Session 5: Advancements in Metal Finishing Technical Improvements
By adopting the presented innovative technology, manufacturers in the surface finishing industry can dramatically increase their production efficiency, reduce operational risk aspects and hence increase their ability to be more competitive. In an ever changing environment, where workforce turnover becomes a dramatic factor, the ability to preserve operational knowledge and easily train new personnel is a must. The proposed solution exposes the audience to extending of industry 4.0 revolution into maintenance operation domain.
Innovative Best Practices for Performance & Efficiency,
Technologies for Improved Performance or Increased Efficiency
The manufacturing maintenance ecosystem incorporates solutions for maintenance resources management using various systems. Industry 4.0 added automation to manufacturing world. It automates machines, it optimizes maintenance scheduling according to equipment actual performance rather than maintenance scheduling according to OEM directions. But when it comes to actual hands-on operation and maintenance tasks on production floor, these are yet based on documented procedures (word, excel, etc.) and gained knowhow of workers. Feedback from production floor is based on manual reports, often divided to several reporting forms (procedure execution, spare parts, Job Safety Analysis etc.). Furthermore – it doesn't include knowhow and techniques sharing for improved performance.
This results in ever growing gap between the documented data and actual knowhow required for correct and efficient job performance. It leads to increased equipment downtime, increased operation costs and risk to equipment and personnel. In the presentation, I will propose a new approach to manufacturing maintenance and operation management ecosystem - incorporating a new management layer - Maintenance operations management.
The maintenance operations management creates a new cycle of information and dataflow between the organization database and the production floor and maintenance resources management. 1st level, it shall equip the production floor with most updated and detailed data, provided by AR/VR visual tool that ensures correct execution of preventive and corrective maintenance procedures. 2nd level, it generates digital operations environment that enables to manage operations on production floor based on digital data. 3nd level, it ensures automatic feedback and reports from the production floor to the database that enables accurate performance monitoring and analysis. 4th level it incorporates AI decision making based on the actual data that is automatically reported. This new approach can dramatically reduce downtime and operational costs (by 30% according to our gained experience), and it can lead to safer working environment.