Understanding Dynamic Work Instructions
Understanding Dynamic Work Instructions
For the project, as described here, the goal was to build Dynamic Work Instructions for the user, specifically tailored for manufacturing using manual equipment. A significant portion of the lab's activities involves educational demonstrations with lab equipment. Although the lab has numerous CNC devices capable of creating the same parts, it frequently uses manual machinery. This reliance on manual machinery necessitates increased human interaction and critical thinking, which can lead to potential issues when operating this equipment.
Example Process: Hammer Handle Machining Operation
An example process that uses the Lathe is the Hammer Handle Machining Operation. This process begins with a raw bar stock of aluminum and ends with a finished hammer handle, as shown below:
Simplified Flow Chart and Problem Points
A simplified flow chart was developed to illustrate the manufacturing process. It highlights the necessary thought process and critical decisions required of an operator to create the hammer handle on the Lathe. Potential problem points for the operator are identified in the red-highlighted areas. These areas present significant opportunities for mistakes, problems, risks, or increased mental workload. During the process, the operator must continuously read the axis values while making calculated movements on the lathe controls. Thus, adding unnecessary complexity to the already challenging task of machining.
Goal of Dynamic Work Instructions
To alleviate these issues, the goal was to develop Dynamic Work Instructions that guide the user through the entire process and provide useful feedback. The idea is to have a dashboard that combines all values, such as spindle speed, feed speed, and axis values, in one place. This dashboard would guide the operator through each step by providing feedback on whether the correct values were reached.
Tool Selection
Several potential tools for implementing these Dynamic Work Instructions were identified: AppSmith, Noodle, and Ignition. After evaluating these options, Ignition was chosen for the following reasons:
AppSmith: While open-source, it lacks MQTT support.
Noodle: Although open-source, it does not have a large user base.
Ignition: Considered the gold standard for HMI, Ignition has a broad industry user base, supports common communication protocols, and although it is not free, provides robust features suitable for the project.
Proof of Concept: Facing to Length Operation
For the Proof of Concept, the "Facing to Length Operation" in the Hammer Handle Manufacturing Process was selected. The Dynamic Work Instructions should achieve the following:
Provide feedback to the user on whether the correct axis values and spindle speeds required for each step were reached.
Explain what the user is expected to do in each step.
Include small videos to support the user with the process.
Provide simple screens for each step with a good overview.
Give instructions based on real-time data.
Benefits
Ensure correct procedures: Helps operators follow the correct steps and procedures.
Improve precision in machining tasks: Enhances accuracy and reduces errors in the machining process.