Discrete Manufacturing
Digitalization Solutions for Discrete Manufacturing
Discrete manufacturing refers to the production of distinct items, often assembled or manufactured in batches or lots. This sector encompasses industries that produce individual, countable units rather than continuous streams of materials, distinguishing it from process manufacturing. It often utilizes assembly lines and specialized machinery to ensure precise production and consistent quality across batches.
Digitalization is crucial for the discrete manufacturing industry, revolutionizing operational efficiency, agility, and innovation. By integrating Industrial IoT sensors, analytics, and automated systems, manufacturers can optimize production, respond swiftly to market demands, and foster continuous improvement.
Overall Equipment Effectiveness
Overall Equipment Effectiveness (OEE) is a metric used to evaluate the efficiency and performance of manufacturing processes or individual equipment, offering insights into usage and operational efficiency. OEE in Manufacturing is a monitoring solution tailored to optimize manufacturing processes by delivering real-time data on machine performance. It offers comprehensive insights, including machine-wise, product-wise, shift-wise, and plant-wise OEE metrics, ensuring precise operational efficiency.
Role of IIoT in OT/IT integration
Traditionally, Information Technology (IT) and Operational Technology (OT) operated in separate domains within organizations, each serving distinct functions. However, driven by the surge in digital transformation and advancements in technologies like the Internet of Things (IoT), organizations are now striving to integrate IT and OT. This convergence enables a seamless flow of data between the digital and physical worlds, bridging the gap between data management systems and industrial operations. By merging IT and OT, companies can enhance operational efficiency, optimize resource utilization, and implement real-time analytics, ultimately driving innovation and competitiveness.
Digital Transformation in Manufacturing with OT/IT Integration
OT IT integration or factory floor data integration is engineered to seamlessly unify all aspects of manufacturing operations, from PLCs to SCADA systems and legacy setups. Supporting a broad array of protocols, including REST API, MQTT, and OPC UA, our solution is highly scalable and can be integrated with any IT system. This ensures a cohesive and efficient data flow across your entire manufacturing infrastructure, enhancing operational efficiency and enabling real-time analytics.
Condition-based Maintenance (CbM) in Manufacturing
Condition-based maintenance (CbM) is a proactive strategy that leverages real-time sensor data to determine when an asset’s performance or condition becomes unsatisfactory. This approach, known as condition monitoring, allows maintenance teams to detect imminent or actual asset failures. With CbM, maintenance activities are conducted based on the actual condition of the equipment, avoiding unnecessary maintenance tasks and ensuring interventions are only performed when truly required.
Condition-based maintenance (CbM) can be applied to a wide range of assets. However, as the name implies, for CbM to be effective, the asset must have measurable conditions that can be monitored. As real-time data is captured, data is analyzed through performance trends. A variation in trend can help maintenance teams determine when an asset is likely to fail.
Manufacturing Execution Systems (MES)
Manufacturing Execution Systems (MES) in manufacturing play a pivotal role in revolutionizing operational efficiency. Industries can optimize line availability and performance through real-time machine data collection, thereby improving Overall Equipment Effectiveness (OEE) with MES. End-to-end visibility of SKUs from raw materials to production to finished goods is possible with the Track and Trace in MES.
MES implementation enables robust connectivity across the shop floor and business systems enabling seamless machine connectivity and device integration. Gain actionable insights into your manufacturing processes, boost resource utilization, and achieve higher quality control with MES, tailored to meet the dynamic needs of modern manufacturing environments.
Mobility Solutions
Mobility solutions in discrete manufacturing provide stakeholders with quick access to real-time alarms and events, enabling immediate notification of issues. These solutions leverage mobile devices and applications to deliver instant updates and alerts, ensuring that key personnel can respond promptly to operational disruptions. By facilitating on-the-go monitoring and management, mobility solutions enhance decision-making, reduce downtime, and improve overall efficiency. This connectivity empowers teams to maintain seamless operations, even when away from traditional workstations, thus driving productivity and responsiveness in the manufacturing environment.
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Case Studies
