Monthly Archives: January 2019

Smart Production Monitoring System

Internet of Things in Manufacturing

Category : Blogs

Internet of Things in Manufacturing

As an Industry 4.0 solution provider, we offer not only machine monitoring through concepts of IoT, but also provides a full-fledged Factory Management System to attend your daily chores at the factoryshopfloor in a much simpler manner which helps the people to connect, communicate & collaborate.

Through this system, you can also aim to go PAPERLESS at your shopfloor apart from deriving seamless flow of notifications & alerts to people making them aware of what, when, how the task needs to be done.

A production monitoring system is a process that is designed to record the overall performance of the production line in real time. … The data that is collected by the monitoring system is used in improving the efficiency of the production line.

In a nutshell, the flow of information divides this into 4 parts –

Plan:
  • In this stage most of your documents transformed into soft-copy by utilizing file management, like process Flow Diagram, FMEA, PPAP, Control Plan, Work Instruction, Checksheets etc.
  • It utilizes the resource allocation of activities of employees, materials and production capacity.
  • It increases production per machine through smart predictive planning.
  • For repetitively planned items, Master Scheduling/MRP and Supply Chain Planning restrict the planning process to advise rates of production within the planning time rails that vary from the current repetitive schedules.
Execute:
  • In execution, the planned activities are carried out on the shop floor making the processes/operations from Control Plan being executed electronically to achieve the maximum production optimization and quality.
  • It automates the data capturing mechanism on the shop-floor right from inwarding of material till dispatch.
  • It increases visibility and transparency in every aspect of your manufacturing operation.
Monitor:
  • In this stage, all activities carried out in shop-floor can be monitored by installing simple hardware inside the machine and you’ll be instantly getting the live information in your dashboards, systems, and mobiles.
  • Get notified thru SMS or Email for major events in your factory like idle time pockets, variations in product or process and more.
  • Online SPC to monitor and proactively escalate issues preventing rejections.
  • Monitor and maximize OEE with real-time insights at the plant, cell or machine level.
  • Monitor key Process Parameters in real-time, based on Control Plans, and interlock and escalate on any deviations
  • You can immediately respond to breakdowns, rejections and failure activities.
  • It increases production traceability and reduced production errors.
Analyze:
  • In this section, by referring digital reports like Availability, Productivity, Quality, OEE, Operator,Performance, Production, Machine Activity, Capacity Utilization, and OEE trend user can easily drill down the root causes of failures.
  • It is possible to analyze in detail information regarding the resources involved in the production process, like machines/departments/work centers, operators/cost, centers/work orders/sales orders/material, etc, based on company structure.

Features and functionalities of Smart Factory Solution:

  • Live View of Shop-floor
  • Task Manager
  • Secure access as per the roles and responsibilities
  • Tool Setup Option
  • Digital Work Instruction by ballooning drawing
  • First-off Inspection Approval
  • Operator Dashboard
  • Escalation Matrix- System Alarms for accounting losses
  • Shift hand-over notes
  • Advance documentation in a centralized platform
Reports:
  • Live dashboard
  • Live Machine Performance
  • OEE trend
  • Availability trend
  • Productivity trend
  • Quality trend
  • Live Production Report
  • Live losses for downtime
  • Live Productivity Report
  • Operator Performance Report
  • Overall OEE

Benefits of Smart Factory Solution

  • Improve productivity, transparency and capacity utilization.
  • The transparency of the system allows you to acutely understand issues by getting real- time information.
  • Production increases by making better decisions driven by data, enabling better, real- time communication between management and the shop floor.
  • Real-time production level notifications
  • Live feedback of employee/operator performance.
  • Eliminates manual data input.
  • Improve on-time delivery.

Smart Factory - Industry 4.0

Digital Transformation

Category : Blogs

The power of Industry 4.0 and Internet of Things in manufacturing

Industry 4.0, the fourth Industrial Revolution, the Internet of Things and the Internet of Services are among the most commonly used terms to describe the accelerating intelligent connections among people, products, equipment, services, things and the data generated during production and throughout the entire lifecycle of the product.

The term “Industry 4.0” continues to garner worldwide discussion. Beginning with the German government’s involvement, this public-private partnership supports the next revolution in manufacturing – creating decentralized, autonomous real-time production.

But what does that really mean? The core of Industry 4.0 is about creating adaptive, agile manufacturing networks. Industry 4.0 envisions the ability to harness intelligence from production while using connections from the objects being built to the people and machines building them – all to accelerate innovation, quality and efficiency. The virtual design and simulation of products must connect to the intelligence gathered during manufacturing, but it goes beyond that.

Demands from the current society – including trending preferences and customers’ experiences while using products – require manufacturers to listen to the products themselves, understand the consumers’ trending voices and predict shifts in market preference.

The orchestration of all of these pieces requires an infrastructure with unique capabilities. The Industry 4.0 initiative defines what manufacturers need and what operational changes are required to be successful in the next generation of industrial production.

This blog series is dedicated to helping strategic manufacturers understand and prepare themselves to be leaders in this next leap forward in manufacturing innovation. 

The Internet of Things and Industry 4.0 

The terms “Internet of Things” and “Industry 4.0” are hot topics, and they continue to spark global conversations around what they are and how they’ll affect us personally and professionally.

Some people assume that the Internet of Things is a subset of Industry 4.0, but that isn’t the case. The Internet of Things relates to Industry 4.0, but they aren’t the same thing: the consumer version is pushing the industry version, in all of its complexity, forward much more quickly than we realize.

The Internet of Things in manufacturing. The Internet of Things, or the IoT, is an abstract concept about the interconnectedness of physical things that have their own intelligence.

For example, my car can talk to me and tell me when it needs an oil change, and it can make an appointment on my calendar with my dealer for a checkup at the same time. Or, my home heating system texts me and says the weather is getting cooler, and unless I get it serviced within the next three days, it won’t work.

These types of intelligent network of “things” are becoming reality – and more quickly than we realize. With the IoT impacting our everyday world, manufacturing thought leaders are gaining attention as they apply the same concepts to their industry.

If we have the ability to avoid running out of oil, or if we have the ability to know when to repair one of our heating units before it breaks down, why can’t manufacturing companies have systems that automatically replenish, provide real-time feedback and avoid failures?

With the Internet of Things in manufacturing, they can.

The connectivity of the IoT has become a driving force of Industry 4.0. The realization that a machine or system can catch and prevent human errors on a daily basis has led to greater scrutiny of how to rethink supply chain complexity, and to create the infrastructure that supports the intelligence of the things in those networks. 

Industry 4.0 and the Internet of Things. Industry 4.0 makes manufacturing industries as modern as our personal lives. It focuses on the support that this next generation of intelligent manufacturing needs to be successful.

Today, connections are made among products as they are produced. The connections involve the equipment producing these products, the real-time feedback on product performance in the field, the changes in consumer preferences and the virtual world of the product design and simulation.

The manufacturers who will win in this next industrial revolution will have to harness the intelligence being produced in real time to get innovation at higher quality to market – faster than their competitors. That’s what is pushing the urgency of Industry 4.0 – fundamental market competition, which equates to revenue growth and profitability.