MECHANICAL ENGINEERING PROGRAM

FACULTY OF ENGINEERING

KM41903 MANUFACTURING SYSTEM

FUTURE MONITORING MANUFACTURING SYSTEM

ELCY ELENNA KEFFNUS (BK15110078)

EFA SUZIANI BINTI ALI (BK15110297)
DANNY JALIUS (BK15110294)
DUNSTAN BANIUS (BK15110074)
EDDIE BIN ALFRED (BK14110105)

2018/2019
 Contents

1.0 Introduction to Monitoring

1.1 Definition
2-4
1.2 Importance of monitoring
1.3 Advantages and risk in monitoring
2.0 Future Manufacturing in Automation
2.1 Type of production automation
2.2 Importance of Manufacturing in Automation
3-7
2.3 Advantages and disadvantages of Manufacturing in
Automation
2.4 Automation and Artificial Intelligence
3.0 Cloud Monitoring
3.1 Definition
3.2 Benefits of Cloud Monitoring 7-10
3.3 Basic architecture of cloud monitoring
3.4 Advantages and disadvantages
4.0 Intouch Monitoring Limited
4.1 Overview
11-14
4.2 Monitoring, Reporting, Scheduling
4.3 Case study
Tutorial 15-16

1
 1.0 Introduction

Manufacturing trends imply the need for higher machining speed, lower tool wear and reduction
in the use of machining fluids in order for an increase to achieve productivity. The increasing
price of energy and the current trend of sustainability have exerted new pressure on
manufacturing enterprises that have to reduce energy consumption for both cost saving and
environmental friendliness. Modern manufacturing equipment has to be flexible, sustainable and
operative with minimum human interface, while machine tools have to operate free of errors.

Monitoring can be defined as the periodic tracking of any activity’s progress by systematically
gathering and analyzing data and information. Monitoring can be daily, weekly, monthly or
annually which involves the collection of routine data that measures progress toward achieving
program objectives. It is used to track changes in the outputs and performance over time which
will provides regular feedback and early indications of progress or lack of progress. Its purpose
is to allow the management to make informed decision about the effectiveness of programs and
efficient use of resources. Any variable can be monitored and preferably as soon as they become
available

Types of Monitoring

1. Process Monitoring (Real Time Monitoring)

Process Monitoring informs management about the actual implementation of project
activities in the field, while at the same time let the project employees knows about the
improvement that can be made in the field. It is conducted by using checklists and
guidelines that will help staffs identify gaps during the monitoring. The following
information can be obtained:

i. Purpose of the monitoring visit

ii. Activity that the visit covers
iii. Methodology adopted
iv. Key findings from the field
v. Feedback from the field staff
vi. Debriefing points agreed
vii. Deadlines and responsibilites

2
 2. Progress Tracking
Progress Tracking involves tracking the progress of output target that has been set for
the project. For this monitoring, a tracking sheet is required to outline all output indicators
for key activities along with target values for those output indicators. Progress is entered
against those targets and the trackers automatically calculate deviation against the
targets.

Progress is tracked for two reasons:

i. To identify whether the project is on-track or off-track
ii. To track time-critical activities if they are taking place as per the calendar

3. Progress Validation
Progress Validation is by means of validating the output progress reported and is initiated
by collecting Means of Verification followed by verifying thoroughly the process being
adopted in field.

4. Performance Monitoring
Performance Monitoring involves assessing performance before implementation of project,
as a permit to rate the targeted outcomes. An outcome indicator has two components
which are the baseline before the project begins and the expected target at the end of
the project.

Importance of Monitoring

- To achieve high level of final product quality, systems should be producing low variability
product at every step of the manufacturing process.

- Protect machine and tools from excessive damage, thereby reducing operating costs and
increasing machine uptime.

- Catch poor quality production parts in process, eliminating scrap and the need for costly
100% inspection post production

3
Advantages of Monitoring

The use of monitoring system is one of the important aspects in manufacturing process. The
benefit that it brings are way beyond than the obvious such as reducing downtime. Downtime is
a time in where a machine is out of action or not available to be used especially during setup or
making repairs causing production to be stopped. The phenomenon is one of the biggest obstacles
for smooth and efficient operations for every manufacturing plant as it uses up valuable resources
that could have been utilized for production. Implementation of monitoring system in the
manufacturing process will surely assist managers and supervisors by informing them as soon
the machine goes down.

