Machine Downtime and Root Cause | Packaging World

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Check the different causes of downtime and use the correct automated methods to find the root cause.

good afternoon everyone. My name is Justin Jeans. I am the digital leader of ITW Hartness. Thank you very much for your attention to me this afternoon. I hope you all have a good time during these crazy times we have experienced together. Even if we can't face each other in person as we usually do at this time of the year, I am glad that we still have the opportunity to connect virtually. I hope you all have a good time in the virtual PACK EXPO experience and learn a lot of new things. Of course, this is different from our past habits, but I think we are here for exactly the same reasons as before. Each of us wants to learn how to do more with less money. Many people in our industry feel this pressure now more than ever. This allows us to have greater trust in technology than ever before, so that we can continue to move forward.

            But what does this mean for manufacturing?

We must seek the overlord of technology to help us provide the maximum results we are seeking by ruthlessly eliminating the most notorious villains in the manufacturing process. If you have been in the industry for half a minute, you will undoubtedly hear these popular buzzwords. Industry 4.0, IIoT, digital transformation. They all survived the storm here. For many of us, we often hear it, and maybe we are a little tired of it.

We hear so many amazing tools and solutions from time to time, but they seem to lack clarity, strategy and focus. People ask: "How will we get so excited about this technology when we don't really understand how to fully unlock its potential?"

Some people have indeed joined this vision, but they are skeptical because they have not yet reached the promised land that these technological advancements should bring us. Before COVID-19 was hit, PMMI announced that global IIoT user spending will increase from US$65 billion in 2018 to US$118 billion in 2025. Now, COVID is the main catalyst, and this growth is accelerating, and this number will grow further. However, despite this growth, many companies are still struggling to understand how these technologies are at the core of their business day-to-day problems. Many people have taken a ready-made, targeted approach to digital conversion, and left a unique impression that the technology they are working on is not what they expected, just a silver bullet or a magic wand.

            My grandmother used to own this old TV. The TV is this kind of huge tweet furniture, but the screen itself is a small square with rounded corners. She has bunny ears on this thing, so she can watch soap and QVC channels. But her eyes got worse and worse, because she was looking at the small granular screen, she reached a place where she could no longer read the phone number on the QVC channel. This thing is very old. I'm sure she looked back and saw the moon landing on this thing. Therefore, we think it is time. We spent Christmas together last year and we bought this big and beautiful 60-inch Roku smart TV for her. As you can see, after about a month of preparing everything and training her how to use it, she now has a very beautiful setup.

            Now, if because of her slow internet connection, just let her stop playing when the TV starts to buffer, then what are you going to do, right? I will tell you to say so.

Although you may get the impression, no technology is silver bullet or magic wand. Sometimes, it is more like a scalpel, and only when we apply it skillfully and accurately, can it help us eliminate cancerous tumors called downtime. At ITW Hartness, we focus on optimizing performance and reducing the total cost of ownership for our customers. One of the most effective ways to achieve this goal is to help customers apply technology to eliminate downtime.

            We have developed a set of sophisticated tools and skills that can help our customers master the science of performance optimization. The first and most critical step to achieve this goal is to realize that all downtimes are different. In other words, the downtime to consider is different, which will affect your production line. In order to help customers evaluate and solve their unique situation, we divided downtime into seven levels and determined how to solve each problem by applying the right technology to improve the overall production line performance. So, for the rest of the day,

            The seven levels will be ranked based on two common indicators used to measure downtime;

, It measures the impact of each event based on the time required for recovery. Generally, lower levels of downtime will result in a much shorter mean time between failures and mean time to repair. In other words, these incidents occur more frequently, but can be resolved quickly. Although there are higher levels of downtime, the average time for each type of downtime is much longer. They do not happen often, but when they do, it is important. Combining these two measures, we can understand the total impact of each type of downtime on your unique situation. So let's take a look at the different types and gradually understand what should be considered when checking each level.

. After solving the external problem, the machine will automatically recover by itself. And because the operator does not need to perform any operations here, this level is often ignored. But in many cases, these states may be the catalyst for other downtime events. Consider buying a used car. If the used car you bought has already driven 100,000 miles, do you find it useful to know these road or city miles? Some cars have poor driving performance when they are parked. Actually, no one did. The same can be said for machines. Stopping traffic will cause a lot of extra wear on the equipment. When the machine returns to [inaudible 00:07:34], it is more likely to create other downtime events.

