Blog

Posted on April 05, 2023

In the era of Industry 4.0, manufacturing companies are being faced with a critical decision: how to implement the Industrial Internet of Things (IIoT) to optimize their processes and gain a competitive edge. One crucial aspect of this decision is choosing between Andon/OEE providers that use long-polling to achieve real-time information and those that use SignalR for true real-time communication. In this op-ed, we'll discuss the pros and cons of both approaches, with a special focus on network traffic and the potential trade-offs in real-time responsiveness. We will also consider the affordability of ProAlert, an innovative solution that leverages SignalR technology.

Long-polling: A Tried and Tested Method

Long-polling has long been a common method for achieving real-time information in manufacturing settings. It involves the client periodically sending requests to the server for updates. When new information is available, the server responds with the data, and the process repeats.

Pros:

1. Simplicity: Long-polling is relatively easy to implement, making it a popular choice for many manufacturers.
2. Compatibility: It works with most networks and devices, offering a reliable solution for a wide range of scenarios.

Cons:

1. Network traffic: Long-polling can generate a significant amount of network traffic, as clients continuously request updates even when there is no new information.
2. Latency: This method can result in delays in receiving real-time information, potentially affecting decision-making processes.

SignalR: The Path to True Real-Time Communication

SignalR is a more modern approach to real-time communication. Instead of the client repeatedly asking the server for updates, SignalR enables the server to push new information directly to the client as soon as it becomes available.

Pros:

1. True real-time: SignalR offers a more efficient and faster communication channel, ensuring that critical information is delivered in real-time.
2. Reduced network traffic: With updates sent only when necessary, network congestion is significantly reduced.

Cons:

1. Complexity: SignalR can be more challenging to implement, which may be a deterrent for some manufacturers.
2. Compatibility: Not all networks and devices may support SignalR, potentially limiting its applicability in certain scenarios.

Enter ProAlert: Affordability Meets Innovation

ProAlert is an Andon/OEE solution that has "cracked the code" by offering a cost-effective way to connect any work center using SignalR. By leveraging this cutting-edge technology, ProAlert is able to provide true real-time communication without breaking the bank. Manufacturers can now enjoy the benefits of SignalR without sacrificing affordability.

In conclusion, the choice between long-polling and SignalR largely depends on the specific needs and constraints of each manufacturing company. While long-polling offers simplicity and compatibility, it can result in increased network traffic and latency. SignalR, on the other hand, promises true real-time communication and reduced network congestion, albeit at the cost of higher implementation complexity and potential compatibility issues.

However, with innovative solutions like ProAlert entering the market, manufacturers can now experience the best of both worlds: true real-time communication with SignalR at an affordable price. As Industry 4.0 continues to evolve, manufacturers must carefully consider their IIoT implementation options and adapt to stay competitive in an increasingly connected world.

Posted on April 05, 2023

In today's fast-paced and competitive manufacturing industry, efficiency and productivity are key factors in ensuring success. This is where an integrated Andon/OEE system comes into play. By combining these two powerful tools, manufacturers can improve their overall equipment effectiveness (OEE) and enhance their communication and problem-solving capabilities.

An Andon system is a visual management tool that enables operators to quickly alert supervisors and maintenance staff of any issues on the production line. By using a simple signal, such as a light or sound, operators can quickly indicate when a problem arises, allowing for faster resolution and less downtime.

Meanwhile, OEE is a metric that measures the overall efficiency of a production line by considering three factors: availability, performance, and quality. With an OEE system in place, manufacturers can identify areas where production can be improved and take corrective action to optimize the manufacturing process.

By integrating an Andon and OEE system, manufacturers can benefit from a more comprehensive approach to production management. They can quickly identify and resolve problems while also optimizing their production line for maximum efficiency. And with ProAlert, an integrated Andon/OEE system that runs on an intranet, manufacturers can do this with confidence.

ProAlert offers a unique advantage over other integrated Andon/OEE systems by ensuring that sensitive data is not exposed to the outside world. This is particularly important in industries where proprietary data is essential to a company's success. With ProAlert, manufacturers can enjoy the benefits of an integrated Andon/OEE system without worrying about the security of their data.

Furthermore, ProAlert is incredibly easy to implement. It can run on just about any device, making it accessible and convenient for operators and maintenance staff. By leveraging the power of ProAlert, manufacturers can improve their production line's efficiency, reduce downtime, and optimize their manufacturing process.

In conclusion, an integrated Andon/OEE system is an essential tool for manufacturers looking to stay competitive in today's fast-paced manufacturing industry. By combining the power of Andon and OEE, manufacturers can identify and resolve problems quickly while optimizing their production line for maximum efficiency. And with ProAlert, manufacturers can enjoy the benefits of an integrated Andon/OEE system without compromising the security of their data or the ease of implementation.

