotions in those whose job it is to bring new efficiencies to their factories and to impart greater quality in their products. In the question’s context, “there” has become an achievable aspiration, a happily anticipated capstone. “How do we get there from here?” When this question is asked, it often elicits two contrasting emotions: excitement and apprehension. Re-imagining factory floor operations for agility, resilience, and sustainability It is, essentially, a common translator based on Internet standards that enables CNC and non-CNC machine tools and other shopfloor equipment to communicate with each other and with a central production monitoring system.Prerequisites for the data-driven, lights-out factory of the future A number of manufacturers use MTConnect for universal connectivity. Many CNC machine controllers and peripheral equipment are designed to work with Ethernet or other communications tools that can send alerts to PCs or mobile devices located anywhere they are needed. That’s when having a remote monitoring system is invaluable. Although using reliable equipment and following a planned preventive maintenance program will minimize problems, there is always the possibility of machine failure, cutting tool breakage, power outages and other unexpected issues. Whether using an in-house plan or contracting with a reliable service provider, a preventive maintenance program is critical for lights-out operations. When a machine breaks down in the middle of a lights-out shift, work grinds to a halt and precious run time is lost until someone is available to correct the problem. If a machine goes down at any time, it’s a problem, but if machine operators are present, they can shift production schedules or use other machines until help arrives. Although such a program is invaluable regardless of whether or not lights-out manufacturing is performed, it’s extremely critical for overnight operation. If loading barstock, is the feeder capable of holding an adequate amount of material in its magazine or holding tray to supply the run? Does it have the ability to continuously feed and support barstock in synch with the machine tool to eliminate crashes? If running a family of parts, can it communicate with the machine tool program schedule and automatically adjust itself to a new part? Is it sturdy enough for continuous operation? Once the cycle is completed, can the part simply be pushed out of the machine tool into a bin? Is a vacuum unloader required to help protect part finish? Is a robotic arm or other device called for to unload the machine tool? The two most common loading methods are bar feeders for loading barstock, and robots for just about everything else. Can the chip conveyor adequately handle the quantity and types of chips produced throughout the production run, or will the chips begin to back up and create problems? Can the conveyor efficiently filter coolant to prevent fines from contaminating the cutting fluid and potentially clogging coolant delivery nozzles or causing a pump breakdown? If high-pressure coolant delivery is required, can the delivery system be programmed to vary the pressure throughout the machining cycle as necessary?
0 Comments
Leave a Reply.AuthorWrite something about yourself. No need to be fancy, just an overview. ArchivesCategories |