Internet of Things in Manufacturing

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.