Real-time information about what’s happening on the factory floor can provide management at all levels with tremendous advantages. Such information can improve understanding of operations, help identify problems, allow timely adjustments and enhance communications with customers.
When Komatsu USA opened its “plant of the future” in Columbia, S.C., it turned to Bigston Information Technologies to implement a customized, transparent, real-time assembly control system that lets Komatsu management world-wide know what’s happening at the plant, while providing plant workers with detailed instruction and the ability to communicate quickly and effectively with supervisors. To enhance flexibility and mobility on the plant floor, the system uses a combination of modules from the Wago input/output system, including the Ethernet fieldbus coupler to interface through a wireless network.
“We worked closely with Komatsu to develop a customized system that could not only provide comprehensive assembly controls, but also detailed information that maximizes the efficiency of the company’s operations,” says Norm Plummer, president of Bigston IT.
Products are identified with bar codes as they flow through the assembly process. Workers use a wireless device to access detailed assembly instructions, including diagrams, photos and inline inspection checklists. Using a touchscreen terminal, operators indicate processes completed and provide alerts as necessary to supervisors.
Management then accesses real-time production information through the system, tracking production, identifying problems, checking defect data and gathering other manufacturing information.
See the story that goes with this sidebar: Factory ethernet hits the floor running
