- Beacon sensor: This is a device in the form of a strip, which attached to a machine beacon is able to detect its status and trace it back to our platform. In this way, finished parts, alarms and stop states can be detected on machines without connectivity.
- Inductive sensor: Finally and for the final counting, an inductive sensor was introduced in the last machine of the line, which allows us to directly count the parts it produces, key data to measure productivity and OEE.
- Interaction with management data: Not only focused on obtaining real-time data, another objective of this project was to link these with Nissan's management data. To achieve this, we connected to a self-developed MES system, already implemented for some time in the company and where managers and operators could enter work data manually. By crossing their data with the line data, we managed to unite two worlds, normally separated or only linked through Excel, being able to compare what was planned with reality and being able to add context to the line data, on the same screen!
Benefits obtained
Once it has been put into operation and with the iterations and full involvement of the Powertrain team, these are the main benefits obtained:
“The solution has also allowed us to save on structural personnel, since all management is done without having to travel thanks to mobile notifications.”
Miguel Ángel González, Senior Supervisor Machining
“With this solution we have had control of a key line for the factory which, being automatic, is unattended, being able to know and correct its efficiency failures.”
Jorge Ferrís, Ingeniería de Producción y Facilities
Real-time line visibility at a glance
One of the first and fastest was the visualization of information in real time (parts, production rates, cadences, etc.). But thanks to Minerva's calculation capacity, from this input data, we generated calculations of efficiencies, rates, etc. with which to give more value to the information, respond with data to new questions, but above all to be able to know in reality how their lines were working with respect to planning and "theory".
As it happens in almost all our projects, being able to share this useful data for day-to-day planning, the Nissan Powertrain team decided to add TV screens in their offices, from which to see the platform in real time, viewing the different lines, at a glance, with their indicators and alarms. In this way they can make informed decisions in real time, minimizing the impact of the problem and thus increasing the efficiency and production capacity of the lines.
It can also be viewed from any mobile device connected to Nissan's corporate network.
In addition, the visualization allows both generic and variable-specific visualization. Advancing from a view of each plant, to the data of each machine, to never see more data than is necessary according to the user profile allowing the solution to scale seamlessly.