MACHINE STOPPAGE

Ascom has over 40 years experience in designing and providing innovative on-site wireless solutions. In terms of a specific single task application, using one of the Ascom’s VoWiFi, IP DECT, DECT or Paging solutions can produce significant cost savings in what is a common operational task.

A large manufacturing plant in the Midlands has equipped all it’s maintenance staff with an Ascom DECT system. The brief was to achieve a quicker response to machine failure, and the ability to interface and control existing process management systems for ongoing monitoring.

The solution used Ascom modules, with customised configuration and programming. These work with most types of process equipment that has digital outputs indicating machine alarms and stoppage. They can be outputs directly from the equipment itself, or via a unified automated process control system.

The object was to instantly communicate process malfunction, in real time, directly to the people that need to know. However the Ascom solution takes this much further by escalating, or cascading alarms through the organisation to ensure action can be taken as quickly as possible, and if it is not, alert managers further up the line.

Research shows that when a problem occurs, up to 50% of downtime is spent finding the right resources. Using a communication system that includes a specific machine stoppage response mechanism will have a significant impact on time saved.

A typical sequence of events is as follows:

• When a machine stoppage alarm is generated, first line personnel, in this case one or more named operators, are automatically notified immediately by a pre-programmed text message on their Ascom DECT handset. The information can be tailored to different situations, but includes the machine identifier and possibly the nature of the stoppage – material shortage, excess operating temperature etc.
• When any operator acknowledges they are responding to the alarm the others on call will be informed of who has taken responsibility – this is done by a one key press on the handset.
• If for whatever reason there is no acceptance within a pre-set time limit, a message ‘Stoppage machine X, no response’, is automatically forwarded to the line manager for action.
• If the operator, after having analysed the cause of the stoppage, is able to restart the machine, there is no need to escalate further and a ‘Machine Recovered’ message is sent.
• However should the operator require more technical assistance they choose from a pre-programmed menu on their handset to alert a specific technician or group of technicians. When a technician has accepted the work the operator is informed and again, if no technician responds the line manager is automatically alerted.
• The accepting technician receives a message with details of which machine is involved, the nature of the problem, and the forwarding operator’s id and phone number so they can be contacted immediately using the two way communication facility inherent in the Ascom DECT handset.
• When the technician has accepted the task, a return message, ‘Help coming’ will be sent to the operator. The technician also receives a menu in his display, with the following options; ‘Forward’, ‘Speak’ or ‘Machine Recovered’. Forward is used when after analysing the problem, the technician realises he needs help from a colleague. The forwarded message will read: ‘Stoppage machine X, need help’ plus the id of the forwarding technician. ‘Speak’ is chosen when the technician wants to talk to the operator. If the technician has been able to fix the fault, the machine-recovered message will be sent.
• If at any stage of the event, the machine is not up and running within a predefined time, an alarm is automatically sent to the line manager.

The overall increase achieved in mobility and flexible working makes for quicker responses, with increased efficiency and cost effectiveness. This Ascom solution has proven to save labour costs and down time significantly improving OEE. However system flexibility means that Ascom’s on-site communication platforms are rich in other functionality, offering options such as group calling, lone worker alarms, interfaces with PBX and on-line control of a wide range of third party equipment. There are a range of VoWiFi, IP DECT, DECT and Paging applications and handsets designed for specific tasks, whether it be voice, text, data, tone, or alarm functions.