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1. Fig 7 Productivity displayed in Android Application of NIRMAN FIS Customer Satisfaction is the basic objective behind every manufactured product Quality of the product determines the level of influence of the product on the customers Hence Quality Testing of products is essential to before the manufactured product is delivered to customer A manufactured product is approved for delivery to customer only if it passes all quality tests For large products like cars or tractors quality testing involves documentation of many parameters of the product It undergoes many tests the results of which are DOI 10 9790 1676 10331428 www iosrjournals org 18 Page A Smart Manufacturing Execution System recorded on papers Thus quality testing consumes many papers NIRMAN FIS aims towards minimization of paper usage and promotes Green and Paperless Factory A list of quality control parameters is prepared in the android application of NIRMAN FIS as shown in Fig 7 When a product passes the test for that parameter we place a Correct Mark on that parameter The procedure is repeated for all the parameters of a single product and pressing Submit button when all parameters for a product are correct will increment the count of Approved Products by 1 When any of the parameters is not correct pressing Submit button will increment the count of Rejected Products Productivity of the factory is calculated by using formula M Approved Products Productivi2. I 3 p Daily Report Section Il Completed 75 1 0 Expected Production Section Il 3 Section lll Completed 100 3 0 Expected Production Section iil 3 Section Efficiency 66 66667 Section lll Efficiency 100 0 Fig 3 Production Details displayed in Android Application of NIRMAN FIS Shift wise data for each stage is made available in Production section of android application As shown in Fig 3 each stage is allotted with percentage i e 25 for stage I 75 for Stage II and 100 for stage III This indicates partial manufacturing of a product For e g Say at the end of the day 50 45 and 30 products have passed through stage I II and III respectively This means that 50 45 and 30 products have completed 25 75 and 100 of the total production process respectively Thus at the end of the day a manager can know the count of products that are partially manufactured and the count of completely manufactured products We can also track the number of products that are available for delivery from Stage I to Stage II or from Stage II to Stage III or from Stage III to Shipping B Factory Environment For complex industrial processes that are automated by process management systems disruptions or short term interruptions of workflows cause high failure costs in the worst case even danger to people or the environment Hence the factory environment should be constantly monitored to check some vital parameters l
3. Similarly when no light falls on the LDR its resistance increases and analog input to AO decreases giving lower values of light intensity Light Intensity consumes only 1 character in the string as it has values between 0 and 9 F Production Status The production status of 3 stages in supervised by the system For the same 3 sensors can be installed at the end of each stage To demonstrate the working of production section 3 button switches as used as DOI 10 9790 1676 10331428 www iosrjournals org 23 Page A Smart Manufacturing Execution System Assembly Line Sensors as shown in Fig 12 These 3 switches which represent 3 stages of the assembly line are connected to pins 5 6 and 7 of Arduino respectively Refer Fig 12 An active low signal is given to Arduino pins when the switch is pressed Pressing a switch is equivalent to product passing from one stage to another stage in an assembly line This active low signal is detected 15 by Arduino to send 1 when the switch is pressed and send O when switch is not pressed 3 characters are used one for each stage whose value will be either O or 1 depending upon the condition of the switch Thus production status consumes 3 characters in the transmitted string In practice a pair of light source and photodiode 2 can be used at the end of each stage of assembly line to detect the movement of products as shown in Fig 16 When no product passes through a stage of assembly line the light e
4. or optically readable barcodes A new feature can be included such that whenever a machine has a problem the machine itself will call for help that will be notified to the user in the application A User Interface UI that supports all major OS platforms like Android iOS and Windows can be developed for making interaction with system easier than ever DOI 10 9790 1676 10331428 www iosrjournals org 27 Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 A Smart Manufacturing Execution System REFERENCES Robert L Boylestad and Louis Nashelsky DC Biasing BJTs in Electronic Devices and Circuit Theory 10th ed New Delhi India Dorling Kindersley India Pvt Ltd 2013 pp 220 222 Robert L Boylestad and Louis Nashelsky Other Two Terminal Devices in Electronic Devices and Circuit Theory 10th ed New Delhi India Dorling Kindersley India Pvt Ltd 2013 pp 814 817 Heiko Meyer Franz Fuchs and Klaus Thiel Factory of the Future in Manufacturing Execution Systems New York McGraw Hill 2009 pp 5 30 Seung Woo Lee So Jeong Nam and Jai Kyung Lee A Real time 4M Collecting Method for Production Information System World Academy of Science Engineering and Technology vol 64 Apr 2012 BMP180 Digital Pressure Sensor Bosch Sensortec Reutlingen Germany 2013 PC bus Specification and User Manual NXP Semiconductors Eindhoven Nether
