A Machine Monitor can generate short video clips of
about 30 seconds. Each time the recording system is triggered a video clip
is saved on to the hard drive. Each video clip can contain information
about a particular malfunction and is represented on screen as an entry in the
log. When the user is ready, he opens the log and selects a particular
video clip. It loads automatically into the player. At this point if
the user finds something interesting he can show the video clip to others.
People from different backgrounds will have different opinions as to why the
malfunction exists. Often the problem is just the speed of the process and
the immediate solution is to slow down production. But what if this is not
desired? "Whadya mean slow it down? Are you nuts?" says
Joe Lunchbox
The real value of a Machine Monitor is that you have
video evidence that the malfunction really exists. The production line may
stutter at certain times, ramp up wrong, or run erratically. But, when people
seeamalfunction, they believe it. Everyone knows
its real. So then you have several experts give their opinion
about the video clip.
The next thing you know someone says "Hey I can fix
that!" and they implement a solution to solve the malfunction. The
solution is usually something simple, like a simple adjustment or change in the
machines PLC program. Often the change is just a change to the machine
operators procedure.
So has the problem really been solved? The
people who adjust or repair things will come back and say. "Yep, its fixed
now!". Well how do you know for sure? In this case the user must go back
to the Machine Monitor and monitor production again. The new clips will
tell you for sure. Yes, the problem is fixed. We don't see anymore
malfunctions.
A Machine Monitor helps you identify malfunctions
that cause defects or slow down your process. Without a Machine Monitor,
process improvement could take years because nobody understands the problem or
believes that it exists. Without video evidence, you can't muster the
support to go after the problem.
To use a military analogy, you need use
reconnaissance to take a picture of the enemy position. Without that
information you can't go after you enemy and kill it.