Other than that, monitoring system helps manufacturing process sectors to make better
informed decisions constantly daily based from the data received from the machines. Information
will be able to be used to have a better decision making on whether to acquire new machines or
hiring new employees. Moreover, monitoring process by machine monitoring increases production
by making better decision driven by data and enabling better real-time communication between
management and production team.

Monitoring tools in a manufacturing system is one of the most remarkable process that
reduces wear to machines. Problems that may results in impairment of tooling or dies can be
prevented and productions could be halt before causing more problems to arise. Furthermore,
monitoring is able to detect gradual tooling wear and gives information when to replace them. In
addition to this advantage, it increases tool lifetime and also eliminate machine smash-ups
likewise reduce tool wear. Savings of post-production too can be achieved with complete
information on orders and parts thus able to reduce sorting costs, order contamination, and
reducing customer returns or charge backs.

Monitoring process gives a great amount of advantages to the manufacturing process.

However, every feature has its disadvantages including implementation of the monitoring process.
The only risk in having monitoring system is the security risk when not done correctly. Information
of manufacturing process could leak and be stolen by another party thus precaution has to be
taken even monitoring system have been installed.

4
 2.0 Future manufacturing process in automation

The industrial revolution we are experiencing now, commonly referred to as Industry 4.0,
is powered by advancements that include smart manufacturing, robotics, artificial intelligence and
the Internet of Things (IoT). For the Industry 4.0, the companies that can adapt, innovate and
utilize global resources will generate significant growth and success. According to Ben Wang
(2018), Optimal resource allocation is important to industrial and manufacturing companies in
order to maximize the output and input ratios since optimization is essential but insufficient in
Industry 4.0. Other than that, all production units such as machine tools, robots, and 3D printers
must have the ability to ‘‘scan” the environment and make certain decisions. Many decisions are
made based on prior knowledge and historical data, just as they are in Industry 3.0.

As for the manufacturing process, the development in automation is increasing rapidly

since Industry 3.0. In the highly industrialized countries, process automation serves to enhance
product quality, master the whole range of products, improve process safety and plant availability,
efficiently utilize resources and lower emissions (Sirkka-Liisa Jamsa-Jounela, 2007). Automation
in manufacturing industries can be defined as the use of robotics, control systems and information
technologies to reduce the need for human work in the production of goods. In the scope of
industrialization, automation is a step beyond mechanization. Whereas mechanization provided
human operators with machinery to assist them with the muscular requirements of work,
automation greatly decreases the need for human sensory and mental requirements as well.

Automation is a vital aspect of the industry’s future. Nowadays, many company’s

manufacturing processes are already fully automated. Automation enables a level of accuracy
and productivity beyond human ability even in environments that would be considered as unsafe
for humans. since automation systems are machine based they do not require to take when
compared to their human counterparts. Also, they are very fast and precise in what they do and
also, they can process a large amount of material in one go, unlike human workers. They are
very fast in their work and hence using automated machines and CNC systems can result in higher
output and productivity. Automation also improve redundancy. in this industry, where precision

5
and integrity is necessary for the output, automated machines provide quality and quantity. They
produce products with less errors and they do not compromise on the production speed for this
purpose. The new generation of robotics is not only much easier to program, but easier to use,
with capabilities like voice and image recognition to re-create complex human tasks. Next,
Automation brings safer working conditions for the worker. machines can be able to perform in
dangerous environments where humans are not supposed to work, or environments where it is
harmful for their health. In term of savings and profit, the capital is usually spent on the machine
maintenance and potential savings can be done, since there are no employee wages, medical
claims and also accident insurance to be given. Automated production results in lower prices and
better products. It has been estimated that the cost to machine one unit of product by
conventional general-purpose machine tools requiring human operators may be 100 times the
cost of manufacturing the same unit using automated mass-production techniques.

