In the last two weeks, I have explained the 1st building block of a Digital Factory (Connected & Transparent) and the Catalysts which accelerate the implementation of this.
The 2nd Building Block is CLOSED LOOP ACTIONS (CLA).
Closing the loop‘ means the output of a system feeds back to directly adjust the performance of the system. For example, a furnace & a thermostat work together in a closed loop to control room temperature.
3 EXAMPLES OF CLOSED LOOP ACTIONS
#1: CLAP (Closed Loop Auto-corrected Production)
The most common example is AUTO-GAUGING OF MACHINED JOBS & AUTO-CORRECTION OF CNC MACHINES. This ensures that near zero defect manufacturing can be done without relying on skilled operators & inspectors.
#2: CLAMP (Cutting Load Analysis based Machine Protection
In any shopfloor, on any machine, tools can get blunt without warning and then break, causing accidents (because of high operating speeds, there is NO reaction time)
CLAMP teaches each tool WHAT is the acceptable load range & WHEN cutting load exceeds limit, it stops machine in a fraction of a second thereby protecting the machine.
# 3: MAIS (Machine Accident Information System)
Majority of collisions/accidents in machines go unreported. These inflict ‘Internal Injuries’ which result in premature failure of Spindles, Axis assemblies & other expensive parts. These sudden failures stop production lines causing huge losses & upset customers.
MAIS detects a) Accident b) Intensity and instantly sends message to designated persons & also records in machine daily performance report. MAIS can also ‘lock’ the machine in case of frequent accidents or heavy accident.
CONCLUSION: CLOSED LOOP ACTIONS are a critical building block of a Digital Factory because of 3 reasons:
- Certainty of Action
- Speed of Action
- Correctness of Action
Indian manufacturers should lay the 2nd Building Block immediately after the 1st is laid. Huge jumps in PROFITS & COMPETITIVENESS will come as a result.
JAI HIND.