5. that the use of smartphones in daily activities is making human life easier and faster than ever The concept of using smartphones if extended to industrial and commercial world can help manager to acquire data about his industry or business from anywhere in the world The ever increasing use of Android Smartphones and various applications that run on it led to evolution of NIRMAN Factory Information System FIS An Android based MES that not only monitors important safety parameters in a factory but also provides information about production status and quality NIRMAN FIS provides real time production status calculates production efficiency plots real time graphs and provides many other features for efficient analysis of data II PROPOSED SYSTEM Data Acquisition System of NIRMAN FIS consists of 4 important blocks 1 e Factory Power Control Production Status Factory Environment and Bluetooth Module Details of Data Acquisition System will be discussed in the later part of the paper Arduino Uno Microcontroller Board 11 acquires data about production process and factory environment to process and convert it into required form A Data String Pattern is designed to send this data to Android Application of NIRMAN FIS using HC 05 Bluetooth Module 20 21 With a Data Refresh Rate of 1 minute android application continuously displays and monitors various parameters of the factory The android application also communicates with the web server 8
6. the manager s smartphone screen and helps him to react and take important decisions quickly and flexibly Index Terms Sectional Efficiency Factory Efficiency Assembly Line Threshold Limit Productivity Morale Factory Environment Data Acquisition Analysis Automatic and Manual Control Bluetooth Arduino Android Remote Monitoring I INTRODUCTION Production Managers share a significant task in the production process They continuously monitor the factory operations and are involved in optimizing the operations so as to escalate factory efficiency However monitoring factory operations and production status is not an easy task Many existing computer based industrial automation systems help managers towards accomplishment of his objectives However these systems being bulky are not portable and information is not available to the manager unless he makes use of computer 3 Hence updates about production process are not conveyed to manager when he is away from the system and this may delay some important decisions related to production This drawback necessitates development of new Manufacturing Execution System MES which can be portable and can provide information about factory operations whenever required without physical presence of manager before the system Smartphones are the best portable devices capable of providing enormous information Single click on the smartphone can fetch enormous information for the user We cannot deny
7. 10 to receive some commands and then conveys these commands to Arduino through bluetooth module so as to enable Arduino to take appropriate action to ensure safety inside factory and thus control factory operations DOI 10 9790 1676 10331428 www iosrjournals org 14 Page A Smart Manufacturing Execution System Factory Power Wireless Control Module Production Assembly Line Arduino Uno Microcontroller Board NIRMAN FIS installed in Ami Android Web Server Factory Smartphone Environment Fig 1 Block Diagram of NIRMAN FIS II WORKING OF THE SYSTEM Data received from the Data Acquisition System of NIRMAN FIS is fragmented inside android application to display appropriate data in the respective section of android application The login screen and primary interface of android application is shown in Fig 2 Sections Nirman FIS ty v7 1 Production Safety toe Quality Efficiency icon G Morale Analysis Fig 2 Login Screen and Primary Interface of Android Application in NIRMAN FIS A Assembly Line Efficiency Production Process for any product consists of number of stages A product before completion has to pass through all stages Thus an Assembly Line is divide into appropriate number of stages depending upon the requirements of the production process For simplicity let us consider a factory has 3 stage section assembly line as follows 1 Stage Section I Primaries where raw s
