Production-line weighing system modernization

Objective: Save resources, protect investments

A 15-year-old production-line weighing system, part of the assembly line, stopped itself on a weekly basis, resulting in inaccuracy in products’ unit weights and missing production line information. Since data concerning weight was of poor quality, it provided limited insight for post-production analysis.

The weighing system did not integrate with any other systems, and two to three hours of human labor was needed on a daily basis to reconcile data. This caused delays in information availability, made data prone to errors, and was waste of human resources.

Understanding Production Lines

Benefits of Using Production Lines

Production lines offer numerous benefits that can significantly enhance business operations. One of the primary advantages is increased productivity, as the linear arrangement of workstations and the division of labor streamline the production process. This setup reduces labor costs by minimizing the need for manual intervention and allows for consistent product quality, as each item is produced under the same conditions. Additionally, production lines help reduce waste and increase production volume, enabling businesses to meet higher demand without compromising on quality. Overall, the use of production lines makes the production process more efficient and cost-effective.

Types of Production Lines

There are several types of production lines, each tailored to different manufacturing needs and product types:

• Mass Production Line: This type involves producing identical items in large quantities. Each product is uniform in form, size, substance, and assembly, making it ideal for high-demand goods.
• Batch Production Line: In batch production, items are made in groups or batches. All products within a single batch are identical, allowing for flexibility in production without sacrificing efficiency.
• Project/Job Production Line: Also known as job production, this type customizes the workflow based on specific orders from clients. It is suitable for specialized or bespoke products.
• Just-In-Time Production Line: This method produces items only when orders are placed, reducing inventory costs and ensuring that products are fresh and up-to-date.
• Flexible Manufacturing System (FMS) Production Line: An FMS production line is optimized for customization, allowing for variations in product lines while maintaining efficiency and quality.

Each type of production line offers unique advantages, making it possible to choose the best approach based on the specific needs of the manufacturing process.

Modernization through software re-engineering

The project began by Proekspert engineers paying onsite visits to the factory to observe the problem and its cause. Our objective: To protect the investment in the existing weighing system and to enable integration with the production line, without adding any new hardware.

The reengineering process involved a detailed analysis of the existing software system to identify areas for improvement.

The Proekspert team protected the original investment by re-engineering the existing system through a structured re engineering process so that it would run on new software. To enhance the data, the team integrated OEE monitoring software Evocon via the API, which enabled the pairing of weight data with its relevant product. This information is now available in a web application that combines business logic and data. New data sources are easily added to the system.

The modernization project also focused on enhancing the software system to ensure it could support future upgrades and integrations.

After the first development phase, Proekspert helped Paljassaare to integrate a brand new scale into its system.

Reverse Engineering in Production Line Modernization

What is Reverse Engineering?

Reverse engineering is a method used to deconstruct an object to understand how it was created. This process involves taking apart a device, system, or piece of software to analyze its components and functionality. In the realm of software development, reverse engineering is particularly valuable for understanding and documenting existing systems, especially when the original developers are no longer available. By employing reverse engineering techniques, engineers can gain insights into the software architecture and behavior of the existing system, enabling them to recreate or improve upon it.

Reverse engineering is utilized across various fields, including computer engineering, game development, mechanical engineering, design, electronic engineering, chemical engineering, and systems biology. In the context of software modernization, it plays a crucial role in re-engineering projects. Experienced engineers use reverse engineering to analyze and document the system, ensuring that the modernization process is thorough and effective. This approach not only preserves the functionality of the existing system but also enhances it, making it more compatible with modern production lines and business operations.

Trusted data enables better business operations decisions

The project accomplished its objective, which was to protect the investment and eliminate manual labor. The hardware investment, made more than 15 years ago, was protected by software re-engineering, and was then integrated with other production systems. Also, manual labor is no longer required for collecting, handling, or reconciling data.

Results

• People are freed for more valuable work.
• Change enables production line work and assembly lines to be monitored, analyzed, and improved.
• Better business decisions are made due to reliable data.

Having a quality weight control system in place, is also important for production to respond the prepackaged products EU directive 76/211/EEC e-mark standard for which audits occur annually.

Client comment

“The project accomplished its objective, which was to protect the investment and eliminate manual labor. The hardware investment, made more than 15 years ago, was protected by software re-engineering, and was then integrated with other production systems. Also, manual labor is no longer required for collecting, handling, or reconciling data.”

Jüri Mallene
Production Manager, Paljassaare Kalatööstus AS