Internet of Things in Overall Equipment Effectiveness Production

System Applications

Dina Fitria Murad

, Bambang Dwi Wijanarko

, Denny

and Alfath Syahrian

Information Systems Department, BINUS Online Learning, Bina Nusantara University, Jakarta, Indonesia

Computer Science Department, BINUS Online Learning, Bina Nusantara University, Jakarta, Indonesia

Keywords:

The internet of thing, industry 4.0, Overall Equipment Effectiveness (OEE), manufacturing, machine services.

Abstract:

Utilization of Internet of Thing (IoT) can increase efﬁciency, and real-time optimization. IoT integration in

industrial machines helps the process of monitoring the production processing, thus avoiding single point of

failure and easier for resource expansion, so that the machines will be optimal in their use because it can be

known at the right time for maintenance. The purpose of this study is to optimize the use of machines in

production, especially the process of monitoring production machinery. Using the IoT and Overall Equipment

Effectiveness (OEE) approach to the machine, the data is calculated to facilitate the analysis process. The

application of the Internet of Things in the ﬁeld of manufacturing production especially in this company has

proven to be effective in making industrial machine services become smarter, more transparent and efﬁcient.

1 INTRODUCTION

PT. Ultra Sakti is a pharmaceutical company that pro-

duces OTC (Over The Counter) medicines, which are

drugs that can be sold freely on the market. In car-

rying out these drug production activities, PT. Ultra

Sakti always makes efforts to produce quality prod-

ucts by differentiating through quality strategy and

value strategy. Quality strategy is to provide prod-

ucts with better quality than competitor products to

build satisfaction and loyalty from customers. Strat-

egy value is carried out by submitting more amounts

to customers, both through more functional and bet-

ter services, while always maintaining an affordable

price for the products sold.

PT. Ultra Sakti is present in the pharmaceutical in-

dustry with the awareness that this industry must be

faced with innovation and the creation of high qual-

ity and competitive products. To strengthen the com-

pany’s presence, PT. Ultra Sakti is positioning itself to

be a pharmaceutical company that implements stan-

dard and modern production standards. Accompanied

by ﬁrm commitments and innovations that are carried

out sustainably, the company’s contribution to indus-

try acquisition is expected to increase. To create a

quality product, one of the systems development that

is carried out is to use internet technology that is im-

plemented on a production machine, its application is

carried out in the form of machine and data integra-

tion that can be used for the OEE (Overall Equipment

Effectiveness) process (see ﬁgure 1).

Figure 1: Production Process Flowchart.

To support the implementation and implementa-

tion of Industry 4.0 in PT. Ultra Sakti, the process of

developing technology and information that can help

the means of production activities, must be done auto-

matically and has been integrated with the core ERP

system, where data and information processing can be

done and generated quickly, easily and precisely. One

of the things that can be done to support this process is

to optimize the use of machines in production. To ﬁnd

out and monitor the effectiveness of the use of these

machines, it can be done by calculating OEE on these

machines, so that the device can be known easily.

The application of IoT to manufacturing and sup-

ply chain management has become popular in vari-

ous industries like smart cities (Tanwar et al., 2018),

transportation (Murad et al., 2018), bigdata (Hashem

et al., 2016). Connected equipment, tracking peo-

ple and goods or devices, sampling cycle manage-

ment, and production cycle monitoring are one of

the IoT applications in the industry, data acquisition

Murad, D., Wijanarko, B., Denny, . and Syahrian, A.

Internet of Things in Overall Equipment Effectiveness Production System Applications.

DOI: 10.5220/0009909503050310

In Proceedings of the International Conferences on Information System and Technology (CONRIST 2019), pages 305-310

ISBN: 978-989-758-453-4

305

at the level of PLC (Programmable Logic Control)

and supervisor systems, then the data is processed

in Computing to connect to MES (Management Ex-

clusion System) and ERP (Enterprise Resource Plan-

ning) system. Meanwhile, a system that is interre-

lated to connect the central system owned by the com-

pany (ERP) with production tools can help the process

of monitoring the performance of existing production

machines and can assist in analyzing and calculating

OEE.

