Lab 11-1: Use Data to Optimize a Machine's Performance

INTRODUCTION

Now that you've run the Basic Automation Trainer, let's learn how to improve production by optimizing the machine's performance. Thus, in this lab you will change the machine setup to optimize production.

Many machine operators are expected to make minor machine adjustments so their machines will build as many good parts as possible without producing any failed parts. For this lab, the variable you will adjust to make your machine run more efficiently is "Slide Speed".  

In this lab, starting with Model 1, you will run a few parts, evaluate machine performance, make an adjustment to Slide Speed, run a few more parts, and evaluate the results of your adjustments. You will continue to make Slide Speed adjustments until you have found the optimized setting where you are producing 100% pass parts and zero fail parts. 

As you are going through this optimization process, the closer you get to the optimized setting, the fewer fail parts you will produce.  

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OBJECTIVES 

In this lab, you will: 

• Use data to monitor a machine's performance
• Demonstrate how to use data to find a machine's optimal performance settings
• Demonstrate how to use the HMI to read data and adjust a machine's performance

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MATERIALS 

You will need the following items: 

• Basic Automation Trainer board with PLC, HMI, and robot connected

Ask an instructor where to find the above items if necessary.

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LAB INSTRUCTIONS 

In this lab, you will optimize machine production by finding the precise slide speed setting for model 1. There are 3 major steps: (1) Determine the machine's current performance baseline; (2) Test alternative slide speeds; and (3) Record the optimal slide speed for the machine for model 1. 

Watch the video for instructions on how to complete this lab.

Part 1: Determine the machine's current performance baseline.

The first thing you need to do is determine how the machine is currently performing. 

Before beginning, navigate to the Model Change HMI screen and select Model 1, if it is not already selected.

Step 1: Put the machine in Manual Mode.

Navigate to the Manual Screen. Put the machine in Manual Mode. 

Step 2: Check the slide speed.

While manual mode is selected, the following numeric entry indicator will appear:

When you touch the above numeric entry button, a popup will appear that will let you change the speed of the slide.

 The numeric entry on the HMI for Slide Speed will allow you enter a Slide Speed value anywhere between 1-1000 milliseconds. 

As a quick refresher:

100 milliseconds = 0.1 seconds

250 milliseconds = 0.25 seconds (or 1/4 of a second)

500 milliseconds = 0.5 seconds (or 1/2 of a second)

750 milliseconds = 0.75 seconds (or 3/4 of a second)

1000 milliseconds = 1.0 seconds

Step 3: Navigate to the Hourly Counts HMI screen. 

Step 4: Select the Reset Batch Count button. 

This resets both Pass and Fail counts to zero.

Step 5: Run 6 parts through the machine.

1. Go to the Manual Screen on the HMI and select the Manual Mode button.  
2. Navigate to the Home Screen and select "Cycle Start."
3. Watch the machine to verify that it is running correctly.
4. After it has run 3 parts, the machine should stop. Press "Cycle Start" again and watch the machine produce 3 more parts. 

Step 6: Check your results.

After you have run 6 parts through the machine, check the results.

1. Go to the hourly counts screen. 
2. Check the batch count. If it says 6 parts have passed and 0 have failed, you have found the optimal speed. If it doesn't say 6 have passed and 0 have failed, then you will need to test a different slide speed. 
3. Run 6 more parts (so your batch count totals 12) to confirm that you have found the optimal speed.

Part 2: Test an alternative slide speed.

If the slide speed you just tested didn't produce 6 good parts and 0 failed parts, then you will need to test an alternative slide speed.

Step 1: Reset the batch count. 

Once you have noted the performance results of the previous slide speed, reset the batch count. 

Step 2: Change the slide speed. 

Navigate to the Manual Mode screen. 

Touch the Slide Speed button and a numeric entry popup will appear that will allow you to change the Slide Speed value. 

Pick a new slide speed to test. 

Step 3: Run 6 parts through the machine.