8. E II Safe Set Threshold Air Quality Tile Management P r Configure by QR is ZONE Ill Safe ZONE IV Sate Create QR ID Logout About Fig 4 Safety Section in Android Application of NIRMAN FIS C Automatic and Manual Power Control If the temperature inside factory exceeds Threshold Limit due to fire the tile of the zone will turn red to indicate an emergency situation inside factory as shown in Fig 5 When clicked on that zone the tile of temperature is found to turn red When temperature crosses its Threshold Limit android application communicates with Arduino through bluetooth module and instructs the microcontroller to shut down the main power supply to prevent further damage Sometimes automatic control of the system might introduce a delay in conveying information about an emergency situation or might even fail due to some technical problems At such times if an emergency situation is visible before the eyes of a manager he can use Power ON OFF to manually cut off the power supply to the factory as shown in Fig 5 Similarly Buzzer ON OFF option can be used to notify workers about an emergency situation in the factory When we click on the Power OFF button the system will automatically turn ON an auxiliary power supply as discussed earlier and generate an alarm 0 wa OB 10 53 Air Quality 90 Pressure 0 95 bar Power OFF Buzzer ON Humidity 39 0 Temperature 30 45 C Buzzer OFF
9. Fig 20 Adding a User Account and Voice Recognition in Android Application of NIRMAN FIS DOI 10 9790 1676 10331428 www iosrjournals org 26 Page A Smart Manufacturing Execution System C Voice Recognition Voice recognition allows the user to control application using simple voice commands For example if manager says Open Production the application will receive the voice command and open production section of the NIRMAN FIS Voice recognition enables hands free operation of the application However it requires internet connection to be enabled on the smartphone D SMS Notifications The critical parameters in the factory are informed to manager by NIRMAN FIS through SMS notifications For example if the manager is not present in the factory and temperature exceeds threshold value an SMS is sent to manager by the application Set Phone number Enter 10 digit phone number The SMS alerting about the critical conditions will be sent at this number Fig 21 SMS Notifications in Android Application of NIRMAN FIS The manager needs to save his mobile number in the application as shown in Fig 21 When SMS notification system is turned on the saved mobile number is used by the application to send critical updates to the factory manager VII CONCLUSION NIRMAN FIS is the most reliable solution for Integrated Data Recording and Performance Monitoring in real time Short term and Long term analysis for a factory is therefore po
10. IOSR Journal of Electrical and Electronics Engineering IOSR JEEE e ISSN 2278 1676 p ISSN 2320 3331 Volume 10 Issue 3 Ver III May Jun 2015 PP 14 28 www iosrjournals org A Smart Manufacturing Execution System 1 12 3 Kunal S Jagdale Suyash A Patil and Sanjaykumar K Parchandekar we Department of Electronics Engineering Walchand College of Engineering Sangli 416 415 Maharashtra India Abstract This paper presents a novel design of a smart and efficient Manufacturing Execution System MES to acquire data from the shop floor in a factory With increasing complexities in the production process improving industrial productivity using production information systems is a challenge for all industries in the world Manufacturing Execution Systems MES since their introduction in the factory environment are gaining popularity due to their ability to control and monitor production process using integrated data However employers managers are still confronting with many complications in understanding huge information on the production process and reacting quickly based on such information In this paper we propose the design of NIRMAN Factory Information System FIS A Smart MES to enable the control and monitoring of multiple factors of the production process like assembly line personnel quality control safety etc NIRMAN FIS a MES based on Android Smartphone presents data about factory environment and factory operations on
11. Light Intensity 50 ZONE Ill Unsafe ZONE IV Unsafe q O o lt O o Fig 5 Safety Parameters displayed in Android Application of NIRMAN FIS DOI 10 9790 1676 10331428 www iosrjournals org 17 Page A Smart Manufacturing Execution System As shown in Fig 6 when a safety parameter is below its threshold value power is continuously supplied to the factory This is indicated by Green LED in the system When a safety parameter exceeds threshold value the android application instructs Arduino to make its pin 3 High 16 This pin is connected to the base of transistor Q1 BC 547 Red LED Green LED RL1 au 12 5V PIN 3 OF ARDUINO Fig 6 Power supply to factory turned OFF when a parameter exceeds Threshold Limit When it goes high transistor turns ON and causes the relay to switch 1 turning OFF the Green LED connected to relay thus indicating that the power supply is cut off As indicated by Red LED an auxiliary power supply is turned ON to light evacuation path D Paperless Factory 0 a U 10 58 al Quality Paint Test w Paint Test Electronic System Test Electronic System Test Engine Test Engine Test Braking System Test v Braking System Test Visual Inspection Visual Inspection Approved Products 3 Approved Products 7 Rejected Products 1 Rejected Products 5 Total Products 4 Total Products 12 Productivity 75 0 Productivity 58 333332 lt O 0 lt q O o
