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Smart Edge Computing Device for IIoT
Background
In an effort to fulfil the customer expectations, manufacturers are continually seeking ways to make their production processes more efficient. The majority of manufacturers believe they have little visibility and control over the activities on their shop floor. Controlling the activity on your factory floor is crucial if you want to maximize production efficiency, reduce losses, and boost revenues. Industries worldwide will find it challenging to retain themselves in this competitive age without technological advancements such as Industrial Internet of Things (IIoT).
Old methods of keeping records of shop floor data involve paper reports and spreadsheets. It is less accurate and more time-consuming process. There is reduced visibility within the production process. Not only are these spreadsheets and reports time-consuming to produce, but it takes hours to modify the schedule if there are changes in demand or unexpected problems occurring on the shop floor. The supervisors and machine operators have to invest their valuable time in gathering and reporting information along with the planners and schedulers.
An integrated real time IIoT based system is set to bring revolution in manufacturing industries. This industrial IoT product suite is a perfect solution to optimize machine operations, enhance legacy manufacturing processes, improve the availability of machines. It drives new revenue streams and business models related to machines.
Solution
Intrinsig’s IIoT product suite provides actionable real-time information of the shop floor. It can manage, collect, analyze and integrate production data from all sources including PLC, CNC, SPMs, SCADA and various sensors. It transforms machine data into insights using our edge devices, data-lake, and state of the art analytical engine.
Intrinsig was a key contributor with designing the concept- hardware, software and prototype development. Real time data collection and data transfer can be done in two ways-
1) IoTIZER which is a electronic device for transforming manufacturing machines into IoT-enabled nodes. It collects machine data through various interfaces. A powerful edge computing ability transforms data into accurate information. These information snippets are then sent to the cloud wirelessly.
2) Latest Industry 4.0 enabled machines can be connected through LAN interface by using a PC based machine adaptor which is interfaced to numeric controllers through the Ethernet.
This IIoT product suite also comes with a visualization dashboard displaying high-level factory insights and recommendations. It displays real-time insights of key production metrics such as OEE, Part Count, Downtime, Root cause of Production Losses, etc. Real-time technology plays a vital role in allowing the manufacturing and production processes to become fully automated and intelligently responsive.
It can drive decisions of the production processes in the following steps-
- Connect–
Collect and transform data through machine data adapters and data lake infrastructure.
- Analyze–
Discover data-driven insights using data lake and analytical engine to diagnose and predict problems.
- Act–
Various notifications to the right person at the right time to improve the process and act fast
Benefits of IIoT
- Real-time Data Collection – Due to highly automated process, it reduces the time required to collect data and eliminates the amount of manual data entry errors. The important part is that the latest data is immediately available, which greatly increases the visibility within production.
- Quality control – It allows you to identify problems in production before they occur on the shop floor and helps to improve the quality of the products by reducing the number of scrap items.
- Automated Reporting – With this IIoT product suite, error-prone manual data entry processes can be eliminated. This will ensure the availability of accurate inventory data, production status reports. it eliminates the time required to manually open work orders, issue materials, and report production status and scraps.
- Production Time Monitoring – Measuring production time is important to track production performance to ensure the availability of resources in full capacity. If production time efficiency decreases, which means that a machine needs maintenance work or that an operator requires additional training. As a result, these measurements will be beneficial in improving production processes.
- Data-Driven Decisions – When production does not meet the intended demands, manufacturers generally add new machines or workers. With real-time data, it’s easy to drive decisions and find the causes of the inefficiencies in production processes.
- Maintenance Management- It allows maintenance team to perform proactive maintenance of the tools to make sure the machines are up and running without any catastrophic tool failures.
Intrinsig’s IIoT product suite is helping the manufacturing companies to overcome the oldest and most complex challenges while growing and operating their businesses.
