principles how does it work? - rs components · 2019. 10. 12. · to the tablet. examples of...
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Real-time machine performance tracking
Principles
Developed in collaboration with industries and Lean experts, PerfTrak is an innovative turnkey
system based on Internet of things that allows industries to understand the root causes of their
performance losses and to gather, visualize and export information from any of their
production facilities in real-time. PerfTrak relies on advanced algorithms, combined with the
input from the operators and the latest communication technologies (Sensorics, Android,
Bluetooth Low Energy, WIFI) to deliver real-time meaningful production information, to monitor
performance and to generate continuous improvement in an intuitive and cost-effective manner.
How does it work?
The PerfTrak electronic module is connected with sensors (or to automaton) to machines or
control points and brings objective data about the current working state and cycle time. By
registering the deviations of working state or of cycle time, the module identifies performance
losses (stops, slowdown) and sends them per Bluetooth to the PerfTrak tablet. From there,
operators can complete the loss information with rich/subjective information (the what and how)
on the Android interface by selecting an issue for each loss among a list. This data is then encrypted
on a secured server and is available on a monitoring website for data consolidation, visualization
and exportation in real-time. On this website, operators and managers can visualize production
information through user-friendly analysis tools (Product Count, History of Losses, Pareto of
Losses, Dashboard of KPIs, Automatic Reports, etc.). Real-time alarms are also available on
smartphone to be alerted on any critical production or performance deviation.
Application fields
Thanks to their external implementation and their autonomous operating mode, PerfTrak systems
can be installed quickly in a wide range of situations and are compatible with nearly every
manufacturing equipment, modern or recent, to track causes of down-time and slowdowns.
PerfTrak can also easily be integrated into information systems (ERP, MES) to complete them as a
« brick » for real-time performance tracking. The high compatibility, the price and the scalability of
PerfTrak systems have seduced more than 50 factories worldwide, SMEs or MNCs from several
industrial areas such as automotive, aircraft, food, railway, glass, white goods or electronics
industry.
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Acquisition of production information
Identification and calculation of performance losses
The PerfTrak electronic module measures the time between two production events (ex: two
passages of product or two different machine states) by recording the rise and fall of the sensor’s
output voltage: each time the time between two detected voltages is higher than the configurable
theoretical time, the modules records a loss and sends it per Bluetooth Low Energy to the Android
tablet (range between 30 and 100m).
In order to acquire production data through cycle time or working state signal, the module can be
externally connected to sensors (optical, contact, magnetic, position, current) or to an automaton’s
output through a relay (by receiving a simple binary IN/OUT electric voltage). The PerfTrak module
captures data with its 10bit ADC circuit, which makes it compatible with most analog sensors such
as optical, hall or contact sensors, as long as their voltage is compatible with a supply within the 5-
25v range. The module runs with a 230VAC-12VDC supplier (12 or 24V). Once paired with the tablet,
communication with the module is not possible from another device.
Module reinforcement
Types of concerned machines
Thanks to its quick and external implementation, PerfTrak is compatible with most production
setups and covers two types of machines:
1. Cycle time machines
Every rise or fall of voltage means the end (or
the beginning) of a cycle. When the cycle time
measured between two periodic events is
superior to the configurable theoretical cycle
time, the module records a loss and sends it
to the tablet. Examples of compatible setups:
press machines, machine tool, packaging
machines production with discrete parts, line
bottlenecks, etc.
2. Start/Stop machines
Every rise or fall of voltage indicates if the
machine is in “Start” state or “Stop” state.
Every time the machine is stopped longer
than stated in the configurable theoretical
operating time, PerfTrak records a loss and
sends it to the tablet.
Examples of compatible setups: conveyers,
pump, machine tool with very long
production cycle, single part production, etc.
To fit the harshest industrial environments, the PerfTrak DIN
module can be assembled in an industrial solid box to prevent
from microstops, overvoltage and electromagnetic
interferences.
DIN module
Pre-assembled box
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Input of causes of non-performance
The PerfTrak Android rugged tablet allows operators to select among several loss categories the
proper reason of each performance loss transmitted by the electronical module via Bluetooth Low
Energy. Each loss is displayed on a line on the tablet with date and duration information. Each
tablet is dedicated for one machine and can have several products with their own standard
theoretical cycle and alarm triggering time.