1. Go to the Manual Screen on the HMI and select the Manual Mode button.  
2. Navigate to the Home Screen and select "Cycle Start."
3. Watch the machine to verify that it is running correctly.
4. After it has run 3 parts, the machine should stop. Press "Cycle Start" again and watch the machine produce 3 more parts. 

Step 4: Check the performance of the new slide speed. 

Return to the hourly counts screen to check the new batch count. If it says 6 parts have passed and 0 have failed, you have found the optimal speed. If it doesn't say 6 have passed and 0 have failed, then you will need to test a different slide speed. 

If any of the parts fail, you will need to make an adjustment to the Slide Speed and try again.

Part 3: Record the machine's optimal speed.

Repeat the above process of adjusting the slide speed and checking the results until you find the slide speed where the machine's performance is optimized.

You will know that your machine is optimized when you run at least 12 parts and they all pass.

Once you have found the optimal speed, take a picture of (1) your batch count screen, showing at least 12 passes and 0 fails and (2) the slide speed at which you found the optimal speed. Be sure to include your face in the picture somewhere. (You may need to have another student take a picture of you.)

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TIPS

• The default Slide Speed value for all three models is 500 ms. This is a good starting point.
• Starting with a value of 500, run six parts and write down how many parts pass and how many fail.
• Make a small adjustment (add or subtract 1 from the Slide Speed) and test again. Do not go lower than 495 and higher than 505.
• When you test a new speed, be sure to reset the batch count.
• Write down on paper the Slide Speed values you test and write down how many parts pass and fail each time you test.
• The closer you get to the optimal setting, the more parts will pass and the fewer parts will fail.
• Continue running the machine making the adjustments until the machine runs 12 parts with all of them passing and none of them failing.
  

  

• When you find the optimal setting, write it down. You will need to submit it at the end of this lab.

How the Basic Automation Trainer Works:

• Start the machine by touching the "Cycle Start" HMI push button, or by pressing the green push button on the trainer board.
• At any time as the machine is running, if the red push button on the trainer board is pressed, the sequence and robot will "Pause".
• Resume from "Pause" by pressing the "Cycle Start" HMI push button, or by pressing the green push button on the trainer board.
• The "Cycle Stop" HMI push button tells the machine to stop at the "End of Cycle".
  
  NOTE

  One cycle consists of the robot picking and placing all 3 cylinders or blocks.

• If you want the machine to automatically stop after all 3 cylinders or blocks are picked and placed, while the machine is running, press the "Cycle Stop" HMI push button. The machine will stop once it has finished picking and placing the 3 parts. 
  • Pressing "Cycle Stop" on the HMI will not pause the robot; the robot will continue to pick and place the parts. 
  • If you need the machine to stop immediately, press the red push button on the trainer board to "Pause" the sequence and robot, then cycle the "Maintained" switch back and forth to cycle the sequence home.
  • If there is an emergency with the robot, press the E-Stop to stop it.
  • The Maintained switch must be in the correct position to start the sequence.
  • If the Maintained switch is in the wrong position when Cycle Start" is pressed, a message will be displayed on the HMI telling you that the Maintained switch is in the incorrect position.
  • If the machine gets lost in its sequence or you just want to start the sequence over, move the "Maintained" switch to the wrong position, then turn it back. This resets the sequence.
  • When the "Maintained" switch is cycled back and forth, a "Cycle Home" button appears on the Main Screen of the HMI. 
  • Touching the "Cycle Home" HMI push button tells the robot to go to its "Home" position.
  • If the Maintained switch is in the wrong position when Cycle Start" is pressed, a message will be displayed on the HMI telling you that the Maintained switch is in the incorrect position.
  • If there is an emergency with the robot, press the E-Stop to stop it.
  • If you need the machine to stop immediately, press the red push button on the trainer board to "Pause" the sequence and robot, then cycle the "Maintained" switch back and forth to cycle the sequence home.

If you have any questions, ask an instructor.

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SUBMISSION 

• Submit the two pictures you took as part of this lab.
• Enter in the final slide speed.