12. annel 10 bit ADC The analog output of MQ135 is connected to channel 1 A1 to get digital output 14 varying from 0 tol023 Here lower values of digital output 17 indicate clean air while higher values indicate polluted air Using mapping function in Arduino Uno i e map AirQuality 0 1023 9 0 13 the values for air quality from 0 to 1023 are mapped between 9 and 0 Thus as a simplification to human understanding higher values between 0 and 9 will now indicate clean air and polluted air will be represented by lower values Since the values between O and 9 are used to specify air quality it consumes only one character of the entire string pattern DOI 10 9790 1676 10331428 www losrjournals org 22 Page A Smart Manufacturing Execution System C Temperature and Pressure BMP 180 5 requires DC power supply of 3 3 V and is interfaced with Arduino Uno using Serial Data SDA and Serial Clock SCL pins 1 e Inter Integrated Circuit I2C protocol 6 It delivers pressure and temperature values in bar and C respectively 19 For example pressure 0 95 bar and temperature 34 89 C It therefore consumes 9 characters in the transmitted string dot is also considered as a character The measurement ranges are as follows 1 Temperature 40 to 85 C 2 Pressure up to 10 000 hPa D Humidity DHT11 Temperature and Humidity Sensor features a temperature and humidity sensor complex with a calibrated digital signal output By us
13. ike temperature air quality pressure humidity light intensity etc because factor of safety is directly related with these parameters NIRMAN Factory Information System acquires factory conditions using various sensors to be discussed later For safety parameters like temperature air quality and pressure we can set Threshold Limit using NIRMAN FIS as shown in Fig 4 When these parameters cross their threshold limits following actions are generated by the system The power supply to the factory is cut off Auxiliary power supply turns ON the light for emergency exit path The tile of the corresponding parameter turns red Emergency situation is notified to all workers in the factory using an alarm ee a When entered into section of Safety tiles for four zones will give details of various parameters like temperature pressure humidity air quality and light intensity as shown in Fig 5 Thus NIRMAN FIS monitors and ensures safe working conditions in the factory The sensors used in the system to procure the above mentioned safety parameters consists of DOI 10 9790 1676 10331428 www iosrjournals org 16 Page A Smart Manufacturing Execution System Temperature and Pressure BMP180 5 19 Air Quality MQ135 17 Humidity DHT 11 18 Light Intensity LDR 2 ee ae ae 4 0 11 00 al Safety S C Monitor Web Socket Safety Set Threshold Temperature A Set Threshold Pressure la la Pre ZONE Safe ZON
14. ing the exclusive digital signal acquisition technique and temperature and humidity sensing technology it ensures high reliability and excellent long term stability This sensor includes a resistive type humidity measurement component and an NTC temperature measurement component and connects to a high performance 8 bit microcontroller offering excellent quality fast response anti interference ability and cost effectiveness Although DHT11 provides both temperature and humidity values we use only the latter part Single bus data format is used for communication and synchronization between Arduino and DHT11 sensor 18 As shown in Fig 12 digital output of DHT11 is connected to pin 2 of Arduino and requires a pull up resistor of 5 kQ DHT11 measures humidity between 20 90 RH Humidity consumes 5 characters in the transmitted string For e g humidity in a factory is 38 59 E Light Intensity LDR is used to measure light intensity The circuit diagram is shown in the Fig 15 As the resistance of LDR varies with light the voltage available at the analog input AO of Arduino changes The digital output 14 has values from 0 to 1023 These values are mapped 13 between 0 and 9 in Arduino 5V AQ Analog Input to Arduino 5K Fig 15 LDR Connection Diagram to measure Light Intensity When light falls on the LDR 2 its resistance decreases and analog input to AO increases resulting in higher values of light intensity between O and 9
