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M-Box Introduction
- 1. Smart Monitoring: Connect existing SME manufacturersto the IIOT in an affordable way.
- 2. What is theM-Box? A shop-floor monitoring tool: • Monitor machine uptime and electricity consumption • Applicable to any equipment • Operator and product / project identifications • Instant notifications on mobile device on issues • Job scheduling via the portal • Integrated project management functionality
- 3. How it works Hardwarecomponents: • M-Box: 100 x 100 x 60 mm, is set to each machine via magnetized back or DIN rail • External sensors: • Photo voltaic sensor • Proximity (magnet) • Current sensor • PT 100 • Etc. • (Optional) Electricity meter • Smart cards: register operator and job ID • Wi-Fi Access point: dedicated Wi-Fi network for data transfer and remote access
- 4. External Sensors only •Universally applicable: sensors fit to any machine. • No interference with equipment electronics or processes • No connection to PLC: • No remote control • Completely safe against hacking • Easy to install, 30 minutes installation time per station
- 5. Smart cards • Employeeidentification Employees can have more than 1 card if running multiple stations • Project / production identification Card is assigned to job via the portal. As soon as the card is set to M-Box, the job is recognized and the system records. • Cards are re-usable Simply (re)assign cards to user/job via the portal
- 6. Optionals M-Box allows additionalconnections via 3 available USB Ports: • Additional Sensors, multiple through Rpi-Bus • External (Touch) Screen • USB Camera’s
- 7. Benefits • Increase uptime •Notifications to key team members • Cost price insight for smart decision making • Minimize electricity waste • Optimize workforce output • Improved maintenance scheduling • Fits to any machine: type, brand or age
- 8. Boost efficiency and effectiveness •Essential to cost-leadership • Uptime monitoring • Analyze downtime: cause and duration • Analyze cycle time and optimize production speed • Team (member) KPI’s: Set and improve • Team involvement through transparency
- 9. Instant notifications • Issueinstant notifications on any production issue • Reduce response time to unscheduled interruptions • Flexible system generates notifications on basis of recipient, place and time • Record of notification handling by team members
- 10. Cost price insight •Essential information for commercial decision making. • Guesswork leads to incorrect decisions: • Reject profitable order • Accept non-profitable order • Analyze and validate variable or integral cost price calculation.
- 11. Control electricity waste •Monitor waste on both production or auxiliary equipment • Get notified on a-typical power consumption • Awareness to realize substantial savings • Basis for financial incentives from government
- 12. Maintenance scheduling and conditionmonitoring • Increase equipment available time and optimize maintenance costs • Running hours or cycle-based maintenance as opposed to calendar based • Condition monitoring of (auxiliary) equipment to avoid unscheduled downtime • Performance monitoring of remote (auxiliary) installations
- 13. Implementation • Get startedimmediately with your IoT project • No IT expertise required, no consultants or development cost • Set modules for: • Injection moulding • Metal fabrication (CNC, EDM, Welding etc) • Assembly • Data are available immediately upon installation 28 percent of organizations don’t have the budget or human resources to implement and manage IoT projects MS-Azure’s report: IoT signals 2020 https://azure.microsoft.com/en- us/iot/signals/#challenges
- 14. Injection Moulding Module •Uptime / Downtime / OEE (in reporting) • Mould open / Mould close / Total cycle time • Electricity monitoring • Set or upload all your mould (configurations) and identify these on machine with Smart cards • Set or upload all materials / masterbatches • Set or upload production jobs • Video registration of machine/operator activity, auto save footage before and after machine goes idle • Notifications on: • Machine goes idle • Electricity usage when idle • Deviations from time set to specific mould configuration • Auto schedule machine and mould maintenance based on shot count, running hours or calendar.
- 15. Pricing • Highly affordable,fits small budget • SaaS based • Fees consist of: • hardware set-up (one-off, US$ 130 -180 per machine) • Subscription (monthly or annual plan, starting from US$ 0.26 per day per station)
- 16. Note: Customers haveaccess to all functionalities at the standard fees Monitor uptime and cycle time + Monitor Energy Consumption (optional) Understand where the wastes of your process are Level 1 Ensure a continuous-flow manufacturing by eliminating wastes from your process Improves the overall function of your business workflow • Assign Project manager • Classify reasons for downtime • Determine Cycle Time Deviation • Find the biggest cause of quality defects • Identify sources of energy waste (optional) Job scheduling for transparent planning + full analysis of completed jobs and orders • Reduce downtimes, cycle time deviation, quality defects and power consumption • Identify and implement improvements by Operator / Equipment / Project Full project management functionality with flexible Kanban boards and optimal work file management • Assign and track tasks to project team members for overall monitoring of project progress • Ensure timely completion of each project • Level your factory workflow based on demand Real time dashboards Kanban Boards Floorplan view Notification system Cost Price calculator Smart Cards Level 2 Level 3 M-Box implementation roadmap Make optimal use of M-Box in your total business process • Determine exact needs for revolving reporting • Discuss system integration with M-Box for communication between different systems (if required) Level 4 Tailored reporting and (ERP) integrations Tailored reports and API’s Here we give an impression on how the roadmap for implementation could look. “Diff’rent folks, diff’rent strokes” applies though. Select from all functionalities what is useful to your organization.