A main disadvantage often associated with automation is the subjugation of the human
being by a machine. Automation tends to transfer the skill required to perform work from human
operators to machines. Thus, it reduces the need for skilled labor. The manual work left by
automation requires lower skill levels and tends to involve rather menial tasks which tends to
downgrade factory work. There will be a reduction in the labor force, with resulting
unemployment. It is logical to argue that the immediate effect of automation will be to reduce
the need for human labor, thus displacing workers. Despite the social benefits that might result
from retraining displaced workers for other jobs, in almost all cases the worker whose job has
been taken over by a machine undergoes a period of emotional stress. In addition to displacement
from work, the worker may be displaced geographically. In order to find other work, an individual
may have to relocate, which is another source of stress.

Other disadvantages of automated equipment include the high capital expenditure

required to invest in automation as an automated system can cost millions of dollars to design,
fabricate, and install. In addition, a higher level of maintenance needed than with a manually
operated machine, and a generally lower degree of flexibility in terms of the possible products as
compared with a manual system. On the other side, automation will reduce purchasing power.
As machines replace workers and these workers join the unemployment ranks, they will not
receive the wages necessary to buy the products brought by automation. Markets will become
saturated with products that people cannot afford to purchase. Inventories will grow. Production

6
will stop. Unemployment will reach epidemic proportions and the result will be a massive
economic depression.

In the coming years, AI (Artificial Intelligence) is going to make automation more

widespread and even more reliable. Based on the trajectory of current automation trends, the
future of manufacturing is predicted to have an entire factory run by just a couple of people with
the rest of the operation performed by automated machines and robots. However, even the most
fine-tuned machine needs human interaction and correction to recognize and prevent
manufacturing failures. This is where AI just might change the situation. AI could make it possible
for manufacturing machines to understand far more complex goals than those which they
currently execute. This will make it possible for operations to become 100% automated at a given
location with regular remote check-ins from a central hub. In theory, AI could not only alert a
human overseer in the event of a manufacturing failure but possibly correct it as well. This means
that there will be more errors caught before they cost a big loss in producing the products.

The importance of automation technology continues to increase in the process industry.

The barriers between information, communication and automation technology are, in the
operational context, gradually disappearing. The latest technologies, which include wireless
networks, fieldbus systems and asset management systems, are boosting the efficiency of process
systems.

3.0 Future monitoring manufacturing system: cloud monitoring

What is cloud monitoring?

The term cloud denotes to a set of applications, services or resources that store and allow
access to data over the Internet (cloud computing provider’s servers) instead of on a computer’s
hard drive. Meanwhile, cloud-monitoring is a method of serving manufacturing data over the
internet. The data of the system can be shared at any time or place, hence, reducing the time
consumed for a product to be processed (Jeong et. al., 2014).

Due to the development of internet and technology, cloud-monitoring is becoming a

popular systems that are being implemented to monitor the behaviour of manufacturing

7
information and services (Toro et. al., 2018). Cloud monitoring technology is the new Internet-
based IT services that maximise the usage and delivery model to provide flexible, dynamic,
scalable and, often, virtualized resources.

In the cloud computing environment, system software applications and processes can be
executed or maintained as a service. This service may include infrastructures, system resources
and platforms for the users to share or gather manufacturing data.

Manufacturing is under pressure to achieve cost-production reduction as well as to

minimize its impact on environment. As manufacturing system has becomes more integrated and
complex, the open-source cloud-service in this work is a flexible network for monitoring processes
and resources in support of advanced manufacturing.

Benefits of Cloud Monitoring

The most significant benefits of cloud monitoring are its ability to interact with
manufacturing resources over the web. This helps the manufacturing industries to enhance
efficiency of their products. Furthermore, the advantages of the implementation of a cloud-
technologies to manufacturing systems includes increasing products’ reliability and quality (Toro
et. al., 2018). Errors can be detected and fixed quickly to minimize any damage to performance
and functionality.

Cloud monitoring offers real-time visibility into performance of equipment which are
important for continuous improvement. It enables quick diagnosis issues to provide potential
solutions because data can be easily accessed anywhere, anytime from any device. This
advantage, in turns, results in the reduction of the production costs while still maintaining an
improved production.