15. lands 2014 SMARTER WAYS TO USE THE INTERNET OF THINGS Wind River Systems Inc Alameda CA USA 2014 Configuring Google Cloud Messaging Service for Android Devices Novell Inc Provo UT USA 2014 How To Develop Smart Android Notifications using Google Cloud Messaging Service Software Engineering Competence Center SECC Giza Egypt 2013 Implementing GCM client on Android Android Developers Online Available https developer android com google gcm client html Arduino ArduinoBoardUno Online Available http www arduino cc en Main ArduinoBoardUno Serial print Arduino Online Available http www arduino cc en Serial Print Arduino Map Online Available http www arduino cc en Reference Map Arduino AnalogRead Online Available http www arduino cc en Reference AnalogRead Arduino DigitalRead Online Available http www arduino cc en Reference DigitalRead Arduino DigitalWrite Online Available http www arduino cc en Reference DigitalWrite Arduino Playground MQGasSensors Online Available http playground arduino cc Main MQGasSensors DHT11 library Arduino Playground Online Available http playground arduino cc main DHT1 1 Lib SFE_BMP180 Library Online Available https github com sparkfun BMP180_Breakout archive master zip HC 05 ITEAD Studio Online Available ftp imall iteadstudio com Modules IM 120723009 DS_IM120723009 pdf Bluetooth Android Developers Online Available h
16. lation between these conditions and productivity we can conclude the most favorable conditions when the workers can perform at their best level Maintaining a pleasant factory environment will increase the output from workers thus resulting in increased productivity and efficiency F Factory Efficiency The data available from three shifts will be collectively analyzed to generate a report If actual period for which machines are active is greater than expected period either machine efficiency or worker efficiency has been decreased and should be addressed immediately This will increase the energy consumption and increase the overall production cost The final goal is Increase Efficiency Reduce Costs DOI 10 9790 1676 10331428 www iosrjournals org 19 Page A Smart Manufacturing Execution System The efficiency shown here is Factory Efficiency and considers 2 factors 1 Average efficiency of 3 sections 2 Productivity F Efficiency Expected Prod 100 Actual Prod 3 0 Efficiency 58 333332 lt O O Fig 9 Factory Efficiency displayed in Android Application of NIRMAN FIS It is calculated by taking average efficiency of 3 sections and then multiplying the obtained average with productivity to get answer in percentage The formula used is as follows Productivity in percent Factory Efficiency Average efficiency of 3 stages x ry w For e g if average efficiency of 3 sections is 70 and productivity is 50
17. mitted by light source will continuously fall on photodiode The presence of product will obstruct the light beam falling on photodiode that can be detected by properly interfacing photodiode with Arduino Photodiode detector Fig 16 Use of Photodiodes to detect a product passing through a stage of assembly line Thus each time a product obstructs the light beam the count of products passing through a stage will be incremented by 1 and displayed in the android application of NIRMAN FIS V REMOTE MONITORING By using NIRMAN FIS Web Portal or NIRMAN FIS Companion it is possible to monitor and control all factory operations remotely When a manager wants to have a manual control over factory operations while he is not physically present in the factory he can use Remote Monitoring methods The user has to authenticate his account while using any of these methods Using internet connectivity he can send commands to android application which is connected to NIRMAN FIS using bluetooth Table I Commands Used In Remote Monitoring Command Function 141 Turn ON Buzzer in the factory 142 Turn OFF Buzzer in the factory 143 Turn ON Power Supply of the factory 144 Turn OFF Power Supply of the factory The android application on reception of commands will instruct Arduino to take appropriate action These commands can be configured based on user requirements The option of Web Socket Monitoring in the android application must be turned ON to use rem
18. ol the same android application installed in another smartphone using internet connectivity DOI 10 9790 1676 10331428 www iosrjournals org 25 Page A Smart Manufacturing Execution System Od d 2 40 E Commander Configure Device Address N Launch Companion Nirman FIS v7 1 Commander user 141 Fig 19 NIRMAN FIS Companion VI ADDITIONAL FEATURES Android Application of NIRMAN FIS incorporates many other features like SMS Notifications Voice Recognition Adding a user account etc A Configure Device Address NIRMAN FIS Android application is connected with hardware using Bluetooth module In order to establish a connection Media Access Control MAC address of the bluetooth device needs to be configured by the application The MAC address of the targeted device after encrypting in a QR code will be scanned by the application to establish a connection Using this feature an old bluetooth device can be easily replaced with new one without any major alterations in the existing system Configure Device Address is available on the login screen of android application as shown in Fig 19 B Adding a User Account The administrator or manager of the factory can add a user account for his subordinate in the android application as shown in Fig 20 This will let you to add a SUB USER account under the main account SUB USER will be able to access all the functions as of the main user Speak now