            Traditionally, we hope to reduce these risks by adjusting the machine, and adding dynamic accumulation such as the DYNAC model, which will be very effective when added to the production line.

The right technique can help us determine the root cause. For example, implementing good data collection and analysis can really help you understand which part of the production line causes the most downtime for fillers, and where to start continuous improvement to keep the production line unimpeded.

Generally, operators can fix these problems quickly with little effort or training. Through good production line design and accumulation, these stoppers rarely directly affect the filling machine. However, they may still consume a lot of resources, thereby seriously affecting the performance of the production line. Over time, these small problems became bigger problems. We have all heard this old proverb, if you want to cook a frog, you will slowly heat up the heat over time, and he will be cooked unknowingly. Likewise, if your operator just adapts to these types of problems, but never solves the root cause, then these problems will worsen over time.

            Restarting the machine and running it again can only solve the symptoms, but not the disease. We can reduce the impact of these events through DYNAC accumulation, and we absolutely should. Micro-parking will definitely happen, but a good root cause analysis can alleviate many of the troubles of keeping in touch with the production line. Have good tools to eliminate this type of downtime, such as video recording.

This allows us to solve real problems, not just to restore the production line and run quickly, but also to ensure that we solve the fundamental problem, and we will not continue to fight the same battle over and over again.

This will include more complex events such as failure recovery, conversion, and other standard operating procedures. Having well-trained and skilled operators for these tasks is critical to reducing such downtime. But this has become another challenge for operators' plans with high turnover rates. Many people are struggling with this these days. We can help reduce reliance on well-trained operators by improving the interface between them and the machine. To this end, good interface design and real-time operator guidance are essential. Our team has developed a tool called... which essentially digitizes the on-the-job training process and provides operators with the information they need only when they need it in an easy-to-digest way to help them perform the task at hand task.

In addition, we can provide remote on-site training to help further improve the operator’s understanding of the equipment. We have also found that an effective method is to provide operators with data-based feedback from their respective production lines and equipment to help improve employee initiative and overall production line performance. Operators are our most valuable partners. We never want to use technology to splice them, or as a tool to persist in production, but to equip and assist our operators to reduce or eliminate their greatest pain. We can accomplish this task by providing real-time operator guidance and automating part of the conversion process. We just provide them with data-based feedback.

We believe that

. But as time goes by, it is inevitable that everyone will be fine, and they will adjust the settings to make it better, until eventually the machine stops operating normally. When the machine starts to have problems, it is usually inferred that the physical input changes, such as material tolerances, incorrect conversions or machine products, but operators and technicians usually do not try to conduct a thorough root cause analysis, but try to pass the following Method to solve the problem: install the program to get a short-term fix. Although things will inevitably get out of control, this will cause the startup process after each conversion to be very slow. As they make more and more conversions, the problem becomes more and more serious.

            Traditionally, we have used passwords, interlining documents or manual notes to solve these problems. But due to human nature, over time, these solutions often prove to be ineffective. In these cases, technology can help by automatically tracking changes. For example, through our configuration manager tool, we can keep a version control history of all settings changes, so that we can easily compare the settings version with the machine performance, and easily roll back to the most important parameter set. Of course, this tool alone can only solve the symptoms of the problem. Similarly, we must equip ourselves with a suitable set of tools, such as data tracking, video recording and troubleshooting guides, to find out the root cause of machine performance degradation. Once we do this, we usually don't need to replace the machine so frequently.

Although planning for proper downtime is important for preventive maintenance, sometimes the task may become more ambitious because the maintenance staff will take on a heavy workload. They try to maintain the health of each device through an ever-increasing production range. Good CMMS software is very helpful for management and maintenance work. The realization itself is a huge obstacle. In our company, we help customers digitize PM schedules and track maintenance and their task due dates to provide alerts and guidance to ensure that PMs are completed on time and efficiently. However, even the best preventive maintenance program may still miss some critical and impending failures. Technology allows us to close the feedback loop during maintenance and capture early warning signs of critical component failures that would otherwise be missed through preventive maintenance alone. This is what we call predictive maintenance.

