Smart Manufacturing - Using Predictive Analysis in CNC Machining
Data collection has been a key aspect of manufacturing since its inception, but the methods of acquisition have rapidly evolved in recent years. Historically, operations personnel have manually checked gauges and taken measurements based on visual inspections. Then, the data is analyzed to make decisions regarding the health of the equipment. With this process, manufacturers are making decisions based on data that is days or weeks old, not to mention this method is prone to error.
What is Smart Manufacturing?
Significant advances have been made in data collection technologies in the past decade. The digitalization of manufacturing, also known as Industry 4.0 or the Industrial Internet of Things (IIoT), is the use of connected technologies across sectors, like manufacturing, to optimize operations. This form of smart manufacturing is revolutionizing shop floors by enabling the acquisition and accessibility of far greater amounts of data, at far greater speeds, and far more efficiently than before – allowing manufacturers to make decisions based -on real-time data. Smart manufacturing with its increased connectivity reduces the amount of human intervention needed to collect and analyze data. The IIoT has enabled companies to automate many of the design and production processes, allowing for better flow of information through the entire manufacturing process and improved efficiencies due to use of robotics and other automation technologies on manufacturing lines.
What is Predictive Analysis?
There are many benefits of the IIoT for manufacturers – one of which is predictive analytics, namely for the purposes of equipment maintenance. Predictive analytics is the use of data, statistical algorithms, and machine learning methods to create failure prediction models that estimate the probability of future events based on historical data. This form of data analysis has been around for a while but is much more attainable with smart manufacturing.
Smart machines collect and use data to monitor their own health, alerting of potential failure points or anticipated issues based on the data collected – a process known as predictive maintenance. The IoT enables predictive maintenance, which is based on real-time condition of a specific piece of equipment, compared to traditional preventative maintenance which is generally based on averages and historical data of equipment that is collected manually.
How is Predictive Analysis Used in CNC Machining?
Smart manufacturing can be utilized with a variety of equipment including CNC machines. The type of real-time data collected by sensors during CNC machining includes temperature, vibration, power, torque, speed, current, and voltage. Various machine conditions are monitored such as gear and bearing health, wear on drills and cutting tools, and machine balance.
Smart machines create a signature of a CNC machine’s health. When the machine varies from the norm, artificial intelligence uses predictive analytics to foresee an issue and allows manufacturers to proactively schedule downtime for maintenance and repairs before the CNC machine suffers damage or a failure that would unexpectedly stop production, resulting in costly delays. Machine learning also utilizes real-time data to take corrective actions - improving quality and consistency and reducing the potential for products that do not meet tolerances.
Manufacturers are becoming increasingly aware of the downtimes and costs resulting from unexpected equipment failures, and are adopting preventative maintenance plans to secure a competitive edge. Maintenance programs that rely solely on manual data entry and tracking are slow and are often too “reactive” in nature – it is key to integrate smart, condition-based monitoring systems into existing manufacturing processes. There are various software solutions available for specific machinery including CNCs. These programs provide manufacturers with scheduled maintenance events based on known wear, use or observed conditions as well as dashboard monitoring and trends. In addition to a plan to manage on-going maintenance of existing equipment through the life cycle, manufacturers are developing multi-year roadmaps to proactively plan equipment retrofits, upgrades, or replacements. The bottom line is to be proactive rather than reactive.
ABS’ CNC Machining Expertise
Established in 1971, ABS Machining has grown to become the recognized global leader in large machining, fabrication, and assembly for OEMs. The key to our success has been exceptional people, unparalleled facilities, and an unwavering commitment to quality. Our people are experts in their given field. Their expertise is matched only by their passion for serving our clients. We continue to invest in our people with education programs, cross training and in our internal accredited apprenticeship center. Our facilities are state-of-the-art and equipped to serve our client’s requirements in:
Our massive fleet of machines and automated welding systems has delivered solutions to the most technically challenging projects. Our commitment to maintaining unparalleled facilities is evidenced by our renowned continuous capital reinvestment initiatives. Our commitment to quality goes well beyond our ISO 9001:2015 Registration. From the inception of all programs, ABS quality professionals work closely with each customer to ensure all their unique requirements are met or exceeded. It is this commitment that has positioned ABS as a strategic supplier to leading OEMs worldwide.
Contact us today to see how we can help with your machining project, or give us a call at 1-844-227-6224.
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