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MEMEX @ Mfg4

Mfg4 is the most efficient way for you to see and evaluate the latest Aerospace, Defense, and Medical manufacturing technologies The aerospace, defense, and medical device industries share similar challenges: long project lifecycles, stringent regulations, mission-critical quality control, and a vital need for advanced manufacturing technologies.

Attending Mfg4 2016 provides a unique opportunity to explore the methods and products that are working in these industries and discover how they can be adapted and implemented within your operation. Collaborate with suppliers who already understand the challenges your firm faces and have proven solutions you can put to use immediately.

Nearly every hour on the show floor, professional presentations will provide important insights into each featured industry. Attend keynotes presented by industry leaders and hear how the technologies on the exhibit floor are tackling production issues in innovative ways during the Information Interchange

Attend the MEMEX sponsored smart manufacturing panel along with hearing from industry leaders on topics vital to industry manufacturers, network with peers and find ideas and solutions you didn’t even know you needed.

Meet up with MEMEX representative and discover what the Brilliant Factory means for you along with the tools you need to plan and execute successful strategies for your own digital factory of the future.

Date: 3rd – 5th May, 2016

Time:  Tuesday, May 3

10:00 a.m. – 5:00 p.m.

Wednesday, May 4

10:00 a.m. – 5:00 p.m.

Thursday, May 5

10:00 a.m. – 4:00 p.m

Venue: Connecticut Convention Center

100 Columbus Boulevard

Hartford, CT 06103

 

Learn more about Mfg4

Register for Mfg4

Smarten Up

April 2016, Machine Metrics | Quality, Kip Hanson

When I started on the shop foor, machine tools were dumb. Communication levels weren’t determined by protocols or baud rates but by which machinist could yell the loudest. NC programs were loaded from paper tape, tool offsets made with a hammer, and part quality results recorded on handwritten forms.

What a change a few decades make. Today’s technology allows shops to monitor virtually every aspect of production, from what tools were changed yesterday to how many minutes the spindles sat idle last week to what jobs are running on which machines right now. So much has changed, in fact, that some say the next industrial revolution, or Industry 4.0, is upon us.

Getting everyone on the same page

One proponent of this revolution is David McPhail, president of industrial communications platform provider Memex Inc., in Burlington, ON, who counts Mazak Corp. among key global customers for the company’s flagship product, Merlin. McPhail points to data driven manufacturing and the Industrial Internet of Things (IIoT) as two examples of the technology companies can leverage to improve productivity and part quality, if only they have the will to overcome fear of the unknown.

“Change of any kind is hard, especially when people don’t understand the technology behind it,” he says. “But when someone thinks to themselves, ‘if I don’t do anything, then there’s no risk,’ it brings about the worst kind of paralysis. Manufacturing companies must learn to embrace technology if they are to gain a competitive advantage.”

Those advantages are numerous. Lights out production, shorter lead times, improved tool life—the list goes on. One often-overlooked benefit of integrated machine communication is better part quality, says McPhail.

Click here to read more: Smarten Up

Towards a Service – Oriented Business with Connected Machines

March 7 , 2016 – Doug Bellin

Mazak Corporation is pulling ahead of its competitors with an innovative connected machine deployment. A global leader in the design and manufacture of machine tools, Mazak has partnered with Cisco and machine – to – machine solutions provider MEMEX Inc. to drastically improve digital integration across all its processes.

To see the full article please click here

To Measure Is To Know – MTConnect book

The world’s first book on MTConnect, an open and royalty-free interoperability standard and the application of open systems in manufacturing has been released and it is titled,  MTConnectTo Measure Is To Know”.  Written by Dave Edstrom, CEO/CTO of MTConnect, the book discusses the many lessons learned in the world of open systems and the value this means to the manufacturing industry.

Dave Edstrom has spent over 35 years in the computer industry.  He helps the reader understand that MTConnect is not just an evolution in manufacturing, but that it is a revolution, a true game changer.  “MTConnect will be more important in the 21st century for manufacturing than CNC was for manufacturing in the 20th century” said John Byrd, former president of Association Manufacturing Technology, www.amtonline.org   (MTConnect: To Measure Is To Know. Ashburn: Virtual Photons Electrons, 2013. pg xiii).  MTConnect is making the dreams and desires of generations of manufactures possible.  Machine tool builders and manufacturing equipment providers alike all want to see the same goal of different devices having a common connection on the plant floor.  With MTConnect, anything is possible.

