To optimize their production processes and increase machine efficiency significantly, Festo AG capitalizes on Manufacturing Software from STIWA.
To optimize its production processes and significantly increase machine efficiency, Festo AG leverages STIWA's Manufacturing Software. The AMS ZPoint-CI Shopfloor Monitor and the ZPoint-CI Andon Board are new features that ensure more efficient production at Festo. Due to real-time monitoring of key production figures across all plants, power losses are immediately recognized, and malfunctions are repaired significantly more quickly.
The technology factory Scharnhausen is Festo AG's leading plant for the production of valves and electronic components and is the initiator of the digital production of the future. Efficient processes characterize this location. To improve machine efficiency, the company has relied on STIWA software for many years. Through seamless data recording and analysis of production machines, complex connections in production can be recognized, weak spots identified, and, therefore, a significant increase in performance achieved.
Individually adapted software
“It is especially important to continuously incorporate experiences from the production of innovative companies in the development of our software tools. In doing so, we test our software products in the real production environment from the start. Our customers, on the other hand, help to shape new features from the beginning and therefore have a significant influence on which tools that perfectly match their production requirements will be developed”, reports David Hinterreither-Kern, Product Owner of STIWA Manufacturing Software.
Target: Higher machine efficiency
The collaboration with Festo for developing new STIWA visualizing systems „Andon Board“ as well as “Shopfloor Monitor” was obvious: “We were already utilizing Andon Boards at some production lines. But the visualization of key figures was unclear, and relevant key figures were hard to read. To immediately recognize malfunctions, spot-on and clear information is necessary”, reports Benjamin Heim, Management assembly VUVG valves at Festo. “What was missing was an unmistakable overview across all machines and key figures. Additional headaches at Festo were also caused by the programming: The programming of Andon Boards via the machine control unit - depending on the machine supplier - was a very cumbersome process. “A simple, flexible and individually changeable configuration of displayed values and key figures was urgently necessary”, says Heim.
Optimized Andon Boards
For two days, STIWA analyzed production processes along with Festo production managers. Here, it became clear that the Andon Boards need to be clearer and more informative, especially for error messages. The displays were significantly upgraded with icons, color, and symbolic markings instead of text messages. All relevant key figures are now depicted self-explanatory, individual, and flexible, while also being adapted to current requirements. In addition, multi-layered recording and display can distinguish significantly more malfunctions. “Therefore, the machine operator is led to the problem much more accurately. This ensures significantly shorter distances and a more rapid identification as well as troubleshooting”, adds STIWA Software Developer Mario Mader.
Escalation levels ensure clarity
Additionally, the escalation management of the machine was optimized: The Andon Board now moves into focus of the machine operator according to a previously defined prioritization of various malfunctions and machine losses; this way, depending on the problem, the next authority, e.g., the shift manager, is immediately informed according to a clearly defined chronological order.
More overview and communication via Shopfloor Monitor
The improved integration of shift managers and therefore optimized communication among each other was defined as another key project goal: “The assembly shift manager did not have a direct overview of the various machine states at their workstation. This is why they also did not immediately notice when a machine operator required support”, says Heim. The “AMS ZPoint-CI Shopfloor Monitor” - a cross-plant visualization with prefabricated dashboards directly at the workplace - now provides real-time key figures and information regarding the performance levels of all machines. “Of course, this makes it much easier to control day-to-day business”, adds Heim: “We constantly keep the Shopfloor Monitor activated these days; with the optimized escalation management, it also immediately becomes clear where and when rapid intervention of other persons or divisions is necessary”.
Easy configuration
A big advantage is also the easy configuration. All features, as well as key figures, are standardized and can be retrieved or changed by operators with a few movements, without requiring intervention in system control. “Of course, this facilitates work incredibly, guarantees rapid opportunities for response and raises the OEE”, says Heim. There is also a social component to this: “The dashboards are very motivating; the employees measure themselves via the transparent displays. This improves communications among each other and leads to “challenges” about who gets better values”.
Successful cooperation
The new Andon Boards and Shopfloor Monitors have already been rolled out across all automation machines at Festo in Scharnhausen. “The collaboration between STIWA and Festo was very pleasant. Nearly all ideas and wishes were implemented quickly; the regular agile voting sessions have led to success rapidly. The features help us now to continuously improve production”, Florian Sieber, Manager of Construction Control Engineering at Festo in Scharnhausen.