- 17. Database Portal Introduction •The following slide gives an impression on working with the M-Box portal. • A series of brief user-instruction video’s is available on YouTube (Link: www.tinyurl.com/mboxvids) • Our team is at your disposal for a demonstration
- 18. Data collection byM-Box (L1) • Which job is being worked on now • Who is working on it • Total productive time: • Per job • Per machine • Per operator • Cycle time (current and deviation from target in filter period)
- 19. Views: Dashboard (L1) •Overall information on different levels (1): • Per station • Per station group • Per department
- 20. Views: Station detailtable (L1) • Overall information on different levels: • Per station • Per station group • Per department • Details per station
- 21. Side panels (L1) 1-clickdrill down on stations / projects / jobs and tasks for easy access to relevant details and entry/editing details
- 22. Timeline view (L1) Stationactivity and details over time with job and operator details
- 23. Floorplan view (L1) •Unlimited and customizable plan views with machine tiles for individual machines • Create Andon boards
- 24. Notification system (L1) • Flexiblesettings on what to register as station activity (filter out short interruptions) • Set period of inactivity after which station is reported inactive • Send notification to supervisor and/or manager (according to settings) • Identify stop reason via programmable push button on the M-Box • Send alerts to support department for immediate response • When activity resumes, machine registers as active automatically. Notification alert remains for handling by superiors.
- 25. The Workflow (L2) UsingProjects and Orders 1. Work Orders (and jobs) are entered into the system: • Manually in portal OR • Excel upload OR • API with ERP 2. Work Orders are assigned to welding bay Production manager does this in M-Box portal 3. Jobs from work orders are created (assign smart card to each job) and assigned to stations 4. Welders receive job list with smart cards 5. Welders place cards on M-Box assigned to station when they go to work Quick Job Creation 1. Create a quick production job and assign to welding bay 2. No relation to client or project 3. Welders receive job list with smart cards 4. Welders place cards on M-Box assigned to station when they go to work
- 26. Schedule Jobs byswiping job cards (L2)
- 27. Work time andshift scheduling (L2) • Fully flexible work time scheduling into shifts for correct data presentation (OEE based on actual working hours) • Different schedules for different departments or machine groups can be set.
- 28. Project management (L3) “Papertasks” can be assigned and tracked to project team members for overall project progress tracking All tasks go through a sequence of statuses to monitor the progress Flexible Kanban board views with filters allow quick and clear insight in status per: • Project’s pending jobs (production) and tasks • Open tasks per team member • Jobs and job queue per station
- 29. Data storage (L3) STOREDATA ON PRODUCTS AND JOBS FOR USAGE IN REPEAT ORDERS ATTACH FILES (WORK INSTRUCTIONS, DRAWINGS, PICTURES) ALL USERS HAVE ACCESS TO LATEST, UP-TO-DATE FILE VERSIONS CONTROL WHO CAN ACCESS AND DOWNLOAD FILES VIA EASY AUTHORIZATION MATRIX
- 30. Reporting and (ERP)integration • All data remain stored while subscription is active • All data are downloadable in excel, csv for own analysis • Standard reports via Microsoft Power BI • Tailored reports via Power BI: • Prepared by client • Prepared by M-Box (chargeable) • Integration APIs on request (chargeable)
- 31. About MGC • Netherlandsregistered company (since 1961) with operational base in Guangzhou China (since 2006) • Privately owned • Business activities: • Injection moulding • Mould design and manufacturing • Assembly • M-Box • 46 employee workforce
Editor's Notes
- #2 Title: Industry 4.0 affordably attainable for existing operations and installations. Description: Affordable and creative monitor systems allow any existing operation to access the Industry 4.0 era. Boost productivity on the shop-floor via tracking of equipment uptime, labor productivity, and electricity consumption. Condition and performance monitoring of any remote, independently operating systems pre-empt issues. Universally applicable systems use external sensors and smart card technology. They come with proprietary software to present real-time data, issue push notifications (via website or mobile devices) and allow elimination of guess-work in cost price calculations for correct commercial decision making.
- #3 A: Instead of asking: What is M-Box? the question should be what does M-Box mean? or what does M-Box represent? or what does M-Box entail? Because in the bullets not only the definition of the product is observed, but also part of its attributes. B: Made some changes. I stick with simple question, though.
- #4 A: I think these details need to be mentioned: - Data are sent out via WiFi. - Cloud based. - Visible data in real time.
