September 14, 2012
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Different Devices, Common Connection
by Dave Edstrom
In
2008, Paul Warndorf, vice president of manufacturing technology for the
Association for Manufacturing Technology (AMT), wrote an introductory
article for Precision Manufacturing on the topic of MTConnect. A great
deal has happened since then. A wide range of organizations has invested
in MTConnect, from small shops up to the U.S. Department of Defense.
More importantly, members of the Minnesota Precision Manufacturing
Association (MPMA) can change their shop or plant productivity radically
by embracing MTConnect.
The beginning of MTConnect goes
back to late 2006, when AMT held its annual meeting in Lake Las Vegas.
This is where MTConnect was born—an open and royalty-free standard with
the potential to dramatically change manufacturing around the globe.
In
preparation for the annual meeting, I worked with Dr. David Patterson
of the University of California-Berkeley. Patterson and I worked closely
together on our back-to-back keynotes for the meeting and it was there
that AMT decided to fund MTConnect.
What Exactly is MTConnect?
MTConnect
is an open standard that converts the many different proprietary
manufacturing equipment data formats into the common language of the
Internet, which all applications speak. Think of MTConnect as a standard
using proven Internet protocols that are the “rules of the road” on how
information will be shared. MTConnect is the Manufacturing Technology
Connection between manufacturing equipment and applications.
Another
way to think of MTConnect is like a “bluetooth for manufacturing
equipment.” Bluetooth works when two different devices support it, such
as your cellphone and your car, or your computer and other peripherals.
MTConnect works when both the manufacturing equipment and the software
applications support MTConnect.
To clarify, MTConnect is not an
application, such as Microsoft Excel, but it is how a machine tool would
speak to a shop floor monitoring program. This program might be running
a PC or Mac on the shop floor, on your iPhone or the PC in your office.
In other words, now you can see what is happening on your shop floor
anywhere, anytime on an Internet-enabled device.
Shop floor
monitoring is the first obvious type of application that has become
MTConnect-enabled. Some popular examples of information that could be
analyzed through monitoring include OEE, asset utilization, diagnostics,
and machine health. If you are a shop owner, a plant manager, or anyone
in manufacturing who manages productivity and profitability, the first
questions you should be asking are: How can monitoring our shop floor
improve our business; and why is it important that MTConnect is the
standard that is chosen to connect our shop floor to our applications?
When considering shop floor monitoring, it is important to remember John Turner’s Five Laws of Manufacturing:
- We measure what goes into production and what comes out; we have little data on what really happens on the production floor.
- If anyone says “I know exactly what is happening on my plant floor” – don’t believe them.
- We don’t gather data because it’s hard, and someone has to look at it.
- No one solution or set of data works for everyone.
- If you don’t have an avid champion, save your time and money.
How you Get the Data
When you decide to
monitor your shop floor, remember this: How you get the data matters.
Choose a standard that provides the widest selection of solutions and
provides the greatest flexibility as your needs change. MTConnect is a
standard that provides the most widely adopted manufacturing data
standard in the industry. It currently is used in more than 14
monitoring applications with more coming.
If you are attending
IMTS 2012, please stop by the Emerging Technology Center. We will be
showing MTConnect-enabled applications in the following categories:
- Efficiency: Understanding Hidden Cost
- Utilization: Discovering Untapped Capacity
- Sustainability: Minimizing Negative Environmental Impacts
- Managing Your Plant Anywhere, Anytime (mobile devices)
The Technology Behind MTConnect
In order
to better appreciate how MTConnect works, we need to dive down just a
little bit into the technology. Everyone is familiar with the concept of
a Web site such as mpma.com. If you type that address into your
browser, information shows up on your screen. Information shows up on
your browser because the MPMA has a web server that answers your
requests and sends information back to your browser. The two primary
technologies that make all this work are http, which is how your browser
communicates with MPMA’s web server, and XML, which is the actual
language passed to your browser that represents the data being
displayed. MTConnect basically works the same way.
