Production line optimization and diagnostics

How do production control systems improve the production line?

Plants with production lines are facing many challenges. The fourth industrial revolution will be the automation of processes. The previous revolution was also related to production automation through the introduction of digital coding. Currently, companies are being introduced to modern IT solutions focused on collecting and processing as much data as possible. So it does not matter whether we are talking about a plant with ten or a thousand employees.

Every business owner wants to optimize production processes, increase safety of employees, speed up production, increase efficiency and reduce production costs. All this can, and certainly is guaranteed by modern automation of the production line. More and more we are talking about software and databases, which, it is already obvious, are the future of industry and production line management. 

Definition of optimization

Optimization means organizing, making things more efficient, or structuring processes or activities in such a way that they produce the highest possible results with the lowest possible cost.

Definition of diagnostics

Diagnostics is determining the condition of equipment and identifying sources of failure.

Definition of a production line

Production line is a set of devices (machines) put together and controlled in a way that allows the integrated functioning of the whole. Most often, workstations are set up according to the order in which technological process operations are performed. Each product must pass through the workstation and this is what we call a production process. The finished product is always the end result of the production line. A production line should integrate three components: quality, productivity and safety. It should therefore keep the quality with each product, produce as much as possible and not create any danger to the environment and people.

The characteristics of a production line may be partial or fully automated production, the use of safety systems, and a master control system that integrates the operation of the line. 

Optimization and diagnostics of the production line

We should start talking about optimization of the production line, when there is a doubt that our production line is being used fully and effectively. If we think that the technological process in our plant takes too much time and the costs are increasing, the optimization process will be the best solution. Each optimization is connected with risk assessment and detailed analysis of the production system. Only then we can determine if and what should be improved. It is worth mentioning that optimization is not only data collection and equipment monitoring. Optimization is also direct contact with employees, who have most in direct contact with the machines and can sometimes say more about them than the information in the database. Diagnostics of a production line is a very important element in every machinery park. The benefits are numerous - starting with the reduction of operating costs of machines or material, and ending with the safety of persons operating the production line. Machine diagnostics are based on measuring methods such as thermal imaging, or ultrasound.

How to optimize the production line?

The answer to this question is not easy. New studies, articles, seminars and trainings are constantly being written on the subject of optimization.  Modern software is not enough, if there is nothing to cooperate with it. Supervision over production line must be continuous and uninterrupted. Equipping a production plant with safety systems such as signal towers cooperating with sensors and broadly understood monitoring is the key to success of any production line.

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