Proactive Condition Monitoring and Diagnostics in practice
During the course of the year, ABB’s Condition Monitoring and Diagnostics detected conditions which could have caused a robot to shut down, and were able to proactively alert KOKI so the problem could be addressed before a problem occurred. For many manufactures, the cost of downtime has dramatically increased the past several years. Experts estimate that it costs over $1 million an hour to have an unplanned stoppage at a large automotive factory.
Given the just-in-time delivery expected by many of KOKI’s customers, a welding robot failure can have severe consequences to its commitments. In the past KOKI often had to convert another cell with the same robot model to duplicate the lost production, a time intensive process with risks.
Based on this positive experience, KOKI has connected all their 60 robots to ABB Ability Connected Services. KOKI’s entire manufacturing process benefits from the new options that are available through the networked ecosystem.
Via ABB Ability Connected Services and the data derived from it, ABB can carry out condition based maintenance and inspection more effectively. Ad hoc repair tasks can also be planned quickly and precisely together with KOKI using live data. This allows activities to be prioritized, supporting the efficiency and smooth running of the most important customer processes. The connected robots can also provide intelligence to benchmark the performance of their entire fleet and identify and correct underperforming robots.
“During audits, automotive manufacturers ask us how we can guarantee the safety of the systems. Robot maintenance, monitoring, service and support all play an important and decisive role here,” underlines Sven Sparmann, Site Manager for Maintenance, Repair and Overhaul at KOKI in Niederwürschnitz, Germany.
“The approach is very practical, and we are informed in advance. Error detection allows us to carry out adjustments when production has stopped, without interrupting the production process,” enthuses Sparmann. “We’ll be linking all new robots – both at our domestic and international sites – to ABB Ability Connected Services, that’s quite clear,” Sparmann concludes.