In terms of storage services, cloud monitoring and computing allows users to process and
store the manufacturing data in the cloud. That is, it can provide massive storage facilities
providing to large data storage necessities, such as those of complex services and application
environments. Moreover, by implementing the cloud-technologies, manufacturers will not just
gather the data, instead, gain significant insights from it (Petrowisch, 2017). Whether it’s for

8
quality improvement, sales forecasts or preventative maintenance, predictive analytics or machine
learning, this can distinguish manufacturers over their competitors and possibly, developing a
new complete service to sell.

Basic Architecture of Cloud Monitoring

Toro et. al. (2018) in their paper stated that, in order to support predictive control of
manufacturing process, cloud monitoring allows constant collection of data. This is applied in the
real-time diagnosis on tool conditions and the use of optimization algorithms for selecting optimal
cutting parameters with the most recent available data. Furthermore, cloud monitoring also
enables gathering of relevant data from one or multiple machines are gather and expose to users
in a cloud-based service application.

The basic design of cloud monitoring consists of two layer which are sensor and cloud.
The sensing or sensor layer is a local example of the network that immediately connects to the
manufacturing system. It also comprises of nodes gathering sensor data, where each node acts
as a sensor hub. There are two types of nodes which are the slave and master node. The slave
node is made up of a microcontroller with an embedded radio frequency (RF) module that enables
users to give and obtain data packages, wirelessly, at a fast rate with low power consumption.
Meanwhile, the master node receives data wirelessly from each slave and passes it to an adapter
that resides at a local computer in the floor shop. The adapter bridges the gap between the
sensing layer and the cloud layer, and acts as the component in charge of sending data packages
to the cloud server via Transmission Control Protocol (TCP) socket. The main functions of sensor
layer is to collects as well as compresses the data. This data is then delivered to the cloud server.

Meanwhile, the cloud layer consists of a network of data consumers, as well as other
manufacturing applications. It enables users to share, save, and visualize data from the sensing
layer and from external cloud manufacturing services. Two types of clients which are the adapter
clients (the computers that run the adapter at the machine shops) and browser clients (final
consumer) are connected to the cloud server. The path of the data in the cloud layer begin as
the adapter client sends a data package to the cloud servers that contain readings. The TCP
socket will carry this communication. The next step includes parsing the data and saving it into a
cloud database. A varieties of post process algorithm can be utilized to use the delivered data. As

9
an example, an algorithm can check certain parameters whether it has surpassed the fixed limit.
An alarm or messages containing the diagnosed error will be sent back to the adapter client if
there is an error. Final consumer are significant users in this network because they consume the
data collected by the cloud service from the sensors.

Figure 1 Two-network-layer architecture for cloud-based monitoring service (Toro, 2018)

Both the sensor and cloud layer allow to gather and access sensing data at multiple layers
of the enterprise organizational structure in order to take actions over any manufacturing process
and/or machines. This two-layer-network architecture is proposed by Toro et. al. (2018) and
represented in Figure 1. The dual architecture makes a clear distinction between hardware data-
acquisition and software data-distribution, and gives users the ability to customize affordable
sensing networks, and provides developers powerful tools for data manipulation in the cloud.

The proposed cloud monitoring service is a stand-alone web application that can be
developed into a larger branch cluster of manufacturing services. The unique feature of the
implementation of cloud technology to manufacturing is its ability to gather and linking associated
data such as temperature, position and force from different sources using distributed computing
resources.

10
 4.0 Future Monitoring Manufacturing System: Intouch Monitoring Limited

Intouch system Overview

intouch is a real-time production monitoring, reporting and planning system. Connected

directly to all of the machines, intouch enhances visibility and control in the manufacturing
operation.
With intouch, the costs and errors of collecting production data manually are removed.
Key production information such as scrap and downtime is constantly available in real time. This
allows action to be taken to rectify problems as they happen. The automatic data collection will
enable key personnel’s time to be used most efficiently.
Factory utilisation will be significantly improved. The high factory visibility, viewed from
any office PC, leads to much faster response to stoppages. This high visibility also motivates
production staff to keep machines operational. Increases in utilisation of up to 30% have been
reported within a few months of installing intouch.
intouch’s scheduling system makes planning and progress chasing less time consuming
and more effective. The system is very easy to use requiring no specialised staff to get the best
from the system. Better planning can reduce changeovers and thus reduce down time and waste.

