my work as GET in Simon Electric LTD.

1. Digitization of Cycle Time

2. Digitization of Cycle Time
INTRODUCTION
Present Status:-
 Total Number of assembly machines =42.
 Yield output= Lag of Plan.
 The daily output as per plan is not fulfilled.
 The data shows that appx. 50% on average of the target is
fullfilled.
 This directly effect the routing, indirectly overhead costs.
 There is manual procedure for counting, high possibility mistake.
Issue:-
 The cycle time depends not only the machining but also many
different factors.
 There need to be proper Analysis about machine cycle time,
component placement, loading and unloading, rejection,
breakdown & manpower.
 Need to be specific which factor is more effecting the cycle time,
need statistical data like instantaneous time, average cycle time.

3. Objective-Project
 To monitor 42 machines and obtain real time data analysis.
 To make overhead costs reduction with increasing productivity by means of
needfull manpower and using integrated industrial automation.
 It is necessary to find out where we are lagging.
 It is necessary to award/reward the more productive manpower for motivation.

4. System Block Diagram
RE C
Computer
Control
Unit
S= IR Sensor.
E= End Device:- Controller Atmega 8
R=Router
C=Co-ordinator.
S
Machine Control Unit Master Control Unit(CPU)

5. Machine Control Unit
DS-1307
Timer
Module
Sample Data
1-19030-12:50
2-1390-1:09
3-240-1:10
4-240-1:10
5-870-1:11
6-6150-1:17
7-770-1:18
8-430-1:18
9-3340-1:22
10-780-1:22

6. MCU-Internal Circuit

7. Master Control Unit
 It Consist of an 802.11.15a module (RF) acting as a co-ordinator connected to
remote PC.
 The PC is installed with Matlab and Xctu software as a communication link.
Computer
Control
Unit
R/F
Interfacin
g module
Xbee
Co-
ordinator
Rx
Tx
Vcc
Gnd
USB
Display
Monitor
WiFi-
Internet

8. Detail Component List
S. No. Product Name Quantity Cost(₹)
1 Atmega16L Development Board 1 250
2 ATmega16L 1 150
3 Xbee Board 2 2400
4
XBee / ZigBee Adapter board with USB
interface
3 700
5 Female to Female Cable 20 100
6 AVR-USB-ASP Programmer 1 399

9. Detail Component List
S. No. Product Name Quantity Cost(₹)
7 RTC DS1307 Module 1 120
8 LCD 16x2 Module 1 250
9 USB-TTL Module 1 270
10
IR Sensor Module
1 150
Project Equipment Cost(Appx) 4789

10. Detail Software Tool
Eltima – USB Network Gate MS Excel- Macro Enable PLX-
DAQ
AVR Studio:-6Khazama A.V.R Programmer

11. Model- Prototype
Receiver Module Transmitter Module
Sensor Device

12. Production data proto 27/11/15- reveting M/c
0
50
100
150
200
250
300
350
1 28 55 82 109 136 163 190 217 244 271 298
Piece
P…

13. Future Proposal
• Implementation of IR sensor on all 42 machine.
• Data to be connected and controlled with server.
• LED for monitoring the data in real time.
• Need to purchase licenced software
• A dedicated system is required for this task.