Manufacturing companies with 1000+ parameters to measure.
Manufacturing organizations goal was to improve the decision making process using the data across multiple units to improve efficiency and transparency.
The organization wanted to optimize the overall operational efficiency and cost of operations. The organization had multiple process, sheets that were used for production efficiency tracking and planning. The data was manually filled and required a dedicated personal to enforce the same. The consolidation of data and relational outcomes were not consistent for decision making. Being offline, the actions were delayed, and progress could not be tracked.
Source-right partnered with the organization to understand the challenges faced.
Our Subject matter experts in the domain worked with the key stake holders and visited the site to understand the challenges, current process and benchmarks.
Also undertook analysis to identify areas where of technology intervention could be done and identified implementation challenges.
We enabled a digital transformation, IIoT based solution to collect vital data and process it for actionable outcome and support decision making.
Example was analysis of cost Vs Output for a production batch updated in the CRM and resources utilized. The fixed cost and utilization data were retrieved from ERP and the actual consumption and times (indirect costs) were monitored.
This solution was architected with an accelerator driven integration approach.
The IO cards, android based display, server platform were the accelerators used. They were customized and application specific development and configurations were done to have lower cost of ownership.
Production monitoring: Equipment usage, operation hours, cycle time, idle time. Electricity usage monitoring across the shop floor and for high consumption equipment. Resource performance monitoring. ERP / CRM integration.
Retrofit field monitoring unit with IO cards and Android based touch screen were used. Energy meters were retrofitted for energy monitoring of machines, HVAC and lighting load. Consolidation of the data at a central on-premise platform – with reporting for equipment utilization, worker performance, average cycle time for manufacturing a given product / complete an operation. Alerts / alarms, notifications for preventive maintenance based on usage-based events. Integration with ERP and CRM software for Output Vs cost analysis.
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