Data Logging and Error Reduction via Modern Controls
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Enhancing Reliability with Advanced Control Systems
Modern electronic controls have replaced older control systems, significantly impacting production plant operations and equipment requirements. These systems make life considerably easier for the operator and play a crucial role in data logging and error reduction.
Automated Data Recording and Error Prevention
One key advantage is that administration and registering of line controls are automatically stored and printed without errors. This automated, error-free data logging replaces manual recording, which was prone to mistakes. The ease of use and visual feedback provided by these controls also contribute to error reduction. For instance, scanner signals are now visible on the control screen and adjustable by operators, removing past frustrations and preventing errors caused by operators "working in the dark".
Impact on Cost and Reliability
Reliability and reproducibility are directly linked to equipment designed for 'maintenance-free' operation. Unexpected stops are costly, and controls that help avoid mistakes leading to reject are essential, particularly as reject becomes more costly further down the production line. The automatic check provided by visual machine settings on screen helps reduce mistakes, contributing to lower costs.
Technical Specifications
Metric
Description
Data Recording
Automatic storage/printing of line controls.
Error Rate (Manual vs. Auto)
Automatic recording is without errors.
Reject Cost vs. Overweight
3% less reject saves equal to 1-2% overweight.
OEE Calculation Example
0.9 (Availability) x 0.9 (Performance) x 0.9 (Quality) = 73% production.
FAQ Section
How do modern electronic controls reduce errors in pipe extrusion?
Modern controls reduce errors by automating tasks like administration and data logging, ensuring they are stored/printed without errors. They also provide visual process feedback, like scanner signals on screen, enabling operators to make informed adjustments and preventing errors from manual misinterpretation or lack of information.
What is the impact of data logging and error reduction on production costs?
Reducing errors, particularly those leading to reject, directly lowers costs, especially as reject is more expensive later in the production line. Automatic, error-free data logging and visual controls contribute to reliability and reproducibility, minimizing unexpected stops and lowering overall costs.
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Albert Vaartjes