This research utilizes the Internet of Things (IoT).

IoT is a concept where particular objects have the

ability to transfer data over a network without requir-

ing interaction from human to human or from human

to computer devices. IoT emphasizes the integration

of process and management with the system by pro-

viding all data on-board (Nasir et al., 2018b) (Nasir

et al., 2018a). Utilization of IoT has also been carried

out by (Gunasekaran and Periakaruppan, 2017) where

IoT is implemented to create a smart home by using

Arduino as an I / O signal receiver from the installed

device, the working principle of the invention is the

same, Arduino is programmed to carry out commands

from the received signal, then the system will work as

instructed. With recent developments and the IoT ap-

plication, it has been possible to resolve this problem.

It is hoped that the system created can help the par-

ties involved, including production staff, operators &

heads of production and management, to monitor pro-

duction activities and know the results of OEE calcu-

lations in real-time so that they can quickly assist in

making decisions.

The purpose of this research is to build integrated

system automation between machines, technology,

and information using IoT. Based on that, the research

questions in this study are how the use of IoT can help

OEE systems become availability, performance, qual-

ity, and achievement in the use of machines.

2 LITERATURE REVIEW

2.1 Hardware

Hardware or hardware is all the physical parts of a

computer and is distinguished from the data that is

in it or that operates in it and is separated from the

software (software) that provides instructions for the

hardware in completing its work.

In this study, the authors use the following hard-

ware:

1. Computer

The computer is used as a web server; the oper-

ating system used is Windows 10. The machine

is in charge of storing scripts, images, and web-

site page content. Web Servers must be accessible

from all areas that have an internet connection.

2. M2M Controller

M2M Controller is hardware with Modbus / TCP

as a tool used to communicate between the signal

signaling device and other controller units such

as PLC or SCADA. The M2M controller can also

function as an input/output unit for long distances

in a client server-based communication control

system.

Figure 2: CONPROSYS M2M Controller

3. Arduino Uno R3

Arduino is an open-source single-board micro-

controller, derived from the Wiring platform, de-

signed to facilitate the use of electronics in vari-

ous ﬁelds. Arduino also simpliﬁes the process of

working with a microcontroller. Here are the rea-

sons for the authors to use Arduino, as a signal

sensor to the controller, namely:

(a) Arduino prices are relatively low, ranging from

IDR 100,000, up to the cost of IDR 400,000, -

the price is cheaper than other professional mi-

crocontroller platforms.

(b) Arduino libraries are easy to get, available in

full on the Arduino website and even on other

Arduino community websites.

suitable for working on Linux.

(d) Simple and easy programming, Arduino is easy

to use for beginners and ﬂexible enough for

those who are already advanced. Arduino is

based on a processing programming environ-

ment, so if students or students are accustomed

to using processing, of course it will be easy to

use Arduino.

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space

Figure 3: Arduino Uno R3

2.2 Previous Research

Some of the studies that correlate with this study are

summarized in Figure 4. There are several uses of

IoT in the same ﬁeld with different methods and ap-

proaches.

Figure 4: Previous Research.

space

Figure 5: Previous Research(cont.).

Internet of Things in Overall Equipment Effectiveness Production System Applications

307

space

Figure 6: Previous Research(cont.).

Based on the literature review, the Internet of

things can be used to help make the whole process au-

tomatic, where devices can be controlled by programs

that can be run from various places, according to the

needs that are expected. The results of the research re-

view can also be used by the writer in understanding

the use of the Internet of Things in the manufactur-

ing and smart factory world where these inﬂuences to

provide support in real-time in the world of produc-

tion and improve OEE.

From study 1, the method used is the same,

namely by utilizing Arduino Uno and acting as an au-

tomation system, the difference lies in its use where

this thesis is used to support OEE applications at PT

Ultra Sakti. Study 3 also deals with improving OEE,

but the difference is that study 3 uses DMAIC & Sig

Sixma Approach. In Research 2, 4, and 5, the simi-

larities are discussed concerning the use of IoT in the

manufacturing and smart factory world.