A few excerpts from the book:

“Only one to two percent of all shops monitor their shop floor.  The ability to know what is happening on your shop or plant floor anywhere, at anytime, is vital to the manufacturing process.  As a comparison, the next time you go in for a surgery, tell the surgeon that you want to save money and not monitor any of your vital signs.  Drop me a note and tell me what the surgeon tells you.  Then why is it that 98% to 99% of all shops don’t bother monitoring their shop floor?

Think of MTConnect as the Bluetooth of manufacturing that makes it easy to get information off your manufacturing equipment.  MTConnect is not an application, but it makes it very easy for applications to read data in a common and universal format.

Different Devices, Common Connection.
(MTConnect: To Measure Is To Know. Ashburn: Virtual Photons Electrons, 2013. pg xii).

“The process of standardization is always a political struggle with winners and losers.  The primary winners will be those companies that understand it is co-opetition (competition and cooperation) that drives thriving markets.  The primary losers will be those companies holding on to proprietary solutions at all costs.  With a standard screw, you could now have standard tools, standard assembly lines, and the growth of mass production.”
(MTConnect: To Measure Is To Know. Ashburn: Virtual Photons Electrons, 2013. pg 3.)

“If we look at the manufacturing companies that are embracing open thinking and open collaboration, these companies report secondary benefits in morale as their employees typically tell their management that they have a much higher job satisfaction.”
(MTConnect: To Measure Is To Know. Ashburn: Virtual Photons Electrons, 2013. pg 22).

Memex is mentioned in the acknowledgements

“Huge thanks to Dave McPhail, president of Memex Automation.  Dave is a great guy, and so is his business partner, John Rattray, who is the vice president of sales and marketing, as well as the whole Memex Automation team.  Thanks as well to Bob Hansen of R.C. Hansen Consulting for his help at [MC]2 2013 and educating me on OEE”
(Dave Edstrom, MTConnect: To Measure Is To Know. Ashburn: Virtual Photons Electrons, 2013. pg 209).

There is a paperback version that is available at Amazon.

Top 5 Reasons to use Memex MERLIN MES for OEE & DNC

Serial communications is old outdated technology.  It has slow transfer speeds, it is slow to load today’s big programs into controls, and it is especially unreliable on long distance runs.  MERLIN is built on today’s modern, reliable IT Ethernet network structure.

To help deliver operational efficiency with production visibility to your manufacturing enterprise, here are the top 5 reasons to work with the award winning Memex MERLIN for OEE and DNC.

1)  Memex MERLIN is a true Manufacturing Execution System.

  • MERLIN MES is vertically and horizontally integrated across the enterprise.
    • Vertically integrated means that it executes ERP’s planned production schedule.  It takes all the work orders from your ERP system, mirrors them on a machine and manufacturing cell or assembly basis, and at completion (end of work order and end of shift) sends the ERP an upload of actual results on how production actually ran.  This enables a comparison to be made of how the production ran for an accurate time and cost picture.
    • Horizontally integrated means that the complete shop floor flow-line of production is viewed and communicated in real-time.  This enables situational analysis, bottleneck identification, and resources to be allocated (when and where they’re needed) in the shortest period of time –  all with historical, traceable reporting.
    • Integration means objective visibility about utilization.  True OEE metrics, product run and cost standards, and the requirements of the operator for resources (engineering, maintenance, crane, dunnage, 1st off quality check, etc.) can all be communicated to all stakeholders in real-time.

2)  MERLIN is an independent and unobtrusive monitoring solution.

  • Software protocols and hardware network connectivity (if required) that are electrically (optically) isolated from the control.
  • MERLIN does not affect the machine’s performance.  It does not use programs or memory, it simply listens to the machine.

3)  Memex MERLIN system can operate independent of any DNC solution.

