Improving OEE
Consumer products manufacturers are always exploring ways to improve operational efficiency. Improving overall equipment effectiveness (OEE) requires procurement and engineering leaders to solve a handful of key challenges, which include improving operator training, quickly resolving unplanned downtime, and streamlining access to technical support services.
With consideration of these challenges, today’s manufacturers of automatic labeling machines have invested in developing human-machine interfaces (HMIs) that can significantly improve OEE. These HMIs can provide greater access to training resources, intuitive technical documentation, and technical support for on-the-spot troubleshooting.
In this post, I’ll explain how smart HMIs can improve operational efficiency for consumer products companies and provide a list of HMI features to consider when purchasing a new labeling machine.
How Smart HMIs are Changing the Market
HMI technology has improved rapidly over the past three years. Instead of the flashing warning light of years gone by, today’s HMIs can display an image of the machine, place an indicator where the exact fault is, and provide instructions for how to resolve the issue. They offer significant advances in user experience, including improved graphics, enhanced connectivity, larger screen sizes, and multi-touch functionality. They also provide greater access, not only to a machine in its current state but also to information that can be used to improve the machine’s performance throughout its lifecycle.
Advanced panel-based HMIs, such as BW Packaging's award-winning Opview™ HMI, are forecasted to achieve a high market growth rate due to the demand for mobile HMIs. The ability to connect with a machine remotely and to access all the information required to provide greater insight into labeling operations, and thereby increase the overall productivity of the plant, is more desirable than ever. COVID-19 has also reinforced the importance of remote connectivity and simplification of operations.
Labeling HMI Checklist
When choosing an automatic labeling machine, there are several HMI-related criteria that should be considered that can improve OEE. Below is a list of questions that can be used to evaluate labeling machine HMIs and compare options from various suppliers.
1. Operator Training Resources
How will this HMI improve operator training? Some HMIs include video tutorials and on-demand training guides to make setup and operations simple. They can also come with step-by-step onboarding for key functions, maintenance, and fault recovery processes, including how to maximize machine speed. They may even be available in multiple languages for today's multi-national workforce.
2. Streamlined Troubleshooting
Does the HMI provide links and instructional steps to help you clear faults? HMIs can walk operators through the steps to resolve the fault and reset the machine. Having this functionality as a part of the HMI means operators don’t have to consult manuals. They can address the issue on the spot, keeping downtime to a minimum.
3. Preventive Maintenance Reminders
Does it allow you to schedule preventive maintenance reminders? Reminders can appear as daily, weekly, and monthly tasks for your operator and maintenance team. By taking a proactive approach to machine maintenance, operators are better able to avoid unplanned downtime.
4. User Levels
Can you control access and accountability? To drive consistency of performance, some HMIs allow you to set different user levels, limiting access to parameters and/or range of adjustments, as you deem necessary.
5. Offsite Connectivity
Can the HMI connect remotely? For example, some HMIs allow operators to access machine configuration off-site and even allow them to set up audit trail information from a computer, tablet, or smartphone.
6. Remote Support
Does the labeling machine manufacturer provide remote support via the HMI? Having your OEM remote in the machine via the HMI can help operators resolve issues more quickly and cost-effectively.
7. Rapid Changeovers
Is the HMI designed to accommodate rapid changeovers? Some HMIs store recipes and provide video changeover guides to assist operators in reducing downtime between changeovers and to start up faster.
8. Productivity Reporting
Can the HMI show complex data, such as machine OEE, in real-time? This feature can show operators where a fault lies and offer remedies to fix that fault, which can help improve the long-term effectiveness of the machine. This feature can be accessed on-screen and in real-time via video assistance.
BW Packaging's OpView™ HMI
BW Packaging has designed an HMI that satisfies all of the criteria listed above. OpView™ HMI simplifies operation and training and provides greater access to an advanced analytics dashboard. In addition, because the OpView™ is now standard on BW Packaging equipment, operators transition easily from one machine to the next as they move through the guided onboarding, intuitive navigation, and clear functional parameters.
The OpView™ HMI was recognized for design excellence with its smart user interface (UI), earning two IF Design awards in the prestigious global design competition that evaluates design excellence across many industries. The award called out the Opview™ HMI for “an outstanding focus on the interlinked factors of human, task, process, and machine.” It provides one interface for all machine types, fast access to all information, and user-friendly navigation. Adding to the package the clear alarm system and easy-to-understand troubleshooting workflows, the Opview™ HMI makes a whole new level of operation easily accessible for customers.