19. ote monitoring methods The 4 basic commands used in the prototype are given in Table I A NIRMAN FIS Web Portal NIRMAN FIS Web Portal is a website connected to android application of NIRMAN FIS After user authentication on Login Screen control panel is displayed as shown in Fig 17 and Fig 18 DOI 10 9790 1676 10331428 www iosrjournals org 24 Page A Smart Manufacturing Execution System NIRMAN FACTORY INFORMATION SYSTEM Login to WEB Portal LOGIN Username 1 Password P Fig 17 NIRMAN FIS Web Portal Log In The user must enter appropriate command in the Command Box of control panel and press Submit button This will push the command on android application of NIRMAN FIS which is also connected to internet Web portal uses Google s Cloud Messaging Service 8 10 which is web based push messaging service to push the command on the android application of NIRMAN FIS NIRMAN FACTORY INFORMATION SYSTEM Control Pane CONTROL PANEL Command 2 Logout Fig 18 NIRMAN FIS Web Portal Control Panel B NIRMAN FIS Companion NIRMAN FIS Companion can be launched through android application as shown in Fig 19 By installing android application on another android smartphone and launching the Companion a user can send commands to the primary android application which is connected to Data Acquisition System using bluetooth in the factory Thus android application of NIRMAN FIS in one smartphone can contr
20. ssible in a more efficient manner Manual Data Recording can be reduced to a great extent by implementing NIRMAN FIS This results in a reduced time outlay because it is the system which takes care of recording important parameters like production status efficiencies etc NIRMAN FIS aims towards Paperless Factory Since the system reduces manual data recording to a great extent the use of paper for recording data is also reduced The system provides machine workers with real time information needed for orderly production Reducing human efforts to collect data therefore increases employee productivity in taking important decisions The production status in the assembly line is accurately tracked by the system The estimated time for the completion of order can be calculated and can be conveyed to a client Unacceptable deviations are recognized immediately by the real time monitoring of all influencing parameters in a production process and measures can be taken accordingly This is equivalent to real time cost control as the system takes care about safety inside factory The present system works with a Bluetooth Module The same system can be easily made compatible with Wi Fi Module The use of Wi Fi Module can increase the range of accessibility and allow multiple mobiles to get connected to the system The concept of Internet of Things 7 can be used to locate identify and remotely configure the objects using RFID Near Field Communication NFC
21. teel is converted into machine parts 2 Stage Section Il Paint where machine parts are painted 3 Stage Section III Post Paint where the machine parts are actually assembled The production status of a product in all the above mentioned stages is monitored in NIRMAN FIS When the product passes through Stage I the count of products completing stage I of production process is incremented by 1 and displayed in the Production Section of android application A product is completely DOI 10 9790 1676 10331428 www iosrjournals org 15 Page A Smart Manufacturing Execution System manufactured when it passes through Stage 3 of the assembly line NIRMAN FIS tracks the efficiency of each stage by considering actual and expected production The count of expected production for each stage is incremented by 1 after a predefined standard time required for a product to pass through that stage Presently this time is set as 1 minute for each stage and hence at the end of 3 minutes each stage is expected to complete 3 products as shown in Fig 3 However based upon the actual production efficiency for each stage is calculated and is displayed in the application For e g from Fig 3 actual and expected production for Stage I is 2 and 3 respectively Hence efficiency for Stage I is calculated as 2 3 100 66 66 Production Production Time elapsed 3 Minutes 0 4 10 49 Section Completed 25 7 0 Expected Production Section
22. then the actual efficiency of the factory is 35 It calculates the efficiency based on the number of approved products Thus even though the average efficiency was 70 the actual efficiency is only 35 because only 50 of the total products were approved G Data Analysis D wae 12 44 Production Comparison of Approved and Rejected Products lt q m Fig 10 Graphical Analysis for Production from 3 Stages of Assembly Line DOI 10 9790 1676 10331428 www iosrjournals org 20 I Page A Smart Manufacturing Execution System Data available if analyzed properly can reveal many important facts about factory performance and can help managers to take proper actions for improving its performance NIRMAN FIS generates real time graphs based on the data acquired from Data Acquisition System Line graph of Fig 10 shows the number of products manufactured in each stage per 2 hours Considering the expected number of manufactured products per 2 hours to be 40 indicated by Yellow Line in the graph we can track the actual production for the entire day i e all 3 shifts The duration when production goes down can be tracked and appropriate measures can be taken Bar graph of Fig 10 is the result of Quality Testing of the product The number of Approved and Rejected products can be tracked in each month It is seen that rejected products are more during month of May Factory conditions in the month of May can be reviewed to find the ca