  • Any existing DNC solutions in your site can still be used in conjunction with MERLIN
  • Or, if you  prefer, you can use MERLIN’s built in DNC.

4)  MERLIN is built on the latest & proven technology of the Microsoft platform.

  • MERLIN incorporates MTConnect, OPC, Focas and other advanced protocols for machine communication.
  • It is built on reliable Ethernet network (wired or wireless) rather than the older, slower, and unreliable serial based communication technology.

5)  Memex MERLIN system really is the BEST VALUE solution.

  • MERLIN has delivered our customers 10% to 50% or more improvement in efficiency, all thanks to its horizontal and vertical integration,
  • It adheres to ISA-95 standards of machine connectivity and fits with your IT network infrastructure.
  • It is a safe and proven technology that is being used globally.

To find out more about these 5 points, and even more reasons why Memex MERLIN is the best MES solution, contact Memex sales today at 866-573-3895 or via email to salesgroup@memex.ca

To learn more about Memex’s MERLIN, check out these short videos on topics covered in Memex’s OEE Solution Series webinars.

Value of MES in real dollars $15,000 per machine, every year.

Imagine increasing profit $15,000 per machine, sustained every year.  We can do it.

Modern Machine Shop’s “Top Shops” benchmarking survey, 2012 shows immense value for the use of an MES system.  Critical findings of the survey:

“The average gross sales for the Top Shops were 14 percent higher than the other shops.”

“The Top Shops achieve higher spindle utilization and faster setup times because they put a good deal of thought into optimizing shop floor processes and practices.”

“These shops are also more likely to implement continuous improvement strategies to become more effective as well as lean manufacturing concepts to become more efficient.”

Top Shops had a 12.6% better OEE metric than average shops.  A 10% improvement in OEE (capacity utilization) will increase IFO 22% (from the book: “Overall Equipment Effectiveness: A Powerful Production/Maintenance Tool for Increased Profits”, Robert C. Hansen, Pgs 47-56).

Memex’s MERLIN MES is a tool that allows your organization to achieve these results!

The value of MERLIN, using actual KPI measurements to your operation, is significant:

  • A +10%-20% increase in OEE is achieved by our customers following installation, typically within 12 weeks.
  • Using an average of $302,066 in annual revenue per machine and average profitability of 18.9% (Modern Machine Shop, Top Shops – Benchmark Your Machining Business, 2012, page 24*) a conservative 10% increase across 90 machines translates to +$2.7 Million per year increase in revenue and +$500,000 in profit.
  • This means, by machine, a +$30,206 increase in revenue and a $12,000 to $15,000 increase in profit.
  • At a conservative 10% increase in efficiency the breakeven is typically 3-5 months.
  • ROI of 100% in the first 12 months based on profit, or approaching 1,000% when factoring in increased revenue!

*Sponsored by AMT, the survey covered more than 500 manufacturing facilities.

MES is one of the best strategic drivers to obtain a competitive advantage in the manufacturing landscape improving profitability, reducing waste, and ensuring compliance with regulations.  The top 5 summary reasons are here.  For more detail, including ROI analysis tools and Lean Roadmap tools call Memex directly.

1) An MES system should be the highest priority project as it is more important than a capital equipment acquisition.  The value of an MES is significant to the stakeholders of a company far surpassing any other ROI.

2) Plant wide efficiency improvements greater than 10% are normal and drive a company to significant success.

3) Profitability is exponentially improved and sustained every year.

4) ROI typically of 100% in the first 12 months based on profit, a payback typically in the 3-5 months range.

5) Every day a company waits to implement an MES is lost profits that cannot be re-covered.

Manufacturing journalist TR Cutler profiles the OEE Calculator

Manufacturing journalist, TR Cutler, recently profiled the OEE Calculator by Memex Automation for Industrial Electronics Today.

The leading OEE (overall equipment effectiveness) Calculator, quantifies the increase in Income From Operations (IFO or EBITDA) for Same Sales Volume and Sell Everything scenarios for various improvement criteria. The OEE ROI calculator is a very preliminary ‘rough cut’ analysis tool for developing a business case (to engage real-time manufacturing performance data for shop floor machines in manufacturing plants). Part of the reason Calculator is ‘rough’ is because a Plant average is used for several important parameters such as OEE, shift output, and quality rate.