            The journey of predictive maintenance is a daunting task. Don't let anyone fool you. It should not be underestimated, but with some data analysis techniques, such as condition-based monitoring, we can achieve some major achievements faster and change this balance from passive maintenance to active maintenance. Some parts will wear out and must be replaced. Condition-based monitoring helps us find these problems early so that we can resolve them before they become unplanned downtime. In addition, a good OEM partner can help you through the e-commerce platform for online parts ordering or warranty, machine maintenance and service package e-commerce platform to eliminate friction in the parts replacement process, so as to actively monitor and audit equipment and help you Keep the proper number of parts. Spare parts are available for future use.

Usually, new requirements are introduced after the initial design is in place. Perhaps some limitations or challenges were not anticipated. Excellent OEMs and integrators are partners in the entire life cycle of the equipment. They will help you make the most of your equipment. If you only rely on phone calls, emails, and in-person visits to get the engineering assistance you need, you may experience a lot of costly downtime. Moreover, you may lose valuable opportunities for performance optimization. If this epidemic teaches us anything, it is that remote connections are not only possible, but essential.

            Through successful remote support, OEMs and integrators can not only help reassemble the parts when they hit the fan, but they can also actively monitor the production line and provide support and consultation. I think we all understand the value of remote connections. It's easy to say, but if you have ever tried to implement it, I think you will agree. It's easier said than done. Establishing secure and effective remote access to all parties is a huge challenge. Few people are proficient in equipment and step up their efforts to create a holistic, more feasible approach for everyone in the industry. Doing so requires flexibility, agility and a sense of trust. OEMs or integrators must meet with their customers. At ITW Hartness, we work with some customers to provide them with remote services through the methods they have established. If they have their own infrastructure, DMZ and VPN servers, we are happy to work with them to help them pass these power sources.

            But for those who don't have the resources or strategy to provide us with this connection, we have developed a proven security solution in cooperation with third-party experts, which works well for them. When it comes to remote access, it is still a bit wild, but it is getting better and better. We got there.

We are making great progress, and we will continue to get better. However, establishing a connection is only one part of solving the problem. It makes remote experts and tools and access methods more effective than remote support. It is an often overlooked part of the process of making a solution feasible.

            In this case, tools such as wearable video conferencing devices, smart goggles or other cameras and log records will be a huge help for experts to remotely assess the situation and solve problems that traditionally require repairs. Six levels of downtime are called critical failures. Hope that these situations rarely happen, and they are far apart, but once they happen, they will pay a huge price. This is an emergency when a key component of the machine fails and makes the machine inoperable. And it needs to go all out. Through good preventive and predictive maintenance, we can certainly reduce the frequency and possibility of these events, but they can still happen. When they do, they must be dealt with decisively. The most important part of solving these problems effectively and quickly is knowing exactly what happened, which will help us know what is needed for recovery.

After the expert arrives, she may find that she does not have all the parts needed for repairs. This means that it may take longer to reach the machine and the production line will resume normal operation. With the help of technology, we can place some of the tools we mentioned earlier in post-mortem analysis and root cause analysis. Usually, we can classify the problem remotely, and solve the problem more effectively even if it needs to be powered on the ground. Therefore, these are the main seven categories of downtime, and we will consider these categories when looking for ways to optimize performance. How can we do more with less money? This is the problem here. Of course, we can't cover all the nuances in a short time, but hope this is a good introduction, it gives you some different views on how you solve downtime and how to use technology in specific areas. Happening.

            To eliminate all these different downtimes, it is necessary to attach great importance to the establishment of good partnerships and effective tools. There is no one size that fits all solutions. Without purposeful implementation, no solution will be effective. Hope this overview provides you with some tools that can help you carefully assess the situation, select the right partner, and apply the right technology proficiently, so as to have a real and lasting impact on downtime. Technology is an amazing tool, and digital transformation is an amazing journey. With the right strategy and focus, even under the unimaginable situations and constraints we face today, we can do more than we previously imagined. Thank you very much for your time and attention. If you have any questions, or want to know more information and discuss further, please contact us.

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