23. ttp developer android com guide topics connectivity bluetooth html DOI 10 9790 1676 10331428 www iosrjournals org 28 Page
24. ty a a x 100 As an extension to above features if parameter is being tested by a machine then output from that machine can also be fetched to place a correct mark on that parameter automatically E Personnel Morale The morale of the employees will play an important role in determining the production capacity of the factory Morale and working capabilities of the workers are affected by the factory conditions More favorable the factory conditions higher will be productivity Each employee can be provided with unique Radio Frequency Identification RFID 7 4 tags When an employee wants to enter factory premises RFID tag will serve as an entry ticket and at the same time sensors will record his attendance that can be fetched by the application The application can keep a track of absent employees Shift wise data will be collected to draw some important conclusions related to employee morale GRE Ow ae 245 Morale Expected Workers 1009 Present Number 95 Temperature 33 06 C Humidity 35 0 Light 30 0 Efficiency 56 333332 Fig 8 Personnel Morale in Android Application of NIRMAN FIS As shown in Fig 8 the application will continuously keep a track of expected workers and present workers in the factory The factory conditions like temperature humidity and light intensity which effect physical abilities of the workers will be procured from the sensors installed in the factory With proper analysis of the re
25. use for increase in rejected products Fig 11 is a speedometer that will generate a rating for factory performance based on Factory Efficiency discussed earlier For example if Factory Efficiency is 91 Performance Rating is 9 1 and the factory performance is Outstanding Overall Factory Performance Rating 5 oO Fig 11 Graphical Analysis for Overall Factory Performance IV DATA ACQUISITION SYSTEM Data Acquisition forms the heart of NIRMAN Factory Information System Data about various parameters is fetched from the sensors located in the factory environment Arduino Uno being the central processing unit processes the acquired data and transmits it serially 12 to Bluetooth Module h Button Switches used as j Je 6 fe Assembly Line Sensors Voo V 5 V Va 5V AO Analog Input 5K MQ135 DN l GND DHT 11 DO Digital Output SDA Serial Data Line Voc 3 3 V SCL Serial Clock BMP180 eee Arduino MQ 135 Air Quality Sensor Uno R3 Vata V BMP 180 Temperature and Sali Pressure Sensor TX HC 05 Veo 3 V RX LDR Light Intensity Sensor GND LDR AO DHT 11 Humidity Sensor HC 05 Bluetooth Module Fig 12 Data Acquisition System of NIRMAN FIS DOI 10 9790 1676 10331428 www iosrjournals org 21 I Page A Smart Manufacturing Execution System The composition of string in the transmitted serial data will be discussed later The acquired data is refreshed every second so that live updates about factory status are con
26. veyed to the manager Fig 12 simplifies the idea about the interface of various sensors with Arduino Uno To get acquainted with each block we ll discuss about the parameters fetched by Arduino These parameters include temperature pressure humidity air quality light intensity and production status A constant length string is formed using these parameters to simplify the communication of data between Bluetooth Module and Android Application A Data String Pattern As shown in Fig 12 HC 05 20 is connected to Arduino using TX and RX pins The values serially transmitted by Arduino are received by bluetooth module and transmitted to android application using wireless bluetooth connection Fig 13 shows the string pattern generated by Arduino in NIRMAN FIS Rootes 3 gt s s a Fig 13 String Pattern generated by Arduino for Serial Transmission The string pattern and the length of the string is kept constant so that application on receiving the data through bluetooth connection can divide the string and allot those values to respective parameters This string 1s sent every sec by Arduino to bluetooth module For example if transmitted string is 01000234 590 9537 8959 it actually consists of data blocks as shown in Fig 13 NIRMAN actory Information System Fig 14 Hardware Implementation of Data Acquisition System in NIRMAN FIS B Air Quality MQ135 is used as the air quality sensor Arduino Uno has 6 ch
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