Applications

Production Reporting

By working with global OEMs and enterprise manufacturers, we have created comprehensive reporting capabilities to meet your needs, and turn production and engineering data into dynamic knowledge. Information within our reports is sourced in real time from monitored production equipment to increase accuracy and speed-up delivery.

Valuable production information is analyzed by shift, day, machine, facility, and enterprise to deliver the level of detail required to empower the decisions of shift managers, quality technicians, plant managers, or Vice Presidents. These reports tie in the data from our various productivity tools in order to maximize the value of all information we manage.

Delivery of these reports via the Internet and email makes sure that the right information is in the hands of the people who can use it to best. This helps your organization make more informed decisions in all departments, from operations to sales.

Six-sigma metrics and OEE calculation are standard features of all our productivity reports.

Sustainability Reporting

Company commitments, ISO 50001, environmental legislation, truthful marketing, certification and cost savings are some of the drivers that lead organizations to reduce their total environmental impact. Our Environmental monitoring application supports these actions by providing a global company-wide measurement tool that acquires, analyzes and reports on environmental data across the enterprise.

By taking consumption data from all properties and then normalizing their results for weather use and other influential factors, Key Performance Indicator numbers are generated showing the total impact of an organization’s operations. These KPI numbers show the overall emissions of green house gases, waste produced and the aggregated consumption of energy and water for an entire enterprise. By comparing these KPI numbers against established benchmarks, our web dashboards and reports are used to find the properties that excel in their environmental performance and direct attention to the properties that could benefit from improvement efforts.

Environmental reporting can be tailored to the needs of the organization. Report tools that match the organization’s structure enables sub-reports that show the results on a divisional or regional basis. Also by inputting custom key variables such as the property usage our application calculates KPI numbers that show per-unit environmental impact.

The energy consumption data can be acquired by three methods, automatic remote monitoring of utilities at the manufacturing facility, data input of monthly bills, or periodic meter readings. Multiple languages and currencies are supported as well as all common units of energy, these factors and others make this sustainability reporting tool a truly global application.

Downtime Tracking

Anyone who is striving to improve the overall efficiency of a manufacturing operation can benefit from reducing equipment downtime. By understanding the largest causes of unplanned downtime, reduction programs can be developed. But, getting accurate information about downtime is a challenge that any improvement program faces.

Our downtime tracking hosted web application provides a cost effective, easy to implement solution that provides highly accurate reporting for the downtime of an entire shop floor. Downtime Tracking works by remotely monitoring equipment to determine the amount of time a particular line or machine is not producing, or “down”. Then this measured down-time is categorized into codes by equipment operators using on-line web forms. Immediate downtime reporting can be performed for a machine, group of machines or entire plant using a visual downtime reporting tool.

Local downtime categories and codes can be developed to meet the needs of individual equipment lines or to continue with existing methods of downtime coding and categorization.

The visual reporting tool can provide an up-to-the minute downtime report for a shift, day, week, month or any timeframe that is requested. Downtime can also be evaluated according to individual operators or operator teams. This application integrates with other plant floor and business systems so that the measured downtime can be seamlessly integrated into production management or financial applications.  Learn More…

Lifecycle Tracking

Competitive forces exert relentless pressure on the bottom line of manufacturing companies. To succeed in the global market a manufacturing company must continuously improve the output of their equipment. Searching for improvement leads many companies to seek innovations from their equipment manufacturing partners. One innovation is the use of Lifecycle Tracking, our term for prognostics – an engineering discipline focused on predicting the time of component failure.  Lifecycle Tracking is more efficient than traditional methods of maintenance because a prognostics-based maintenance program takes machine factors into consideration, especially those factors that have the largest impact on wearing parts. Companies who implement prognostics-based maintenance programs demonstrate reduced un-planned machine downtime and reduced need to have spare parts on hand. These substantial advantages should drive widespread adoption of the use of prognostics on the plant floor but that has not occurred. This is probably because implementing a prognostics program is above the capabilities of the manufacturer.

The Ei3 enterprise remote monitoring server has the ability to support an application that delivers Lifecycle Tracking our machine-focused prognostics package.  The setup of the parts and their wear profiles are configured by both the machine manufacturer’s engineers and the machine owner’s maintenance team. The result is a packaged prognostics solution that can be delivered to end customers using the proven Ei3 Software-as-a-Service method.

Each machine is comprised of has many parts and each part has a generally known lifespan where the lifespan is based on machine usage, calendar time, environmental conditions like temperature / humidity or a combination of all. Reports on the suggested replacement and maintenance of parts provided to machine owners to enable better planning of service activities and a reduction of spare parts required on hand. This method reduces inventories, shortens delivery cycles and frees up capital for the machine owner to use in better ways.  By tracking machine usage and other critical machine parameters it is possible to, on a part-by-part basis, determine how much wear has occurred and when the next maintenance activity should occur. Reports describing the upcoming maintenance activities are delivered on a timely basis to enable effective scheduling of service visits.  Lifecycle Tracking is easy to configure and provides visual tracking tools for authorized users. The reports drive the workflows of internal and external service teams and maintenance departments.