Monitoring

Connected to each machine, intouch is able to monitor production in real time and deliver
live, up to date information to any part of the factory. The current status of each machine can be
seen at a glance. Key performance figures such as scrap rate, down time, efficiency, utilisation
and set-up time are displayed on fully configurable mimic diagrams, details pages and summary
pages through familiar Windows based software.
Operators can also interact with the system through easy to use keypads located at each
machine on the shop floor.

11
All data collected by the monitoring system is recorded in the intouch archive database. As well
as being available to the intouch reporting module, the archive database can be interrogated
through industry standard software such as Microsoft Excel or Access.

Reporting

The intouch reporting module draws on the data collected by the monitoring module. Reports can
be configured for any selected period with many different key performance figures such as:
 OEE (Operational Equipment Effectiveness)
 Improved efficiencies
 Run time
 Good production
 Utilisation
 Scrap rate
 Capacity utilisation
 Material usage
 Set up time
 Scrap by reason
 Downtime by reason
 Custom defined parameters

Reports can be generated for each shift, day, week, month, year or job. Reporting is available by
machine, tool, product or workgroup. Reports can be generated on demand at any computer
configured as an intouch terminal, or programmed to automatically print at the end of each shift,
day, month etc.

Scheduling

intouch includes a very easy to use and intuitive scheduling module. Jobs can be input
manually or downloaded automatically from your existing manufacturing system. The job
schedule view gives details of each job enabling operators on the shop floor to prepare for up-
coming tool changes.

12
 The Gantt chart view provides a graphical visualisation of machine loading and capacity
utilisation. Rescheduling is easily achieved through a simple drag and drop operation. Jobs on the
Gantt chart can be highlighted for various reasons. For example, to identify tool changes, late
jobs or resource clashes. The plan takes your shift pattern into account, as well as any planned
maintenance, overtime or shutdowns. Furthermore, each individual job can be forward scheduled
or backward scheduled to highlight spare capacity.

Case studies

Hanson Building Products – Air crete and Brick Division

This company introduced the intouch Production Monitoring system in 6 plants during
2014 and have been delighted with the information it has provided. Since introduction it has
provided real time information on how their plants are performing in terms of Speed, Availability
and Yield which has enhanced production recording and process improvement activities across
our business.
It has become a key foundation block in their pursuits with continuous improvement, the
ability to process Operational Equipment Effectiveness (OEE) dynamically has allowed them to
better quantify loss and enhance their capital expenditure application process with “real” data.
Previously, their original systems were paper based and reliant upon operators recording the
downtime, this led to ambiguity and also a lot of non-value added activity for the management
team processing the information. The intouch system links directly in to the machine operating
systems so it quantifies the downtime accurately.
The mimic diagrams have been tailored to the specific needs of the plant management team,
which concisely illustrates where the plant is running and shows process bottlenecks very quickly.
The production and engineering staff are very complimentary of how information is captured
through the use of HMI displays that are located on each machine.
It has also been used during plant start-ups, having recently reopened the Accrington Brick
manufacturing plant at the start of 2015 it was utilised during the factory acceptance trials to sign
off against the agreed performance criteria.

13
 With a further 4 plants planned for implementation of the system in 2015, it will then
enable an Enterprise strategy to be realised, as it is possible for senior management personnel to
access the information through any PC providing it is on the business network. Tailor made reports
have been created that allows the data to be consolidated and stratified so that key business
decisions can be made quickly.

In some sites, they have already seen up to a 20-30% increase in OEE which we wouldn’t have
been able to properly quantify without this system in place, the intouch Production Monitoring
system has therefore been a major part to our success in 2014.

14
 Tutorial

1. What is monitoring?

- Periodic tracking of any activity’s progress by systematically gathering and analyzing data
and information

2. Briefly explain the importance of monitoring.

- To achieve high level of final product quality, systems should be producing low variability
product at every step of the manufacturing process.

- Protect machine and tools from excessive damage, thereby reducing operating costs and
increasing machine uptime.

- Catch poor quality production parts in process, eliminating scrap and the need for costly
100% inspection post production

3. What are the advantages of product automation?

- High productivity and accuracy

- High quality and quantity

- Improve safety

- Savings and profit

- Lower prices and better products

4. What is cloud monitoring?

- A method of serving manufacturing data over the internet.

