Description
hardware flow control. It is an ideal choice in the field of industrial automation.
3 Case Studies on Reducing Scrap Rates
Any product assembled or produced in a factory goes through a series of quality tests to determine whether it needs to be scrapped.
High scrap rates are caused by the opportunity cost of not delivering products to customers in a timely manner, wasted personnel time, wasted
non-reusable parts, and equipment overhead expenses. Reducing scrap rates is one of the main issues manufacturers need to address. Ways to
reduce scrap include identifying the root causes of low product quality.
3.1 Data processing
Root cause analysis begins by integrating all available data on the production line. Assembly lines, workstations, and machines make up the industrial
production unit and can be considered equivalent to IoT sensor networks. During the manufacturing process, information about process status,
machine status, tools and components is constantly transferred and stored. The volume, scale, and frequency of factory production considered in
this case study necessitated the use of a big data tool stack similar to the one shown in Figure 2 for streaming, storing, preprocessing, and
connecting data. This data pipeline helps build machine learning models on batch historical data and streaming real-time data. While batch
data analytics helps identify issues in the manufacturing process, streaming data analytics gives factory engineers regular access to the latest
issues and their root causes. Use Kafka (https://kafka.apache.org) and Spark streaming (http://spark.apache.org/streaming) to transmit real-time
data from different data sources; use Hadoo (http://hadoop.apache.org ) and HBase (https://hbase.apache.org) to store data efficiently; use
Spark (http://spark.apache.org) and MapReduce framework to analyze data. The two main reasons to use these tools are their availability as open
source products, and their large and active developer network through which these tools are constantly updated.
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Emerson IC200PWR002 Control valve actuator
GE IC200ALG320 Current analog output module
yokogawa A1BA4D-05 Terminal plate
VMIVME-7807RC-410000 VMEbus Single Board Computer
VMIVME-7807RC-41400 VMEbus Single Board Computer
660-088884-002 GE power interface board
HMV01.1R-W0065-A-07-NNNN A driver controller
AO2000-LS25 Advance Optima Integrated analyzer
3500/92 136180-01 Communication gateway module
PFVL141V-14MN Roll Force Load Cells PFVL141
8200-1310 next generation 505D front panel
1394C-SJT05-T-RL servo controller module
V7768-330000 GE V7768 VME SBC
2198-S086-ERS4 Kinetix 5700 EtherNet/IP Servo Drive
IS230PCAAH1B CORE ANALOG I/O MODULE
PXIe-1085 NI PXI Chassis
3BSE080239R1 NE870 ABB industrial router
VMIVME-7768 6U single board computer
PXIE-5164 NI High-Speed Oscilloscope
HCS03.1E-W0070-A-05-NNBV Smart drives and power supplies
PM875-2 3BDH000606R1 AC 870P – PM 875 Controller
HMV01.1E-W0120-A-07-NNNN A driver controller
HDD02.2-W040N-HD32-01-FW A driver controller
PXIE-8861 Quad-core embedded controller
DS2020DACAG2 A power conversion module
IS200EGPAG1BEC Turbine and excitation control systems
PXIE-6556 PXI digital waveform meter
T8311C Trusted TMR Extended Processor
1394C_SJT22_A servo drive
PFCL201CE-20.0KN 3BSE027062R20 ABB Pillow sensors
PFCL201CE-50KN 3BSE027062R50X ABB Pillow sensors
IS210AEBIH1BAB GE Analog processor module
IS200AEPAH1A GE circuit board assembly commonly
D201832 METSO IBC controller module
D201138L METSO IBC controller module
REF543KM129BAAA ABB Mechanical terminal
REM545BG226BAAA ABB Mechanical terminal
8U-PCNT02 HONEYWELL Series 8 Controller
8C-PDODA1 HONEYWELL Series 8 Controller
8C-PDILA1 HONEYWELL Series 8 Controller
8C-PAOHA1 HONEYWELL Series 8 Controller
IS200JPDFG1AED Mark VI printed circuit board
IS200JPDFG2AED MARK VIe DC PDM CARD
PXIE-1095 NI PXI Chassis
8200-1311 Integrated Graphical Front Panel HMI Screen
H92A0K9M0500 FOXBORO DCS system
H92A0N9Q0H00 FOXBORO DCS system
AFV30D-A41262 duplex field control unit Yokogawa
PXIE-5122 779967-03 High-Speed Digitizer
PM865K02 3BSE031150R6 Redundant Processor Unit HI
PFCL201CE-50KN Pressductor PillowBlock Load Cells
MVR1600-4601 GE Air Cooled Rectifier Module
PPD513A24-110110 high-performance control system
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