Enhancing Smart and Autonomous Systems
The adoption of computers and automation in manufacturing has led to Industry 4.0, the fourth revolution in the industry. Data and machine learning fuel these systems, ensuring they are ready for a future where smart machines greatly enhance operational efficiency.
PTA Plastics has made significant efforts to adopt smart manufacturing in our Oxford, Connecticut and Longmont, Colorado facilities. The incorporation of a paperless shop concept happened many years ago, and this eventually led to the interconnectivity of molding machines. By connecting machines to the computer network, this interconnectivity enables real-time production monitoring, regardless of the machines’ operational status. This connectivity offers advantages like automatic uploads, retrieval of set-up information, and access to archived data, all while reducing set-up time.
IT plays a central role in Industry 4.0 initiatives, including system layout, infrastructure, and equipment connectivity. Both of our plants now have upgraded infrastructure to fiber-optic, resulting in improved network reliability and bandwidth. Network enhancement plays a critical role in our efforts to embrace Internet of Things (IOT) and leverage its data for decision-making, enabling us to improve storage and processing of data, thus enhancing our scalability and long-term capabilities. PTA Plastics has established a cybersecurity initiative to safeguard this data, implementing policies, procedures, and various IT systems including 2-factor authentication for the VPN. Simultaneously, our efforts include working towards achieving the 800-171 Certification, a 110-point government certification process, to secure this data as well.
The Internet of Things (IOT) enables connected devices, which also enables Industry 4.0 and smart manufacturing. With increased data access, manufacturing will become smarter, more efficient, and less wasteful, leading to continued growth. The network of interconnected machines, including our molding machines, dryers, and temperature sensors, helps us detect potential issues early on. Recognizing a machine that is not operational or on the verge of failure provides a significant advantage in troubleshooting and preventing potential issues. Real-time monitoring of our machines and conditions is crucial for our Industry 4.0 efforts to achieve predictive maintenance and significantly minimize downtime and scrap. This monitor tracks our process data post-machine and also monitors temperatures, pressures, and shot-to-shot specifications. Additionally, this connectivity boosts our ability to conduct statistical process control of the molding process, ensuring more efficient maintenance of history and traceability by preserving records in the event of process alterations or deviations.
Cell Automation
In response to ongoing production needs, PTA Plastics is currently concentrating on cell automation utilizing Industry 4.0. Our main objective is to simplify set-ups and streamline change-overs, while also ensuring a system that offers (1) increased flexibility and (2) the potential for expanding functionality in future projects or opportunities. By monitoring all equipment and utilizing Internet of Things (IOT), a closed-loop system is established that minimizes waste and detects potential issues.
The rollout of this has been done gradually through a phased process. Phase 1 places a strong emphasis on developing and implementing the essential manufacturing function. In Phase 2, the emphasis will be on connecting all devices and monitoring manufacturing processes, with some offline control given to the system. Phase 3 involves gaining full remote control of the system and introducing ML/AI to optimize processes and automatically correct components.
Augmented Reality
Additionally, PTA Plastics has explored and integrated a virtual Augmented Reality (AR) Light Guide that projects work instructions onto the work surface. The focus of this project was to implement a point-of-use work instruction to assist with training and minimize scrap. Some of our intricate assemblies had issues with scrap parts reaching the customer, leading to financial and efficiency setbacks. To minimize these escapements, our Operators found it easier to follow instructions and receive training by using AR technology. Content creation is crucial for the success of this technology, and our overall goal at PTA is to incorporate AR into multiple areas of our business, such as production, maintenance, and new employee training. This technology can not only aid in knowledge transfer, but also bridge the gap in experienced-based jobs and familiarity, potentially helping new employees reach peak efficiency faster than traditional training methods.
Our workforce is becoming more productive and efficient thanks to the positive impact of digital connections on our systems and business capabilities. This is the ultimate power of Industry 4.0.