IO-Link Makes Improving OEE in Format Change Easier than Ever

One of the primary applications in Packaging, Food & Beverage that is a huge area for improving overall equipment efficiency (OEE) is format change.  Buyers respond well to specialized or individualized packaging, meaning manufacturers need to find ways to implement those format changes and machine builders must make those flexible machines available.

IO-Link Makes Improving OEE in Format Change Easier than Ever_2

Today, thanks to IO-Link devices, including master blocks, hubs and linear position sensors, improving OEE on format change is more possible today than ever before. IO-Link offers capabilities that make it ideal for format change. It communicates:

  • Process data (control, cyclical communication of process status)
  • Parameter data (configuration, messaging data with configuration information)
  • Event data (diagnostics, communication from device to master including diagnostics/errors)

What is format change and how does it impact OEE?

Format change is the physical adjustments necessary to make to a machine when the product is altered in some way.  It could be a change in carton size, package size, package design, case size or a number of other modifications to the product or packaging.  The time to adjust the machine itself or the sensors on the machine can take anywhere from 30 minutes to an entire eight- hour shift.

Types of format changes to consider when seeking to improve your OEE:

Guided format change is when the operator is assisted or guided in making the change.  For example, having to move or slide a guide rail into a new position.  IO-Link linear position sensors can help guide the operator, so the position is exact every time. This reduces time by eliminating the need to go back and look at an HMI or cheat sheet to determine if everything is in the right position.

Change parts is when a part needs to be swapped out on the machine for the next production run.  An example of this is when the bag size on a bagger or vertical form fill and seal (VFFS) machine changes and the forming tube needs to be changed.  Having an RFID tag on the forming tube and a RFID reader on the machine allows for easy verification that the correct forming tube was put on the machine and only takes seconds.

Color Change is when the color of a pouch, package or container changes for the next production run like when a yogurt pouch changes color or design while the size and shape remain the same as previous production runs. Smart color photo electric sensors can change the parameters on the photo eye to detect the correct color of the new pouch occurs instantly upon changing the recipe on the machine.

Developing semi-automated or fully automated solutions can improve OEE in regard to format change by helping reduce the time needed to make the change and providing consistent and accurate positioning with the ability to automatically change parameters in the sensor.

Being smart, easy and universal, IO-Link helps simplify format change and provides the ability to change sensor parameters quickly and easily.

IO-Link Makes Improving OEE in Format Change Easier than Ever_1

How IO-Link is Revolutionizing Overall Equipment Efficiency

Zero downtime.  This is the mantra of the food and beverage manufacturer today.  The need to operate machinery at its fullest potential and then increase the machines’ capability is where the demands of food and beverage manufacturers is at today.  This demand is being driven by smaller purchase orders and production runs due to e-commerce ordering, package size variations and the need for manufacturers to be more competitive by being flexible.

Using the latest technology, like IO-Link, allows manufacturers to meet those demands and improve their Overall Equipment Efficiency (OEE) or the percentage of manufacturing time that is truly productive.  OEE has three components:

  1. Availability Loss
    1. Unplanned Stops/Downtime – Machine Failure
    2. Planned Downtime – Set up and AdjustmentsS
  2. Performance Loss
    1. Small Stops – Idling and Minor Stops
    2. Slow Cycles – Reduced Speed
  3. Quality Loss
    1. Production Rejects – Process Defects
    2. Startup Rejects – Reduced Yield

IO-Link is a smart, easy and universal way to connect devices into your controls network.

The advantage of IO-Link is that it allows you to connect to EtherNet/IP, CC-Link & CC-LinkIE Field, Profinet & Profibus and EtherCAT & TCP/IP regardless of the brand of PLC.  IO-Link also allows you to connect analog devices by eliminating traditional analog wiring and provides values in actual engineering units without scaling back at the PLC processor.

Being smart, easy and universal, IO-Link helps simplify controls architecture and provides visibility down to the sensor and device.

IO-Link communicates the following:

  • Process data (Control, cyclical communication of process status)
  • Parameter data (Configuration, messaging data with configuration information)
  • Event data (Diagnostics, Communication from device to master (diagnostics/errors )

This makes it the backbone of the Smart Factory as shown in the graphic below.

 

IO-Link Simplifies the Controls Architecture

IO-Link OEE1

IO-Link OEE2