- #5 A: I think these details need to be mentioned: - No interference with other equipment’s electronics. - No interference with the processes themselves. - Identification of each data record received. - Verification on the server if all records are complete. H: The latter 2 are IMO not relevant for an intro
- #6 A: I think these details need to be mentioned: - Easily adhered to the M-Box via a magnet connection. (H: not relevant, clutter) - Reusable for new staff/projects. Key to: - Monitor any Operator/Equipment/Project combination. - Improve based on individual KPI’s of team members. - Analyze the final cost price or by components of the final product. H: Key to issue is addressed in following slides, I think.
- #8 A: I think these details need to be mentioned: - Product traceability. - Applicable to any brand or age of equipment H: I think traceability not mention here.
- #9 A: I think these details need to be mentioned: - Analyze Cycle Time: Deviation - Quality controls: Optimize - Production speed: increase - Planned Maintenance system: Improve H: Prefer to focus on main drivers for efficiency. Maintenance and quality not part of them.
- #10 A; I think these details need to be mentioned: - Well informed team - Flexible generation based on recipient, place and time - Preset notification filters - Record of notification treatment - Traceability H: Well informed team = evident. No need to mention. Traceability not relevant here.
- #11 A; I think these details need to be mentioned: - Visualization of the cost price per final product and its components. - Makes it possible to keep the cost price under control. H; we don’t have visualization. Other is evident.
- #12 A; I think these details need to be mentioned: - Monitor the power consumption for a specific area, department or machine group. - Analyze historical data. - Real-time notifications for atypical power consumption. - Awareness and substantial energy savings.
- #13 A: Note, for your review: Usage-based maintenance is a strategy that unites two approaches: The use of usage triggers + The use of time triggers. The idea is to estimate the average use of the asset over time with the help of the meter, establish the time between each occurrence and then associate these values with the calendar through a forecast. Therefore, instead of "Running hours or cycle-based maintenance as opposed to calendar based" I think it is more appropriate to say "Running hours or cycle-based maintenance in combination with the calendar instead of maintenance only based on the calendar" 1.- One question: Condition monitoring thanks to M-Box is only for auxiliary equipment, for now, right? H: Why would you use the system to estimate average running time, if you can monitor the exact production time and have maintenance jobs automatically scheduled when the need for scheduled maintenance is up? A; I think these details need to be mentioned: - Act based on usage triggers (running hours or cycles) + time triggers (calendar) = optimization of preventive maintenance of critical assets. - Optimization of maintenance costs. Increase in equipment available time. Condition monitoring to trigger predictive maintenance before failure (auxiliary equipment).
- #14 A: I think these details need to be mentioned: could be added somewhere on the slide but not as a bullet point: According to IoT signals 2020 (Microsoft's report, 3000 IoT decision-makers in enterprise organizations were interviewed): "28 percent of organizations don’t have the budget or human resources to implement and manage IoT projects" Note, for your review: IoT signals 2020 has already been published (October2020) https://azure.microsoft.com/en-us/iot/signals/ Vs. 2019: According to IoT signals 2019 (Microsoft's report, over 3000 IoT decision-makers in enterprise organizations were interviewed): "Nearly one-third of projects (30%) fail in the proof-of-concept stage, often because implementation is expensive or bottom-line benefits are unclear". I think it would be important to add in a bullet: - User accounts (Task & Job creators: monthly or annual plan, starting from $1 per month per user), operator accounts are free. H: not relevant IMO
- #15 Specific slides for Injection moulding, assembly, textile industry, CNC, EDM, welding
- #16 Specific slides for Injection moulding, assembly, textile industry, CNC, EDM, welding
- #17 Specific slides for Injection moulding, assembly, textile industry, CNC, EDM, welding
- #19 A; I think this is one of the most important slides as it explains how to implement M-Box in your factory and in fact I think this is a differentiator from the competition. I have not seen from any competitor how to implement their tools or advance with them, on the contrary they only show how to install or configure the tool. But this slide answers the question: What do I do after I install the tool? what is the way? hence its importance. From my point of view, the title of this slide should be How to implement M-Box in your factory? or How to advance with M-Box in your factory? I think it could be represented in a more attractive way. Could be a three-rung ladder. Looking at these three levels, I remember the three levels of Lean Manufacturing implementation: Understanding demand, ensuring a continuous flow, and leveling production against demand. So, I think we could give an M-Box identity to those three levels that you mention, for example: Understand where the wastes of your process are, Work for a continuous flow by eliminating wastes from your process, and Leveling your factory workflow according to demand. Although within the 7 wastes that Lean Manufacturing establishes are other wastes in addition to delays, I think that by monitoring uptime and classifying the reasons for downtime, we are working to understand where the wastes in the process are. Considering that the cycle time is also monitored as well as the energy consumption (optional). Below I show an example for the slide, I still think it is necessary to improve it, the idea is to show you an approximation of the idea.