3 RESULT AND DISCUSSION

The system built is to capture machine activity us-

ing internet technology, where the OEE process of

recording activity data from machine activity is done

automatically.

The process of implementing IoT (Internet of

Things) in the production process at PT. Ultra Sakti is

to use a digital input and digital output sensor system

and M2M Controller installed on the production ma-

chine, where the sensor system will send data through

the internet about the activities carried out by the de-

vice, starting from the engine running until it is turned

off. This process is carried out automatically by using

tools and data sent to the server, and then the data will

be processed into reports that can be used for various

analysis and strategy development to make the pro-

duction process more efﬁcient and effective.

The following Figure 7 shows the business pro-

cess and IT infrastructure by utilizing IoT as a liaison

or identiﬁer for several devices in the system is built.

Figure 7: Business process and IT infrastructure by using

IoT

And, to support the system to run better, it needs

several supporting devices such as (1) The server

computer (Figure 8) is used as a web server that func-

tions to receive requests that have been sent by the de-

vice or that are called through a browser application

and then respond to requests in the form of web pages

or more generally in HTML documents, (2) CON-

PROSYS M2M Controller (Figure 9) is used as a data

logger and receiver of signals sent by sensors or relays

from Arduino Uno R3 installed on the production ma-

chine, Sensors or relays installed are LOSS sensors,

DOWN sensors, GOOD sensors and NO GOOD sen-

sors, where the data triggers the OEE (Overall Equip-

ment Effectiveness) calculation, (3) Arduino UNO R3

(Figure 10) is used to receive digital input, and digi-

tal output signals which will then be transferred to the

M2M Controller and the data will be forwarded to the

webserver.

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space

Figure 8: Computer server

Figure 9: CONPROSYS M2M Controller

Figure 10: Arduino UNO R3

As per Figure 7, the system generates informa-

tion that supports business processes that are better

and smarter. Intelligent information systems that are

formed produce information in real-time based on

data input from Arduino supported by IoT. Here are

some access and dashboard views for each system

user:

1. Management

Management has access to see all activities that

occur in the system; in general, management only

sees the whole system through the dashboard re-

port.

Figure 11: Management access

2. Division Head and Department Head (All Depart-

ments)

Division Heads and Department Heads have ac-

cess to view detailed data per production line, per

batch (lot), per item, and view by the target.

space

Figure 12: Report Line Per Lot

3. Production Supervisor & Admin

To make a schedule and conﬁgure the queue list

in the system is done by the supervisor & admin

of the production department.

Figure 13: Production Schedule

4. Production Staff & Operators

The user who interacts the most is the staff and op-

erators of the production department, where every

procedure for the process carried out follows the

conditions set by the system.

Figure 14: Daily Activity Machine

4 CONCLUSIONS

From the results of the ongoing system analysis, it

is known that the OEE calculation process, availabil-

ity, performance, quality, and achievement have sev-

eral problems so that all of these problems can lead to

an analysis process in dealing with issues and obsta-

cles that occur in the production department requires

a long time to ﬁnd solutions and preventive mainte-

nance. So, in the research conducted by the author,

several results have been obtained, namely:

1. Industry 4.0 implementation by implementing

data processing automation between machine de-

vices and systems using IoT technology so that

it can improve effectiveness and can be appropri-

ately measured.

2. Communication between devices can be done us-

ing internet technology, where the tool sends a

signal to the server, and the data is processed into

the system.

3. M2M Controller can be made efﬁciently in a sim-

ple way, by developing a programming language

Internet of Things in Overall Equipment Effectiveness Production System Applications

309

that can give commands to the controller to pro-

vide the data needed by the system.

4. Web Application-based systems can support OEE

calculation processes, availability, performance,

quality and achievement faster than before, this

application system can be accessed by users

through a variety of devices and platforms.

5. OEE calculation system which previously took

3 hours to prepare documents and calculations.

However, the proposed system process that has

been developed, then it accelerates the calculation

process time in real time.

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