MTConnect puts a very efficient and secure web server in front of manufacturing equipment.
Agent.MTConnect.org,
a machine tool simulator running on the Internet, provides information
about the machine tool’s physical components and what data (alarms,
spindle speed, feed rate, etc.) can be retrieved.
One of
MTConnect’s key design aspects is that, when information comes back to
the application, it includes a reference to a dictionary that
specifically defines the physical components and the data items. The
beauty of this approach is that all software speaks http and XML, so it
is very easy for MTConnect-enabled applications to speak to your
manufacturing equipment. A good example of this is using a spreadsheet
to get information with MTConnect. While you likely would not use a
spreadsheet to monitor your shop floor, the point here is that MTConnect
makes it very easy to get the data in a format other applications can
easily use.
The MTConnect Institute
Companies,
organizations, and even individuals can join the MTConnect Institute
for free. Additionally, it is free to deploy the MTConnect protocol.
MTConnect also adopts the open source philosophy, offering collaboration
for multiple end users. We do this because we strongly believe a common
protocol is the technology equivalent of a “rising tide lifting all
ships.” In other words, everyone wins when manufacturing equipment can
easily be connected.
MTConnect Institute members may take the
MTConnect protocol and bundle it with their software or manufacturing
equipment. They are free to sell it or include it free with their
software or systems.
Today, only 4 to 5 percent of machine tools
around the globe are monitored. MTConnect is changing that and impacting
manufacturing in countless ways. You cannot manage what you cannot
measure and MTConnect is making it very easy for shops and plants to get
manufacturing equipment data—to better manage their business in an
intelligent fashion.
Many shops and plants that have embraced
MTConnect. Joel Neidig, technology manager for ITAMCO, has made his shop
MTConnect-enabled. Mr. Neidig has written a mobile MTConnect
application that he gives away for both the iPhone and Android phone
platforms. He and his company use this app so they can check their plant
anywhere at any time. Others can take it and improve the app with the
idea of sharing those improvements with all. This is a classic open
source. MTConnect has improved productivity for ITAMCO because you
cannot manage what you do not know. You know by monitoring your shop and
taking action with that information.
ARC Technology Group wrote
an interesting article titled, “MTConnect Standard for Machine Tools
Drives Sustainable Manufacturing for US DoD.” As the author, Himanshu
Shah, writes, “The Title 10 program has been taken on as a strategic
initiative to further DoD activities and policies that promote the
development and application of advanced technologies to manufacturing
processes, tools, and equipment. While the program does not include
specific metrics, it is intended to ‘… improve the manufacturing
quality, productivity, technology, and practices of businesses and
workers providing goods and services to the DoD.’”
Comments from
those inside DoD have been made that, perhaps, MTConnect should be a
standard for their department. That’s because open, royalty-free and
open source technology already has been proven to help DoD become more
productive (saving both time and money). Why should these lessons
learned not be applied to manufacturing for DoD?
Where is MTConnect Today in its History?
We
are in our third release with MTConnect, with many exciting things
taking place. We had our first ever [MC]2 MTConnect: Connecting
Manufacturing Conference, which was a huge success. We have made 23
hours of videos available on a number of topics, including help for the
first-time MTConnect user, end-user discussions on lessons learned, and
how to write MTConnect-enabled software. Be sure to visit MTConnect.org
to learn more.
At the MTConnect Institute our mantra is “MTConnect
is Different Devices, Common Connection.” As the president and chairman
of the board for the MTConnect Institute, my final message is that
MTConnect is REAL, it is a revolution in manufacturing, and you should
investigate it today to help improve productivity in your shop.
A great place to ask questions regarding shop floor monitoring and MTConnect is at the new
http://MTConnectForum.com.
Please note that I own everything I write and I one the copyright an I allow Minnesota Precision Manufacturing Association to us my writing.
Copyright © 2012 Minnesota Precision Manufacturing Association. For permission to use or reprint this article please contact
Amy Slettum, publications manager for
Precision Manufacturing journal.