Features
• Inform issues to input the root cause of performance loss
• Split loss in two losses to input several origins of loss
• Modify already informed root cause of loss through History
• Access Waste Management to inform issues after the production
• Change products to switch theoretical cycle time or operating time of products
• Display analysis tools: Product Count / Top5 Pareto / 24h loss history
• Display KPIs (OEE, TEEP, custom) of last hour, day, week or shift
• Parameters (update of website configuration, 9 languages, display options etc.)
Characteristics
The 2.4 Ghz tablet, developed for industrial environments is waterproofing, has a high resistance
to shocks, has M8 connectors, an external WIFI antenna and is protected against electromagnetic
interferences. Its screen with tempered glass prevents scratches and makes the tablet easy to clean
and to use. The tablet can be fixed to any support with any VESA 100x100 tablet arm. The PerfTrak
Android app is compatible with any hardware running Android >4.4, with 1gb of Ram, >1ghz
processor, Bluetooth 4.0 chip and an Internet connection using WIFI or Ethernet cable. This product
requires a license to operate. 1 month of license offered.
OEE 90%
OEE
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Configuration features
On the PerfTrak monitoring platform, each tracked machine can be virtually created and assigned
to several related elements such as tree of loss categories, operators, products, shifts, workshops
or factories. This allows PerfTrak to consolidate information and refine analysis tools per
equipment, operator, area and period. Managers can give access rights to sub-managers so that
they can access PerfTrak tablet configuration, modify trees of losses or modify already informed
losses on their perimeters. It is also possible to give some rights to the operators such as access to
tablet configuration or to modify an already informed root cause of loss.
Analysis features
Besides the configuration tools, PerfTrak web platform also offers a set of analysis tools to analyze
the performance of their machines in real-time, consolidate the production data of several
equipment and access analysis tools, based on the registration of performance losses.
Performance indicators
A dashboard is provided on the supervision interface to edit fully configurable KPIs based on OEE
main categories and add as much indicators as wanted with consolidated data for one or several
equipment, workshop, factory, etc. Indicators are in real-time or on any period of time (minutes to
years).
Performance history
PerfTrak users can visualize the repartition (%) of origins of losses by period, factory, workshop,
machine or operator.
Workshop 1 Machine 2 Factory A
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Pareto of losses
The Pareto gives quantified details (rank, occurrences, duration) of each category of performance
losses to quickly understand what the main performance losses are.
Product Count
With the Product Count feature, teams can have a view on the number of produced products and
compare them with the production goals per reference, hour and day. This tool is also available on
the tablet on a diagram and through a real-time counting of produced pieces.
Alarms
Besides visual alarms on the production line that indicate if the machine is running or not, Perftrak
users can get notified on their mobile phone in real time of any performance loss judged critical
and respond quickly to associated issues. Every operator, manager or factory manager can get the
alarms in real time on the machines that they follow and select performance level alarms (if
production team) or machine state alarm (if maintenance team).
Machine 2 Workshop 1 Factory A
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Automatic reports
In order to quickly take the right corrective actions, PerfTrak users can edit manual or automatic
PDF reports to gather the key information of their choice for each equipment, product, workshop,
operator or plant and over a customizable period (per shift, day, week, month or customizable time
basis) and frequency. Reports are available as PDF files and can be directly sent per mail on a
customizable frequency and period.
Raw data
The raw data of each analysis feature is exportable via xls or PDF file. If they want to carry out
further analysis to complete PerfTrak features, PerfTrak users can access at any time the whole
database or export graph data.
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PerfTrak systems include the mentioned earlier Hardware & Software elements in one solution:
the module, the tablet with PerfTrak App, the luminous column (red, white, green andons + buzzer)
and the access to PerfTrak website. Plastic box and tablet arm can be purchased by contacting
directly TEEPTRAK team or can be bought in any industrial shop.
