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For over 30 years, customer has been manufacturing a wide range of epoxy moulded components, Thermoset, and Thermoplastic products, with several plants situated in different locations. Aiming to become a pioneer in Industry 4.0 by digitizing their plant operations, their first course of action sought to establish an open and flexible IIoT Architecture by implementing various digital use cases throughout their organization.
The main objective was to empower management to make informed decisions based on data insights and improve the quality of their manufactured products.
Customer can now access OEE KPIs for Productivity, Availability & Quality
Machine operation data logs helps maintenance team to schedule maintenance based on condition
Logging of critical process parameter can help to back track quality of each product manufactured
Shopfloor level data made available in ERP with precision
Our solution approach involved using a dedicated Data Acquisition Panel (DAQ) for each machine, with a focus on scalability. This plug-and-play model significantly reduced engineering efforts, implementation complexity, and fieldwork.
The existing machine panel was retrofitted with a few components that separated the signals from the field. All critical parameters from the existing machine controllers were fetched and new sensors/transducers were installed to collect additional data. Real-time monitoring and alerts through an audio-visual alarm system was installed to enable operator alerting.
