Introduction
Acquiring real-time data from the production line is a key process that enables the monitoring and collection of information from various sources within the manufacturing environment. Thanks to this process, you can obtain up-to-date data regarding machine status, production processes, and manufacturing performance. Data acquisition allows for a rapid response to failures, process optimisation, and making accurate business decisions.
Companies that want to focus on growth and process improvement should regularly collect and analyse data from the production line. Find out what data acquisition is all about and how modern systems facilitate real-time information retrieval.
Introduction to real-time data acquisition
Data acquisition in manufacturing is the process of collecting useful information from every area of the production line, and then visualising it in an accessible format. This activity is an absolute foundation for effective company management and the first step towards optimising the processes taking place in the plant.
Additionally, properly presented data from the production line makes it possible to catch machine failures before they even occur. In this way, owners save not only time but, above all, money, as they prevent downtime.
Analysis of enterprise requirements
When designing a customised MES system, the most important stage is the analysis of the requirements and goals of the enterprise for which the individual solution will be created. This phase consists of two steps – an audit and defining business goals (if the company has not specified them yet).
Key technologies and tools
More and more entrepreneurs are becoming aware of the risks associated with manual data collection from production. This activity, when performed by employees, significantly extends the entire process and is prone to human error. Just one incorrectly recorded number can affect making an important business decision, and the company’s future could be seriously jeopardised.
Therefore, it is highly responsible to use modern real-time data acquisition systems. Such a solution automates this process and minimises the risk of error almost to zero. What systems can a manufacturing plant use?
SCADA systems
The SCADA system is an indispensable element in the data acquisition process, enabling the monitoring, control, and optimisation of production processes. SCADA (Supervisory Control And Data Acquisition) is an advanced system that retrieves data from the production line in real time, with its additional functions being visualisation and archiving.
Key functions of SCADA:
- monitoring and collecting production data in real time;
- automation of industrial process and machine control;
- collecting events from the production line and analysing the gathered information;
- sending notifications about events and alarms;
- data archiving.
However, if you want the SCADA system to perform these activities, it must be integrated with sensors and other measuring devices. These devices can be either digital or analogue.
Almost every branch of industry uses SCADA systems. Thanks to extensive visualisation and archiving functions of the collected information, they enable the control of the vast majority of processes. Additionally, properly collected and processed data allows operators responsible for supervising production to gain control over the entire automation system.
Internet of Things (IoT)
IoT is a network that encompasses various machines and devices capable of acquiring and transmitting data, equipped with the necessary communication infrastructure – wired or wireless. The most important goal of this modern solution is the optimisation of production processes and their effective management.
However, for the Internet of Things to perform its function, it is essential to connect various smart sensors, controllers, mobile devices, computers, and the necessary software.
IoT is a network of interconnected smart devices that together form a coherent system that constantly monitors, collects, and analyses the gathered data.
In manufacturing, sensors for monitoring machine condition and the quality of manufactured products are most commonly used. Connecting them to the IoT enables the early elimination of potential faults or failures on the production line. In this way, operational costs are effectively reduced, and performance management is significantly improved.
Benefits of real-time data acquisition
Implementing an advanced system for monitoring and gathering information is a step towards a significant modernisation of the manufacturing plant. How does real-time data acquisition contribute to process optimisation and increase performance indicators?
Process optimisation
- Strict control of production parameters – real-time data acquisition enables the monitoring of key production parameters in real time. This allows managers to react instantly to any deviations, eliminating the risk of errors and minimising losses.
- Accurate forecast of material consumption – precise data on raw material and material consumption provides the information necessary to optimise the production process. Predicting and managing inventory becomes more effective, which in turn translates into minimising losses and reducing production costs.
- Real-Time Adjustments – real-time data acquisition enables instant adjustments of production parameters based on information transmitted around the clock. This flexible approach to production management translates into increased efficiency and shorter production cycle times.
Performance indicators
- OEE monitoring – data acquisition enables continuous monitoring of machine efficiency indicators, including OEE. This allows for the identification of areas requiring improvement and a quick response to any downtime or drops in efficiency.
- Predictive maintenance – data collected in real time allows for the early detection of potential technical problems. This makes it possible to implement a predictive maintenance strategy, resulting in minimised downtime and longer machine operating life.
Challenges and solutions
The decision to introduce a change naturally comes with potential challenges. Below you will find a description of situations you might face when implementing real-time data acquisition in your manufacturing plant.
Data integration from various sources
Machine diversity
One of the biggest challenges is the number of diverse equipment models in the plant. How to effectively collect information from each machine? The solution can be the implementation of universal communication protocols, such as OPC UA (Unified Architecture), enabling seamless integration of data from different types of machines.
Communication standards
Communication must be effective not only between humans and machines, but also among all employees. It is worth considering the introduction of cyclical meetings for individual teams, during which employees will share work progress and report any potential problems. At slightly longer intervals, meetings with representatives of each team should also take place to ensure a free flow of information.
Data security and privacy
Real-time data acquisition carries potential risks related to data security, such as cyberattacks or unauthorised access.
To further secure the most important data for the enterprise, information encryption should be used, which means encoding it in such a way that a person without the appropriate key cannot read it.
To protect data, each employee should have a defined scope of access and authorisation to check only the information they need to perform their daily duties. Remember to maintain a hierarchy of access to individual datasets – a manager will have access to different information than a production engineer.
The iPLAS system enables real-time data collection from any point on the production line. Our modern solution also excels at retrieving information from different factories, which it then gathers in one place so that you always have the most important data at hand. Another highly significant functionality of the iPLAS system is the ability to visualise the collected information in your chosen format – a table, chart, gauge, or synoptic map.
Do you want to make accurate business decisions based on reliable data? Choose iPLAS, the innovative software for the manufacturing industry!