PERFTRAK ELEMENTS
TABLET X1
ANDON X1
MODULE X1
TABLET ARM
SENSORS
OPTICAL CONTACT HALL
RELAY BATTERY
OPTIONAL
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Thanks to sensors connected to the module and externally installed on the production line, no
direct connection with automatons software or IT systems is mandatory for the installation of
PerfTrak. Installation may be carried out within 2 hours in 3 easy steps:
1. Connect the module to sensors on the production line
First possibility is to connect the module to a sensor by setting the sensor in a way that allows it to
detect the passage of the machine or of its produced pieces so that factories can properly register
the cycle or operating time.
Otherwise, the module can be plugged to an automaton’s output that represents the production
cycle time or working state (through a simple binary 24V signal).
CONNECT THE MODULE TO SENSORS OR TO AN ELECTRIC SIGNAL
Optical sensor Contact sensor Magnetic sensor Electric signal
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2. Install the luminous column and the tablet on the production line
The tablet has to be connected with WIFI or Ethernet and can be easily fixed to any structure thanks
to its standard VESA mount. The luminous column must also be installed on the line to warn
operators if the machine is running (green light), stopping (red light) or if there is a performance
loss that needs to be informed (white).
3. Configure the monitoring website and access analysis features
The monitoring website allows PerfTrak users to virtually create the different tracked elements and
assign them together. For instance, each tracked product has to be assigned to a machine which
belongs to workshops, operators, managers and factories. To make operators’ life easier, all tablet
configurations can remotely be done from the web interface. For instance, the categories of losses
displayed on the tablet to inform losses have to firstly be created on the platform.
Reminder: The platform gathers all information that is transmitted via the tablet per WIFI in order
to analyze the performance of machines in real-time, consolidate the production data of several
equipment and deliver simply analysis tools, based on the registration of performance losses.
INSTALL THE TABLET
Install the
tablet arm
Bolt tablet with
M4 screws
Connect to the Internet
and install application
installer l’application
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Elimination of paper-based reporting
Intuitive access to performance information
High compatibility
Reactivity
The automation of time-consuming reporting tasks allows teams to
focus on value-added tasks to improve effectiveness in a sustainable,
efficient and continuous manner. The daily production supervision and
the view of root causes of performance losses through intuitive analysis
tools allow teams to easily understand what prevents them from
reaching the "ideal" performance and to quickly take the right
corrective actions.
Factories can monitor their performance in real-time thanks to intuitive
analysis tools and customizable key performance indicators based on
performance losses. For each analysis tool of the monitoring website,
data can be filtered by period, machine, workshop, factory or operator
to get a flexible and precise understanding of equipment productivity
in real-time.
With its external installation mode, PerfTrak is compatible with nearly
all machines, old or recent, and does not need to interfere with
machines, IT systems or automatons. However, Perftrak can be easily
implemented into existing MES or ERP to complete them. The robust
tablet and module are also compatible with harsh industrial
environment and can withstand electromagnetic interferences,
overvoltage or material projections.
Real-time information and mobile alarms allow teams to react to the
smallest gap and continuously improve their machine performance.
Teams can receive alarms on smartphone to be warned of any
performance or working state deviation.
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Enhanced productivity at low cost
Secured data
Operators in the Industry 4.0
Possible custom development
Easy maintenance
With a price 2 to 20 cheaper than its competition, PerfTrak allows
industries to achieve quick ROI and productivity gain from 5 to 15
points within few months thanks to the comprehension of their main
performance losses. causes.
All data is stored on an SSL-encrypted server so that factories can
securely visualize information from all over the world in real-time. The
SSL certificate is verified by the third-party GeoTrust and PerfTrak is
protected against the most frequent cyber-attacks.
Each PerfTrak element can be disconnected and reconnected to the
“chain” without losing data.
By using the know-how of operators for the data enrichment of
performance losses, PerfTrak involves operators in the continuous
improvement process and values them through the use of new and
intuitive technologies. Perftrak users have different login and access
rights to the parameters of PerfTrak.
If needed, TEEPTRAK engineers can carry out custom IT
developments for specific demands regarding the different software
features of PerfTrak (ex: customizable dashboard or reports).
Besides their easy installation, PerfTrak systems are also easily
replaceable and require no maintenance. TEEPTRAK team
guarantees free customer-service and change of defective
components. Both the electronic modules and the Android
applications can be remotely updated allowing factories to benefit
from a lasting turnkey solution.
