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Data acquisition (sidebar)

Improved data acquisition is another benefit that grew out of Project Front Door, says process engineer Bjorn Kinze. The Line Event Data System (LEDS) now in place on the new tube line at Gross Gerau increases productivity by maximizing output through minimizing stops and downtime.

It delivers data that make it possible to measure Mean Time Between Failure and Process Reliability—automatically.

“LEDS is a custom-made program first implemented in another department before we made it part of Project Front Door,” says Kinze. “We use an OPC client/server connection that reports each failure automatically. So whenever we choose we can see an accurate picture of Process Reliability and MTBF for the week, the day, or in real time. Such measurement is not new, but this is a much more efficient and automated way of doing it than having people write down a record of failures. What used to happen is a line would say, ‘I’m in failure mode.’ This new line says ‘I’m in failure mode because the tube supply is inadequate.’”

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