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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EATON C825KN10 200A 600V Contactor Ser A2 120V
1762-IF4 Analog input module
FC-PSU-240516 Power Supply Module
3500/42M 140734-02 Proximitor Seismic Monitor
FOXBORO P0973JX Industrial switch
1440-DYN02-01RJ Dynamic measurement module
GESAS CAN-DPV 1168411 AMPLIFIER MODULE
FBM201D Analog Input Interface Modules
MSK030C-0900-NN-M1-UG1-NNNN R911308684 motor
1746-NI4 four-channel analog input module
Allen-Bradley 1746-NO4I Analog output module
1747-L552 B/C CPU MODULE
3500/92 136188-02 Communication Gateway
05704-A-0146 5704F Fire Control Card
Yaskawa JGSM-06 Position Controller
LAM 853-049542-173 Circuit board
SICK MZT8-03VPS-KUD 1054051 T-slot cylinder sensor
8MSA4S.R0-31 B&R servomotor
Allen-Bradley 1771-P5 power supply
ABB IMFCS01 Frequency counter module
YASKAWA CACR-SR07BE12M SERVO PAK DRIVE
41B5228X232 I/O Module CL6921X1-A6
41B5228X192 Analog Interface I/O Module CL6921X1-A6
41B5228X082 Analog Interface I/O Module CL6921X1-A6
41B5228X072 CL6921X1-A6 Analog Interface I/O Module
41B5222X44R Analog I/O Module CL6821X1-A5
41B5222X422 CL6821X1-A5 Analog I/O Module
41B5222X36R CL6821X1-A4 Analog I/O Module
41B5222X35R CL6821X1-A4 Analog I/O Module
41B5222X33R CL6821-A5 Analog I/O Module
41B5222X242 CL6821X1-A5 Analog I/O Module
41B5222X232 CL6821X1-A4 Analog I/O Module
41B5222X222 CL6821X1-A4 Analog I/O Module
41B5222X072 CL6821X1-A3 Analog I/O Card
41B5222X092 CL6821X1-A2 Analog I/O Module
41B5222X072 CL6821X1-A1 Analog I/O Card
41B5222X032 CL6821X1-A1 Analog I/O Card
41B5222X032 CL6821X1-A1 Analog I/O Card
41B5215X122 CL6721X1-A3 Discrete I/O Module
41B5215X132 Digital I/O Module
KJ3243X1-BB1 Series 2 Plus Profibus DP Modle
KJ3222X1-BA1 Analog Input HART Module
KJ3221X1-BA1 Analog Output HART Module
KJ3221X1-BA1 Analog Output HART Module
KJ3242X1-BA1 Fieldbus H1 Series 2 Card
KJ3241X1-BA1 Redundant Serial Interface Card
KJ3242X1-BA1 Fieldbus Module
KJ1501X1-BC2 Power Supply
KJ1501X1-BC1 Power Supply
KJ3006X1-BA1 Power Supply
KJ2003X1-BA2 MD Controller
KJ2003X1-BA2 MD Controller
KJ2003X1-BA1 Controller MD Module
KJ3005X1-BA1 Controller Module
KJ3005X1-BA1 AS-i Card
KJ3001X1-CA1 Dry Contact Module
KJ3001X1-CA1 Discrete Input Module
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