Optimus
Internet of Things (IOT)
For the improvement of efficiency and productivity IOT allows the evaluation, collection and analysis of data;
➢ To integrate machines, processes, employees and products under the same network.
Our team works passionately to give the best solutions thru development of various web based solutions as per the requirements and challenges to meet your expectations. IOT can be implemented in AUTOMOTIVE and MANUFACTURING sectors. This makes toady’s OEMs to understand their business more closely. IOT can also be considered as one of the self-analysing system to the mentioned sectors.
Automotive (IOT) –
Time is Money
In the present era of man and machine, it has become essential to keep coordination between these two important elements. More often in the automotive industries where “time is money” IOT can play vital role in subtracting non value added time. Thru IOT we are giving you the detailed footprints of each and every second passes on the shop floor and keeping you with and sometimes ahead of time. In automotive sectors IOT can be beneficial for real time data analysis which includes machine data and quality data. This collected data on the system can give you alerts about;
➢ Idle time
➢ Setup Time
➢ Breakdown Time
➢ Product Genealogy
➢ Process Capability
➢ Quality Control Charts
OBI ventures contemporary providing service to the various groups of industries to give them real time data and be more efficient.
Manufacturing (IOT) –
Planning is the Key
In today’s manufacturing world industry is going thru problems like over utilization of resources, unpredictable downtime, and high energy consumption’s by furnaces, lacking in worker’s safety. These problems can be effectively reduced by using IoT. By targeting this global problems OBI ventures is giving solutions for moving towards safe and productive environment which can help you with;
➢ Liberty from labor intensive
environment
➢ Achievable Production Targets
➢ Cycle time reduction
➢ Productivity Gain
➢ Low Inventory
➢ Less rejection rate
We are also providing safety instructions thru the manufacturing applications. Our dedicated team has developed a system named “CINCH” particularly for the safety and work instructions to the semi-skilled and newly skilled workers.
Case Studies
INTRODUCTION
Under Industry 4.0 objective, an automotive part manufacturer wanted to keep a tab on Health management of the machines.
BACKGROUND
The required quantity from the OEM had increased from 250 units/month to 400 units/month and was anticipated to reach 600 units/month. This meant increasing the capacity at the shop floor whilst maintaining the Quality. The defect rate on an average was 10-15% and was suspected to be due to the overcorrection/undercorrection by operator on the machines. However, upon study it was found that the machine capability was hampered due to overriding the machine alarms. Hence, to maintain the health of the machines management decided to monitor Machine health.
ARCHITECTURE
Manual entry of the machine downtime was logged in the maintenance register. Supervisor had to manually verify the data. Also sometimes, reporting of the emergency breakdown/alarms was done manually. Overriding the alarms was is not recommended for machine health in the long run affecting Machine capability.
For this it was necessary to get alerts about the alarms and also about the machine maintenance schedule. This requires getting real-time data from machine controller with an IoT device and our integration software.
Way of getting the real-time data from machine depends on factors like Machine manufacturer, Controller, Year of manufacture and the ports.
Once we get the real-time data, we monitor continuously for the alarms and breakdown. Once this happens, a text message and an email is sent to the Maintenance personnel and Plant manager. Once the alarm/issue is rectified the machine becomes operational. Thus, a maintenance history of that machine is logged as to when it had an issue and how much time it took for maintenance to resolve it.
RESULTS
After the implementation of this Health management system, management could track health of any machine through Web tool. This will have an entire report of when was the last issue, in what time it got resolved thus showing trends. Since there is no manual reporting, the issue is intimidated automatically to the concerned people thus helping in overall health management of the machine.