Ahmed Elmalla
Ahmed Elmalla
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Ahmed Elmalla


How I increased Machine throughput dramatically ?

How I increased Machine throughput dramatically ?

How do you calculate machine throughput?

The less time a product takes to be produced, the more efficient the process. The formula for throughput is TH = I / T. This is also known as the throughput time formula.

What is a PC automation?

Windows PC-based automation is a process that entails the use of software to manage real-time (RTOS) applications written in C#, C++, . NET, etc… that can perform such functions as motion control and machine vision in various industrial procedural environments.

What is multi-axis motion controller?

Image result for servo multi axis motion controller usage

Essentially, a multi-axis motion controller controls the motion of automated systems on more than one axis. They play an important part in enabling smart, discrete multi-axis drive designs.

Xytec machinery

What is VB language used for?

Visual Basic (VB) is an event-driven programming language and environment from Microsoft that provides a graphical user interface (GUI) which allows programmers to modify code by simply dragging and dropping objects and defining their behavior and appearance.

Back in 2006, we used XP embedded OS on industrial PC for all our RFID machinery in Xytec malaysia.

In some of the machines we used the VB programming language as the main machine sequencer. This method was used for machines with less than 8 servo motors.

The key to improve machine cycle time is to study idle times then measure those times. Then design the machine control sequence to use idle times to perform long time tasks.

Then try to use smart cards (Motion controllers like galil or smart cameras) to run machine tasks in parallel to the main control and establish synchronization between them by using flags or sensors.


Fine tuned software for high throughput

The image above is for a machine with a couple of smart cameras and over 7 motors. The machine was programmed using VB + Galil programming language which made the throughput much higher than a similar machine programmed using PLC.   


Timer functions in VB have accuracy of 15 ms per call which was a big limitation that I managed to solve by transferring large chunks of the control code to the motion controller.

By doing so, my machines managed to beat PLC-controlled machinery in throughput.


SMARTRAC is a leading supplier of inlays for contactless credit cards (ePayment) and passports with integrated contactless chips (ePassports). The company, which was founded in 2000, is incorporated under Dutch law and has its head office in Amsterdam. SMARTRAC has its main production and R&D center in Bangkok (Thailand), as well as sales offices in Stuttgart and Singapore. Through an agreement with Xytec Solutions (Kulim/Malaysia), in which SMARTRAC holds a 30% stake, the company has exclusive access to proprietary manufacturing equipment.

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