Maintain process quality with quantity-based monitoring

Advantages of quantity-based process monitoring

By changing your maintenance strategy from time-based to needs-based maintenance, your entire process will be optimised. The added value results from the use of the moneo condition monitoring tool. The exact data on the number of pieces produced is initially recorded and processed in real time. The sensor values are automatically converted and analysed to produce process-relevant information which is visualised very clearly in moneo. The processed data provides detailed information about the plant’s capacity utilisation and the degree of wear on the plant’s components and tools. Any exceeding of threshold values is automatically identified and, through integrated alarm management, triggers a targeted response to avoid failures and to ensure the quality of the products.

Needs-based replacement through quantity-based maintenance reduces resource consumption because the plant’s capacity utilisation is taken into account. Targeted analysis of historical data also makes it easier to calculate maintenance times. Overall, quantity-based maintenance makes for a transparent production process and guarantees quality assurance of the manufactured products. moneo can also be easily integrated into existing production processes – a minor effort with a major impact.

Value proposition

Process optimisation using a piece counter

Piece counting takes place in different quality control processes. Most of the time it involves counting the number of units produced or observing wearing parts during production. Piece counters are also integrated into production processes to distinguish between good and bad parts. This is the basis for key metrics such as first-pass yield (FPY). Defects or failures in the production process are identified at an early stage. Based on the data collected, measures can then be taken to produce defect-free products and adjust maintenance accordingly.

Piece counters are also used in the final testing of sensors by recording strokes on a knuckle-joint press for pressing housings using position sensors. A warning is sent when a degree of wear has been reached and equipment needs to be replaced. This means the maintenance team still has time to replace the equipment. The collected piece count data can be used for documentation purposes for production analysis and other operational purposes.

This allows companies to track the production sequence and sustainably optimise their processes.

moneo simulation video

Automated data transmission through versatile interface management

The combination of hardware and software – or, more precisely, the consistent solution of ifm sensors and the IIoT platform moneo – offers a wide variety of options and interfaces to various systems and supports you in automating your processes. Numerous protocols such as MQTT and OPC UA can be used to extract data from moneo and integrate it into your downstream system. Direct connection to SAP PM is possible by integrating the shop floor integration (SFI) interface.

If the count value is violated, a maintenance order is generated in the SAP system via the SFI interface in parallel to the message in moneo. The person responsible for the system has the opportunity to carry out the appropriate maintenance and then reset the counter. After completing the maintenance order, the replacement can be reported and the counter reset in the SAP system. This also automatically closes the threshold value violation in moneo.

By providing the appropriate interfaces, ifm also enables you to store your data in the cloud and use it for further analysis if necessary.

• moneo
  MQTT or OPC UA →AWS, Azure, SAP
• SAP Integration
  SFI (shop floor integration) →SAP PM
• Alarm
  email notification (threshold)
• Spare parts
  automatic ordering through SAP
• Cloud and on-premises
  possible with the cloud and on-premises solutions

For engineers: how to integrate a piece counter into your production processes

Do you want to monitor your production process based on quantity and therefore ensure your process and products are consistently high quality? Then you should opt for the IIoT platform moneo. You can install the software centrally on a server or use it in the moneo Cloud. For an on-premises solution, IO-Link masters are connected to the server via an internal network (VLAN).

The counter values are shown on a multifunction IO-Link display and frowarded from there to the IO-Link master. Depending on the application and your existing hardware, different counters, including VSE meters, controllers such as Siemens LOGO or other PLC controllers, are connected via an interface. This facilitates data transfer to moneo. moneo then evaluates the data and presents it visually. The analysed process values provide information about the ratio of good and bad parts, the quantity produced and the wear of machine parts and allow conclusions to be drawn about the wear of the components. If a replacement is necessary, this will be indicated by an alarm.

If threshold value violations occur, the SFI interface automatically sends an alarm to the ERP-SAP PM system. After maintenance, the counter in the multifunction IO-Link display is reset via a key-operated switch.

The data can then be saved or further processed in the cloud.If an on-premises solution is not chosen, it is also possible to use moneo directly in the cloud.

Piece counter system structure

1. IO-Link master (VLAN)
2. Power supply
3. Multifunctional display for monitoring analog standard signals
4. Inductive sensor
5. Key switch

moneo software

• Historical data
• Visualisation
• Monitoring
• Alarm function
• Threshold violations via SFI to SAP

System structure – good and bad parts

1. IO-Link master (VLAN)
2. Power supply
3. Multifunctional display for monitoring analog standard signals
4. Inductive sensor
5. Key switch

System structure – wear of machine parts

1. Power supply
2. Diagnostic electronics for vibration sensors
3. Inductive sensor
4. Key switch