Recipe Management

Designed for manufacturers within the continuous processing industry, our complete Recipe Management system uploads machine settings, tracks recipe changes, and monitors process efficiencies. We give you a method of measuring, categorizing, and setting the machine parameters necessary to produce quality product and reduce product changeover time and the possibility for operator error.

By using recipes, operators can input new product setpoints by simply entering a code. This tool includes OEE and productivity analyses to demonstrate which recipes were most effective and which made the most footage or consumed the most machine time.

Recipe Management uses historical information to estimate time to complete future orders and to calculate which recipe setpoints are most effective to maximize OEE.

A change log indicates the exact time a change is made to a setpoint, and alarming capabilities are built in to indicate variation from the product’s designed specification. By implementing recipe management, an organization is able to gain better control over its manufacturing process and achieve better performance.

Quality Management

Quality Management is designed for the converting company that wants to implement quality tracking best practices, six-sigma or SPC. Quality Management puts workflows into action that enable organizations to reach higher yield and productivity goals.

A Critical to Quality, or CTQ, parameter defines the manufactured characteristics your customer expects of your products. Therefore it is important that the results of tests for the CTQ parameters are available for analysis and reporting within your organization. Quality Tracking provides you with the ability to manage, input, track and report on CTQ parameters. Further, machine parameters are constantly monitored and correlated to the CTQs enabling benefits of advanced quality management and SPC.

Quality Management provides tools to implement a product quality program. Quality managers, six-sigma black belts, machine operators and production personnel are provided with web pages that guide their activities. Data is acquired, displayed, reported and archived to drive all facets of a quality program.

Administrators define quality tests and limits for CTQs. Machine operators are provided with clear web page forms to input their test results. All data is stored and displayed in real-time on a quality dashboard. Machine parameters are monitored using patented secure on-line technology. Reports are generated for management. And the archived results serve as quality certificates for end customers.Learn More…

Energy Management

If your manufacturing organization has multiple plant sites and you desire to get an accurate measurement of the amount of energy and water used in the manufacture of your products as well as how much waste is produced, then our Energy Monitoring application may be a perfect fit. Since 2000 we have provided organizations with a tool that enables measurement and reporting of the costs and consumptions for utilities at remote facilities.  Our energy management application can be used across the globe, we support multiple engineering units, languages and currencies. We have linked up to weather services around the world to provide weather data for degree day normalization of energy usage.

You get enterprise reports showing Key Performance Indicator numbers that describe the energy usage, energy intensity, cost summaries, and rate summaries for all the utilities you want to track, including; electricity, gas, oil, CHP, steam, water, and waste. Also if you have organization specific metrics you would like have included for KPI calculations they can be accommodated. Individual manufacturing facilities get their own reports that describe the local performance. Comparisons are made versus prior years, benchmark years, budgets and forecasts.

Our energy management application acquires data through three methods, remote monitoring of production equipment and utilities meters, utility bill data input and manual meter readings. If remote monitoring is used to acquire data, then abnormal consumption alarms can be programmed to alert you if there is a significant change in your use of any of the monitored utilities.

Endoia

Remote service technicians are continually challenged to keep track of complex networking configurations for establishing communications to remote devices. This is especially problematic for the Siemens S-7 family of controllers where unintentional changes made to the PLC communication configuration can alter its program thereby causing a loss of communication and disruption of the machine operation.  Ei3′s Enodia desktop helper application solves this critical issue. Enodia enables IP address and port redirection during simultaneous remote machine connections over Ei3’s Argo remote service network.  Enodia, symbolically named after the Greek god of gateways, creates a transparent gateway over the secure Ei3 network, between computers using Siemens Step 7 PLC programming software to a Siemens Step 7 PLC on a machine.

Enodia is a desktop executable program that requires no installation by the user making the remote connection into the PLC.  In comparison to other PLC applications, Enodia has a significantly smaller footprint that has no effect on other computer programs and requires minimal computer resources.  To further benefit the user, Enodia features status indicators for each device on the machine being remotely accessed.  Enodia makes it possible to easily connect to Siemens PLCs and other remote devices using the local IP address and port configurations thereby making the remote service network completely transparent to the technician’s programming software.

Enodia is a secure application that provides granular access to targeted machine control devices through the use of an Ei3 Argo session security key.  Using an Argo security key ensures that Enodia only grants access to authorized users of the remote service network. One important usability feature of Enodia is its ability to automatically gather a list of machine devices from Ei3’s Argo remote service platform. As with all Ei3 remote monitoring over Internet products, exceptional security measures are implemented and maintained to guarantee the privacy of our partners and end-customers.

Learn more…

Comments are closed.