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OEE & TEEP
The Overall Equipment Effectiveness (OEE) is the most frequent indicator found in manufacturing
industries to evaluate the effectiveness of a given manufacturing operation by measuring
effectiveness against scheduled production hours.
OEE = Availability ratio x Performance ratio x Quality ratio.
The Total Effective Equipment Performance (TEEP) measures effectiveness against total calendar
hours (24/7/365 days per year). Contrary to the OEE, “planned shutdowns” are included in its
calculation.
TEEP = Availability ratio x Performance ratio x Quality ratio x Loading ration
To build its indicators (OEE, TEEP, …) and its analysis tools, PerfTrak relies on the OEE and TEEP
standards of the AFNOR norm. However, they remain fully configurable to custom the calculation
of the performance according to the standards of each factory: each indicator can be customized
by removing categories of loss from its decomposition. That’s how the Overall Operations
Effectiveness (OOE or « Lights On ») can also be calculated.
AFNOR Norm: Decomposition of OEE and TEEP indicators
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Indicators and loss categories
During the installation of a PerfTrak system, users have to create on the monitoring website the
different categories of losses that will be displayed on the tablet. They can create trees of losses
to input, modify or remove different types of performance losses in each main loss category :
-Loading category (example of losses: planned shutdowns and down-time such as meetings,
break time, testing, preventive maintenance…)
-Availability category (ex: unplanned down-time such as break-downs, changeovers, upstream
waiting…)
-Performance category (slow-downs, micro-stops, incomplete loadings…)
-Quality category (ex: quality losses)
Inside these 4 main categories, PerfTrak users can add their own loss reasons on two levels: these
losses are editable at any time and updatable on the tablet software associated to the tree of
losses.
An example of tree of losses with performance losses on two levels
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PerfTrak performance indicators (OEE, TEEP or custom) can be visualized at any time on the
website’s dashboard, on automatic reports or on the tablet.
Their calculation depends from the different categories of loss that have been selected during their
configuration: if it is an OEE, the category “Loading” (planned stops) is not selected.
Furthermore, teams can edit custom indicators by creating new loss categories and putting them
into the calculation of the new indicator.
Creation of an OEE indicator: selection of Quality, Performance and Availability categories
The website’s dashboard allows users to visualize indicators on a selected equipment and period
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Server security
PerfTrak production servers use private network and firewall to expose only public services HTTP
and HTTPS. The HTTPS protocol uses SSL certificate (256 bits) verified by the well‐known third party
GeoTrust and unsecured HTTP traffic is redirected to encrypted HTTPS protocol. PerfTrak system
is operating with an internet connection for tablets (Wi-Fi or RJ45 cables) which sends SSL-
encrypted information to PerfTrak server, ensuring the highest level of security and allowing
PerfTrak users to visualize consolidated performance data from everywhere in real time and on a
secured manner. It’s however possible for PerfTrak engineers to setup a custom dedicated server
either in an external data center or on an internal network to keep data on site if needed.
PerfTrak back office has been developed using Ruby-On-Rails framework that includes technology
and tools to avoid security leaks. Perftrak server is protected against most frequent attacks: SQL
injection, Cross Site Scripting (XSS), Cross‐Site Request Forgery, Header injection and more.
Data protection
All database synchronization code has been programmed internally and all data is backed‐up on
another server provided by OVH. Data is and will always remain the personal property of each
PerfTrak user: the data is stored for 5 years or more in PerfTrak archives with the possibility to
download it at any time. Each Perftrak element can be disconnected from the “chain” and
connected again without losing data. Data usage per system is around 500Mb/month. Transfer
speed is limited to few kb/sec to minimize data traffic and prevent data in rush.
Access rights to PerfTrak interfaces
Administrator can create unlimited sub-administrators, managers and users. For all of them,
specific rights can be allocated (creation of factory, workshop, machines / creation of products, loss
tree / access to parameters on tablet, on supervision interface / etc.). So, even if administration is
centralized, PerfTrak users can easily delegate powers and data access rights through hierarchy
levels.
Each tablet is identified by an UDI (Unique Device Identifier) and needs to be authorized by our
service before being activated. The access to the PerfTrak server is strictly restricted to
administrators and authorized PerfTrak staff.
