IOT or OPC for real-time OEE measuring?

IoT and OPC are used to support the OEE measurement in your manufacturing process. Which one do you choose and when do you start? Cierpa Certified Consultant Willem Siebers works with both systems and gives some advice.

Optimize your machinery with OEE

OEE often starts with a gut feeling: we could get more out of the manufacturing process than we do now. The machines can handle more, but how, and where? OEE (Overall Equipment Effectiveness) offers you the possibility of measuring the production process and shows where improvement is possible. It's useful for all manufacturing industries.

Starting with OEE measurement

OEE often starts with manual measuring of the performance of your machines. It's a great way to get acquainted with the method. You then write down the results in Excel, Access, or any other software not explicitly designed for this purpose. After some time, the downsides of this method become apparent: only one person has insight into the documents (what happens if he is sick or leaves?) or different versions of the document circulate (so which version should you continue with?). In short: continuity isn't guaranteed. That is the moment when people usually look further into specific OEE software.

Working with automated real-time OEE measurement

OEE software, like Cierpa OEE, makes it easier for a company to grow with the OEE process. For example, OEE data is always up to date, and the current version is accessible from different locations with a web application. There's no more need to maintain Excel or Access files. From now on, everyone works with the latest and correct version.

OEE software makes it easier for a company to grow with the OEE process.

OEE software also offers the option of automated real-time OEE measurement. That enables you to make significant leaps forward. There's a lot less to register for the operator, and at the same time, more detailed insight into machine failure is available. That means less work and more understanding.

Automating with IoT or OPC?

When you opt for automated real-time OEE measurement, you can choose either IOT or OPC as your automation system.

OPC

What is OPC?

OPC = Open Platform Communications

OPC is a data exchange standard between industrial automation systems. It's a way for PLCs (Programmable Logic Controllers) to communicate with PCs. Simply put, every brand of PLC speaks its own language, and OPC helps you convert this to a universal language the PC can use.

OPC in practice

In many cases, machine control includes a PLC connected to the network. OPC allows you to read the data from the PLC. It enables you to specifically see when the machine is running, when it halted, or what the problem is. Often, you can also see whether the machine is running at the expected speed (the performance level) and the quality level of the product.

When to use OPC?

OPC is suitable for new machines and complex measurements.

The benefits of OPC

OPC provides detailed information on machine availability, often also on performance and quality losses.

The disadvantages of OPC

A machine can exhibit many failures in many different places, especially on a 50- or 100-meter line with many discrete components. Which fault has caused the line to stop? In addition, system setup takes longer than with IoT due to its complexity.

IoT

What is IoT?

IOT = Internet of Things

IoT consists of small devices that can be put anywhere, with specific tasks like measuring temperature, light intensity, or counting numbers. These devices are connected to the Internet and send results to a server. In daily life, there are many implementations of IoT, for example, in cars, household appliances, and even streetlights.

IoT in practice

With on-the-line IoT you place one sensor module at the bottleneck. This sensor module counts the products passing by. The OEE software can then determine whether a machine is running or halted based on the results. If the machine has stopped, it is up to the operator to determine why it stopped. Although this is more work for the operator than with OPC, it does provide clarity on the reason for the stop. It also ensures that the operator stays connected to the process.

When to use IoT

IoT is appropriate when the people on the work floor are already used to (manually) measuring OEE, but the machines are not part of a PLC network.

The benefits of IoT?

IoT is quick and easy to install: it's a shorter process than OPC. In addition, because the operator still plays such an essential role in data collection, there is often more support on the work floor.

The disadvantages of IoT

With IoT, you monitor little to no automated breakdowns. Often only machine availability is measured. The operator spends a little more time collecting data than with OPC.

IoT offers a quick start on smart real-time OEE measurement in your factory!

Off to a flying start with IoT

Get fast, low-cost real-time OEE measurement with IOT too! The implementation is easy, and for most companies, it's the perfect way to gain insight into the OEE process. Willem Siebers (OEE-specialist.nl) offers you the chance to make a flying start with IoT. Bottleneck analysis is the first step to determine where to measure, while the potential analysis scan shows what result you can achieve. Cierpa Certified Consultant Willem Siebers helps you implement and secure OEE measurement within the organization. Get started now!