- The data of the system can be shared at any time or place
- The new Internet-based IT services that maximise the usage and delivery model to
provide flexible, dynamic, scalable and, often, virtualized resources.

5. Give two layers of basic architecture of cloud monitoring and their function

i) Sensor Layer: to collects and compresses the data

ii) Cloud Layer: to share, save, and visualize data from the sensing layer and from external
cloud manufacturing services

15
6. List five examples of key performance figures that are used in the in-touch monitoring reporting
module.

- Lower prices and better products

- OEE (Operational Equipment Effectiveness)

- Improved efficiencies

- Run time
- Good production

- Utilisation

- Scrap rate
- Capacity utilisation

- Material usage

- Set up time

- Scrap by reason

- Downtime by reason

- Custom defined parameters

7. Explain briefly about scheduling module of in-touch monitoring system

- Jobs can be input manually or downloaded automatically from your existing manufacturing
system.
- The job schedule view gives details of each job enabling operators on the shop floor to
prepare for up-coming tool changes.
- The Gantt chart view provides a graphical visualization of machine loading and capacity
utilization. Rescheduling is easily achieved through a simple drag and drop operation. Jobs
on the Gantt chart can be highlighted for various reasons. For example, to identify tool
changes, late jobs or resource clashes
- The plan takes your shift pattern into account, as well as any planned maintenance,
overtime or shutdowns. Furthermore, each individual job can be forward scheduled or
backward scheduled to highlight spare capacity.

16
 References

Jeong, H., Jeong, Y., & Park, J. (2014). G-Cloud Monitor: A Cloud Monitoring System for
Factory Automation for Sustainable Green Computing. Sustainability, 6(12), 8510-8521.
doi:10.3390/su6128510

Petrowisch, J. (2017). The benefits of cloud computing in the manufacturing industry.

Retrieved from http://www.eurekamagazine.co.uk/design-engineering-blogs/the-benefits-of-
cloud-computing-in-the-manufacturing-industry/154891/

Toro, R., Correa, J. E., & Ferreira, P. M. (2018). A Cloud-Monitoring Service for
Manufacturing Environments. Procedia Manufacturing, 26, 1330-1339.
doi:10.1016/j.promfg.2018.07.128

Wang, B. (2018). The Future of Manufacturing: A New Perspective. Engineering.

doi:10.1016/j.eng.2018.07.020

Jämsä-Jounela, P. S. (2007). Future Trends In Process Automation. IFAC Proceedings

Volumes, 40(1), 1-10. doi:10.3182/20070213-3-cu-2913.00003

Gröhn, L., Metsälä, S., Nyholm, M., Saikko, L., Väänänen, E., Gulzar, K., & Vyatkin, V.
(2017). Manufacturing System Upgrade with Wireless and Distributed Automation. Procedia
Manufacturing, 11, 1012-1018. doi:10.1016/j.promfg.2017.07.207

Chui, M., George, K., Manyika, J., & Miremadi, M. (n.d.). Human machine: A new era of
automation in manufacturing. Retrieved from https://www.mckinsey.com/business-
functions/operations/our-insights/human-plus-machine-a-new-era-of-automation-in-
manufacturing

Chui, M., George, K., Manyika, J., & Miremadi, M. (n.d.). Human machine: A new era of
automation in manufacturing. Retrieved from https://www.mckinsey.com/business-
functions/operations/our-insights/human-plus-machine-a-new-era-of-automation-in-
manufacturing

George Chryssolouris. (2006). Manufacturing System: Theory and Practice. 2nd Edition.
Springer. ISBN: 978-0387-25683-2

17
 Snatkin A. et.al (2012). Real Time Production Monitoring System in SME. 8th
International Conference DAAAM Baltic Conference “INDUSTRIAL ENGINEERING”

Elizabeth Engler Modic. (2017). 8 Advantages from Machine Monitoring.

[http://www.todaysmedicaldevelopments.com/article/8-advantages-from-machine-monitoring/].

Monitoring, I. (n.d.). Production monitoring, reporting and planning systems. Retrieved

from https://www.intouchmonitoring.com/

18