Much greater precision can be developed by using actual OEE data differentiated by product run and by work station. Future monitoring and proactive use of the information provided by an installed system significantly improves accuracy of alternatives; these data assists leadership teams in setting direction and focus to maximize results quickly. Rattray noted that, “First Look results are generated using Small, Medium and Large preselected productivity improvements to show the range of possible results.”

The current input values in the OEE Calculator, use hypothetical but realistic values for a machine tool plant. It is estimated that for most manufacturing plants, the Calculator results have a confidence level of eighty-five percent (85%), plus or minus three percent (3%.)

The OEE Calculator does not apply the Theory of Constraints (TOC) therefore, if the proper application of tools and OEE improvement is not achieved at the constraint, then the increase to IFO is also limited. The quality factor usually has more impact than Availability or Speed Factor for bottom line improvement. When waste or scrap is improved, OEE improves; the result, less material needed. It is important to apply Lean Six Sigma techniques to your manufacturing operations, so as to achieve significant results. Memex offers services in this area, as documented in our website.

Memex suggests that users of the OEE Calculator, “Closely account for the change in material since it determines the new amount of total units made and applies the base case unit material cost to the total number of new units required to make the good units for the associated scenario.” The Calculator zeroes all of the improvement parameters and individually examines what one (1) OEE point improvement is worth for Availability, Speed Rate, and Quality. This data provides the user an approximation of financial impact on IFO for types of improvement activities.

Memex Automation Talks Benefits of Direct Numerical Control Software

Originally published online by SBW!RE.  Link to full article here.

According to John Rattray of Memex Automation, “By monitoring assets such as tooling, raw materials, Work In Progress, computers, vehicles and any moveable assets, companies can know quickly, exactly, and securely where assets are located. Direct Numerical Control Software (DNC) improves machines operational performance and increases shop floor productivity.”

DNC Software for Windows 7, Vista, Windows XP and others is a 32-bit multi-threaded communications & file management system allowing simultaneous upload and download to multiple CNC controls. It includes a CNC Editor, Backplotter and many other utilities and features. DNC Software is easily connected to CAD/CAM systems over industry standard networks and is available in a Client-Server configuration. Besides machine tool DNC communications, other shop floor data can be collected from shop terminals, tool pre-setters, bar code equipment or SPC systems.

2009 was a Banner Year!

Much work was done in 2009 with new product development and many customer deployments. The flagship OEE+DNC product was rolled out this year.

Many customers offered to work with us to evaluate its merits as well as many aerospace customers, including one in a corporate wide multi-plant rollout into production.  Going into 2010 we are working with about 2 dozen customers in various stages of deployment with this enterprise product offering 5-20% increase in productivity at the shop floor.

Memex’s engineering team continued in its reputation as the “Go To machine technology company”, and rolled out many new hardware and software products in 2009, from memory boards, the Ax750 I/O Link – Fanuc Interface Board, Ax2200HS High Speed File Server, AxDNC and AxConfig software tools and many other items.

Although it was a tough year for our manufacturing industry, our business paradigm of offering tools to increase efficiency was in demand, and we responded with solutions, attending trade shows, industry association events and delivering customer successes.

Company-wise, thanks to some timely positioning of resources, our investors and our employees along with our distribution channel are very pleased and we are ready to roll for 2010!

Memex OEE+DNC Increases Productivity and Lowers Costs for U.S. Aerospace Customers

Memex announces that many new aerospace consumers in the USA and throughout North America have chosen our products to monitor and control their machines on the shop floor. They are utilizing Memex’s complete system to address their OEE and DNC requirements. This gives them the ability to monitor production status, run time, down time reasons, reject causes in real time and automatically report on OEE accurately. They have control of their part programs with Memex’s newly re-designed, state of the art DNC software, called AxDNC. Work orders on the floor are managed through Memex’s OEE+DNC and can be integrated to their ERP systems as well as their CAD/CAM part programs and HR reporting.