Posted on April 06, 2023

Subtitle: Why Your Andon/OEE System Needs ProAlert for Complete Transparency

Introduction

In today's fast-paced manufacturing world, efficiency is key. Andon and Overall Equipment Effectiveness (OEE) systems have long been implemented to monitor and improve production processes. However, a crucial question remains: are planned downtimes hiding the real picture of what's happening on your shop floor? Let's explore how planned downtimes can sometimes obscure the truth and why ProAlert is the tool you need to see the whole picture.

The Hidden Truth Behind Planned Downtimes

Planned downtimes, such as those for maintenance, changeovers, and breaks, are a necessary part of the manufacturing process. They help prevent unexpected production interruptions and optimize equipment performance. However, by only looking at the planned downtime figures, manufacturers may overlook underlying issues that could be impacting overall productivity.

Andon/OEE systems are designed to capture and analyze a plethora of data points, but traditional systems may not provide the granularity needed to expose the reality behind planned downtimes. In some cases, these systems can unintentionally mask inefficiencies and problems that, if left unaddressed, could significantly harm your production process.

ProAlert: The Solution for a Transparent Shop Floor

Enter ProAlert, an advanced Andon/OEE solution designed to provide manufacturers with a clearer understanding of their production processes. By offering deeper insights and enhanced visibility, ProAlert allows you to see the real picture on your shop floor, including the details that could be hidden behind planned downtimes. Here are the ways ProAlert stands out from traditional Andon/OEE systems:

1. Comprehensive Data Capture: ProAlert collects and analyzes data from all aspects of your manufacturing process, including downtime reasons and durations, operator feedback, and production rates. This comprehensive data set empowers you to identify issues that may not have been apparent with a traditional Andon/OEE system.
2. Customizable Metrics: ProAlert provides customizable metrics, enabling you to dive deeper into the root causes of downtime and inefficiencies. You can tailor these metrics to your specific needs, ensuring that you're always focused on the most relevant data.
3. Real-Time Monitoring and Alerts: With real-time monitoring and alerts, ProAlert ensures that you're always informed of any deviations or bottlenecks in your production process. Immediate notifications give you the opportunity to address issues quickly, minimizing the impact on your overall productivity.
4. User-Friendly Interface: ProAlert's intuitive interface makes it easy for operators and management to interact with the system, encouraging greater engagement and more accurate data capture.
5. Seamless Integration: ProAlert easily integrates with your existing manufacturing systems, ensuring a smooth transition without disrupting your current processes.

Conclusion

In a world where efficiency is paramount, manufacturers must have a clear understanding of their production processes to remain competitive. Traditional Andon/OEE systems can provide valuable insights, but they may not always tell the whole story. By implementing ProAlert, you can ensure that you have a complete and transparent view of your shop floor, uncovering the hidden truths that might be lurking behind planned downtimes. Don't let planned downtimes mask the reality of your manufacturing process; choose ProAlert for unparalleled visibility and control.

Posted on May 19, 2023

Many businesses today, confronted with the challenge of boosting production capacity, might instinctively turn towards purchasing new, high-cost machinery or expanding into larger spaces. However, before you commit to such costly endeavours, it may be worth considering the possibility that untapped potential resides right under your nose - on your current shop floor.

Optimizing your shop floor can result in significant productivity enhancements. One such method to accomplish this involves the employment of an Overall Equipment Effectiveness (OEE) framework coupled with an Andon system. Before getting entangled in complex solutions, wouldn't it be wiser to explore the power of OEE and Andon on your shop floor?

OEE is a robust metric that quantifies how effectively a manufacturing operation is utilized. It combines availability (is the machine running?), performance (how fast is it running?), and quality (is it producing good parts?). The brilliance of OEE is its focus on identifying and quantifying the six big losses in manufacturing - from breakdowns to reduced speed, from process defects to startup rejects. By measuring these areas, OEE provides a systematic approach to drive improvements.

But that's only half of the story. To have a real-time understanding of your shop floor, coupling OEE with an Andon system is essential. Andon, a concept originally pioneered by Toyota, allows shop floor operators to signal a problem instantly. This provides an opportunity to address issues proactively, preventing minor inefficiencies from snowballing into larger, costlier problems.

The results of this coupling are impressive. On average, companies implementing OEE see gains of 5-20% in capacity within the first year, according to industry studies. By integrating these methods into their operations, companies can make better use of existing resources, effectively increasing capacity without significant capital investment.

The ProAlert system makes this synergy between OEE and Andon possible. ProAlert, with its data-driven insights, allows users to monitor real-time machine performance, compare it against historical benchmarks, and instantly notify shop floor personnel of deviations. In effect, ProAlert not only harnesses the power of OEE and Andon but enhances it.

Utilizing ProAlert with OEE and Andon represents an investment in intelligence and efficiency, rather than mere machinery. In an era of data-driven decision-making, it provides a crucial opportunity to drive improvements without resorting to costly infrastructure expansion or equipment upgrades.

The opportunity to optimize is right there on your shop floor. By taking the time to understand the operations and invest in efficient systems like ProAlert, Andon, and OEE, you can unlock hidden capacity within your existing operations. Remember, real growth and efficiency come from smarter use of resources, not just bigger investments. So, look no further. Your shop floor is more capable than you might think.