Monitoring For Work Efficiency Calculation of a Metal Fabrication Plant
Process improvement and optimization is the prime goal of every industry. If an industry is not continuously improving the way it performs, it will likely fall behind in the market. Succeeding in today?s business environment means constantly adopting ways to do things better. With tools for pro
2025-06-28 16:34:10 - Adil Khan
Monitoring For Work Efficiency Calculation of a Metal Fabrication Plant
Project Area of Specialization Internet of ThingsProject SummaryProcess improvement and optimization is the prime goal of every industry. If an industry is not continuously improving the way it performs, it will likely fall behind in the market. Succeeding in today’s business environment means constantly adopting ways to do things better. With tools for process enhancement, companies can evaluate performance metrics and evolve processes without restricting the way teams work. Reporting and analytics provide insights into delivery trends to remove bottlenecks, predict future issues, and adapt workflow processes for improved productivity.
This project aims to provide a one-box solution around this problem, which can monitor the performance of industry in real-time so that any undesired operation can be diagnosed well in time. This will be achieved by the utilization of real-time data and its prognosis using OEE calculation techniques. Overall Equipment Effectiveness (OEE) is the key metric to monitor the actual performance of a tool relative to its performance capabilities under optimal manufacturing conditions. Monitoring the system's expected future performance along with pinpointing the exact underlying problem and rectifying it so that abrupt shut downs are avoided and productivity is not compromised.
Project ObjectivesThe product will monitor the vital parameters of equipment at plant with the goal to make the system autonomous, reduce human energy and efforts make it cost effective. The system will be designed to be rigorous and more accurate. In the past, extensive research has been carried out on how to calculate OEE and various techniques have been proposed for this purpose, but none of these researches take discusses the actual practical implementation of the system and no such system is designed which can be a plug and play device at industrial level. So the objective of this project is to use the theoretical knowledge to develop a system which can be incorporated in the manufacturing plant of a company while keeping the system’s initial cost low and performance high.
Project Implementation MethodThe implementation of this system requires a survey of the manufacturing plant. Based on the physical structure of equipment, customized solution is proposed. This project is designed for Mechanical Press in a metal fabrication plant where metal parts are processed. There are three factors that OEE takes into account. Hence the developed prototype is able to determine and calculate all the three parameters and find the OEE. For this purpose, a network of sensors and controllers are deployed with the equipment whose efficiency is to be calculated. In this way, the desired goal is achieved.
Benefits of the ProjectThe conventional method of finding OEE i.e. manual calculation is a slower process and hence is inefficient. The proposed system mitigates this drawback and offers improved efficiency by eliminating human intervention. Its real time data processing and autonomous operation makes it a robust and effective device. Cloud computation eliminates the chance of data manipulation, lessens human efforts and makes the product easy to use and adopt. An android application is developed which provides a user friendly interface and offers reliability.
The system is designed with the goal to minimize the development cost and make it a standalone device. It covers a large target market and above all, it’s a green solution which makes it a best fit for industrial environment.
Technical Details of Final DeliverableThe OEE calculation is carried out in three steps. In the first step, a network of sensors and controllers are deployed on the equipment at production line of plant and required data is obtained. The sensors used for this purpose are Current Transformer and IR sensor. Sensors read this data and store it in the microcontroller they are attached with. The microcontroller used for this purpose is Node MCU which has a built-in Wi-Fi module to send data to cloud. Collected data from the cloud is fed on cloud where it is stored in an online real time database. The main controller retrieves the data from cloud and performs computations and calculations and determines OEE. The results are then displayed on an android application.
Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Others Core Technology Internet of Things (IoT)Other Technologies Internet of Things (IoT)Sustainable Development Goals Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 78250 | |||
| Microcontroller | Equipment | 7 | 750 | 5250 |
| Sensors | Equipment | 5 | 2000 | 10000 |
| Motor | Equipment | 2 | 20500 | 41000 |
| Casing | Equipment | 2 | 6000 | 12000 |
| Jumper wires, soldering iron, glue gun, resistors, capacitors | Miscellaneous | 1 | 10000 | 10000 |