Cameras, along with VPN, Skype, FaceTime and other tools, allow technicians to see what’s wrong and remotely repair equipment.
Keeping in constant contact
Perpetual monitoring of equipment now provides early warning signs — excess vibration or an electrical short — that could avert a costly breakdown on a high-speed line. “As we are seeing in the auto industry, many of the diagnostics being performed are run through computer software to identify malfunctions or predict when a car needs service while notifying the driver,” Mr. Maraj observed. “Similar methods can be used on the production floor to keep machinery running efficiently to reduce downtime.”
In addition to preventing failures, regular data collection of key performance indicators (KPIs) enhances line efficiencies and yield. “AMFConnect allows us to tie our equipment together to more rapidly collect data and analyze trends to make more precise recommendations,” Mr. Walker said. “By collecting critical KPIs and runtime information — either on-site or remotely — we can evaluate the data to provide preventive and predictive-type reports.”
In some cases, the biggest hurdle involves some bakers and snack producers who are hesitant to allow remote data collection — often for obvious reasons. “The baking industry is full of trade secrets, and guarding those secrets is, understandably, a top priority for many companies,” Mr. Caupp said. “Finding that balance between increasing efficiency and maintaining security is the key. Most bakery management teams become comfortable with the concept of shared data when they are assured of the platform’s security and the convenience and efficiency of faster response times and less downtime.”
Then again, not seeing a full picture of the line results in delayed responses, according to Mr. Riggle. Remotely gathering information from operators or maintenance personnel who don’t fully understand how equipment functions impedes a swift solution.
Miscommunication results from possible language barriers or varying levels of technical experience. “We’ve run into instances where verbal service instructions become ‘lost in translation’ from a high-level engineer or experienced technician to a less- or non-technical end-user,” Mr. Caupp said. “Whenever that phone or remote access isn’t giving our service team a complete picture of the potential problem, it’s important to arrange an on-site visit to ensure the problem is accurately pinpointed and quickly solved.”
Instruments for training
To educate newly hired operators and strengthen the skill sets of the maintenance staff, companies are building extensive libraries of training tools.
“If a picture is worth a thousand words, video is certainly priceless,” Mr. Caupp noted.
Even recording videos of common tasks familiarizes mixer or oven operators with the equipment. “One of the major benefits of providing video is the ability to implement a thorough and consistent training approach within a facility,” Mr. Caupp added. “An operating staff trained in this manner becomes better equipped to not only use and maintain our products but also to be more capable of communicating with our service team when issues arise.”
Mr. Maraj pointed to the new generation of Google Glass 2.0, which has focused on enterprise applications specifically for assisting with worker education and training. The glasses also provide key information on the fly while allowing remote technicians to see what’s taking place with the equipment on the production floor.
With its built-in camera and microphone, GEA Group’s Remote Eye Wear allows remote technicians to verbally communicate and see a maintenance issue as well as send pictures. These images projected onto the screen assist in repairs, process optimization or inspections. Using a wi-fi interface, the eyewear streams information in real time. The glasses also can send readable documents remotely, according to the company.
With the high turnover in the industry, video training coupled with online interactive eLearning initiatives is gaining in popularity, but developing such a program can be costly.
“Updating training videos and creating new ones where needed is something we have been working on recently to assist the bakery with,” Mr. Lindsey observed. “It takes a considerable amount of time and money to do it ‘right’ because you must make it comprehensive and cover all aspects of the equipment, including operations, sanitation and maintenance. Still, you’re giving access to companies that may now not have to pay for a service trip to their facility.”
That said, equipment vendors must make the up-front investment. “There has been an ebb and flow in the level of interest by the baking community for this over the past decade,” Mr. Walker said. “Customers are interested in it but do not want to pay for the expense of developing this technology.”
Moreover, finding qualified subject matter experts — not all engineers make excellent teachers — complicates developing a comprehensive program.
While online education is a burgeoning business, hands-on teaching combined with videos and interactive training borrows from the best of both worlds,
As technology advances at an increasingly rapid pace, remote maintenance and training bring problem-solving closer to home.
