Wi-Fi DNC and Machine Utilization by CIMCO-MDC, at Manweir-Doha, Qatar

 

Manweir LLC was established in 1976 and is a wholly-owned subsidiary of the Mannai Corporation in Doha, Qatar.Manweir’s large Machine shop in the Mannai complex is well equipped to cater to the needs of the Oil & Gas and petrochemical industries in Qatar and nearby GCC states. The machine shop has heavy duty and precision machine tools including CNC machines, specialising in the Machining & Threading of OCTG including Manufacture, Repair & Remanufacture. Digitech installed wi-fi DNC on all CNC machines, along with CIMCO MDC, Machine Data Collection. Before this installation, all the part programs were being sent to CNC by flash cards. The production report was being generated by manual entry in EXCEL sheet. Now, all reports are generated by CIMCO-MDC directly taking the data from respective CNC. Each CNC has one MDC hardware fitted near the CNC Control Panel.

When the machine goes under down time, the operator scans a reason code from the Bar Code Scanner fixed near to his CNC.

The bar code sheet is as shown. It is customizable on site. Sample reports are shown.

 

For more details, contact digitechpune@gmail.com, or call 94235 86171

CIMCO-MDC at WOM-Velu, Pune

Worldwide Oilfield Machine P Ltd is located at Gat 778, Post Velu on Pune -Satara Road, Tal : Bhor, Pune 412 205, Phone : 412 205. This company uses no. of CNC machines, both turning & milling. To monitor the machine utilization, Digitech installed CIMCO-MDC on 2 CNC Machines.

CIMCO V-7 has been installed at WOM. The down time is scanned by the Bar Code scanner. 

Productivity is monitored on 'per shift basis'. The productivity reports in EXCEL are viewed by the Vice President Mr. Rajeev Kulkarni in his cabin on his laptop.

The down time codes are scanned by Motorola Bar Code scanner, LS 2208. The codes are taken from WOM's existing list of down time. These can be modified if needed.

For VMCs

The same product was also installed on their 2 welding machines. CIMCO's MDC box has been used to get 3 signals from welding machines. The down time codes are different, hence the bar coded sheet is different.

Thus, any production machine which can give few signals from electrical panel can be interfaced with CIMCO-MDC. 

Contact digitechpune@gmail.com or call us at 9423586171 for more details about MDC on production machine.

                                                                                                                                                                                                                  
Deepak Bodhani 

 

Case Study of CIMCO-MDC at M/s Valveworks-Kolhapur

VALVEWORKS INDIA PRIVATE LIMITED is situated at A-8 & A81/1, Fivestar Industrial Area MIDC, Kagal, Hathakangale Kolhapur. About one year back, Digitech Engineers installed CIMCO's Machine Monitoring System on one of their CNC Machines at above works.

We installed CIMCO MDC Software, along with one Bar Code scanner. The live signals like, Active Program Number, Cycle Start, Alarm, Feed Hold etc are taken from FANUC VMC. The Operator Name & Part Number is fed at the start of the shift in the MDC Computer. As the production process starts, the cycle time of each part is recorded in the MDC Computer automatically. The online status show the machine status. The time line shows the activity from the start of the current shift. Whenever the machine stops for any reason, the operator then scans the appropriate bar code. 

The bar codes sheet looks like below -

This sheet has pre defined bar coded down time reason codes. But the codes can be customized as per the users. We use Motorola make, LS 2208 bar code scanner, which works on RS-232 port. This bar code scanner is designed for industrial use. 

The reports from the system are also customized. We have given the template to Valveworks, as per their needs. 

For more details contact digitechpune@gmail.com or call me on 9423586171. 

The photo on the right side is taken during installation & technical training on CIMCO-MDC at Valveworks-Kolhapur.

Various ways to take live signals from Machine for OEE Monitoring using CIMCO-MDC

In CNC Shop, idle time on machines can be up to 25 %. In fact, many CNC Shop Managers even do not know the exact idle time.These firms have bought few costly machines & these are idle for some reason or the other.

What does this mean in terms of production and profitability?

1. Your ROI is straightaway reduced by 25  %.
2. You are maybe producing 75 parts per shift when you could be producing 100.
3. You prices are about 25 % higher, in the cut-throat market out there.

Digitech offer a solution using CIMCO-MDC product. MDC is Manufacturing Data Collection. CIMCO is a Denmark based company. 

CIMCO MDC Max

This is the most advanced module of CIMCO-Denmark for measuring efficiency of a CNC machine in terms of OEE.  This module gives the on-line display of CNC status. The most important feature is that this gives a very true data collected from the CNC.

There are 7 different ways to capture the machine data as below - 

1)    Use  FOCAS interface in Fanuc : It directly gives data from CNC

                                               Memory but all FANUC systems do

                                               not Support this.

2)    Use   DPRNT Commands          : System puts DPRNT Command in each

                                                     Part Program. 

                                                     e.g. DPRNT [CYCLESTART]

                                                The Cycle Start Signal will be sent 

                                                on RS-232 port. But all FAUC do not 

                                                support DPRNT function.           

3)    Use  CIMCO MDC Box              : System can take 3 digital signals from 

                                                    machine via this hardware box on 

                                                    RS-232 port. Most common signals are

                                                    Cycle Start, Cycle Stop & Part Count  

4)    Use Spare Relays in Haas       : Haas has Relays like M21, M22 & M23.

                                                    These can be wired these to MDC box.

                                                    Further you need to use M codes in

                                                    NC Code to activate the relays.

5)    Use Relay Board & Tower Lamp : Take signals from a Tower

                                                Lamp & operate 3 relays. 
                                                Use NO contacts of these relays to take 
                                                signals to MDC box.

6)  Use MTConnect interface           : This is a universal protocol developed 

                                                     recently. Some latest CNC like Mazak,

                                                     OKUMA, FANUC, support  this.

                                                You can directly get Machine Status
                                                in MDC by this protocol.

7)    Use NetLINK for Sinumerik 840 : For Sinumerik 840-D,  NetLINK

                                                 hardware will give most of the MDC

                                                 signals.There is a direct interface in 
                                                 CIMCO-MDC software for NetLINK.

Down time can be scanned by Android cell phone or Tab. 

         

The live OEE will be shown on the Android cell phone. When a machine is under breakdown the system will send the SMS to predefined Cell Number. 

For more information, contact digitechpune@gmail.com

You can watch video here https://www.youtube.com/watch?v=-jehAgyrEjM