IIC Journal of Innovation 8th Edition | Page 39

The Path from Data to Actionable Information as a Driver for the Industrial Ecosystem P REDICTIVE This then becomes the operational recipe that is used for the execution of the process. The prescribed process can be verified with low latency feedback to ensure it is being executed correctly. Prescriptive models also allow us to build digital twins of the process and simulate the outcome to a greater level of accuracy. Predictive analytics can be deployed using a low latency feedback loop to stop or correct process parameters if the grinding wheels are not being used optimally. The possible causes are as follows:  dressing cycles are not being done at the correct frequency,  accommodation of material or wheel differences, or  there is maintenance to be performed on the machine. R ESULTS In production, our experience with this methodology has allowed the customer to gain between 10% and 52% savings based on prescriptive process parameters and verification of correct process execution. The savings are illustrated in Figure 11. Tool management systems will also utilize the insights to correlate variations in the wheels to the lot and manufacturer. This takes the customer from reporting on what was happening in the manufacturing process to predictive analytics to identify potential problems. These alerts created by defining models that can live at the enrichment stage of data analysis are created by analyzing historical data from multiple streams and joining it with requisitioning of material and wheels to the process and geometries being operated upon. The result is the ability to stop processes before a wheel or part is damaged. Figure 11: Grinding Process Improvement The MTConnect standard was used in this project to collect the machine tool and load sensor data. The controller was a FANUC controller and the syntactic transformation was done first with an MTConnect adapter from FANUC’s FOCUS2 protocol to the data as key/value pairs and then into the MTConnect semantic standard. The remaining stages were performed using proprietary technology for the statistical analysis (many open source technologies P RESCRIPTIVE Prescriptive analytics allows us to take this one step further and knowing the wheel manufacturer, the machine, the wear on the machine and the material being ground: The system can determine the optimal process parameters to get maximum life and performance out of the equipment and tooling. - 38 - June 2018