Ready2Wash needed a partner who can connect a diverse set of machines, systems, and sensors, many of which communicate on different protocols, onto a single platform and make them visible and controllable. Furthermore, the amount of data, data types, and their applications were so vast, that the solution handling it needed to be scalable and flexible.
Top ABB customers asked for advanced services and faster parts replacement to keep their plants up and running, where production downtime can cost up to $2 million per minute.
VISIBILITY - Currently unable to see amount of power consumed per machine or plant; need to account for energy used per batch. WASTE - 10% of product fails quality standards, unable to identify point of failure (initial spinning, weaving, final processing, etc). INACCURACY - Acquiring OEE measurements and compiling them is a manual process, which lacks visibility into all parts of the production process and is error-prone. LACK OF INTEROPERABILITY - Outdated machinery still has long, effective lifespans but needs to connect to newer, digital assets
Tetro factory had the following challenges: - Controlling the production flow, tracing mistakes and optimizing performance. - Running a fully integrated knowledge-based business with systems that work seamlessly together. - Centralizing manufacturing production data into one system that can be viewed and analyzed from a single-point-of-entry. - Pinpointing in real-time which stations are compromising production and what can be done to restore and improve efficiency. -Implementing preventative maintenance and ensuring minimum downtime. - Monitoring energy consumption and optimizing material consumption per product.
Manufacturers need to create new revenue streams while competing more effectively in the global market that seems fixated on lowest-cost production. Service revenue is becoming increasingly important to manufacturers to maintain profitability -- manufacturers want to capture upward of 30% of revenue from services, and 74% of manufacturing executive identified service as a significant driver of future revenues.
For industrial applications such as process and machine control to run smoothly, there is a need to ensure that there is low communication latency and minimal jitter in order to meet closed loop control requirements.
Earth moving machines require an immense energy source to provide the power they need for use within civil engineering works. ‘Hydraulic Motors’ allow this power to be applied to enable the machines movement and in addition ‘Control Valves’ also provide the operator with the precise feel and control required to undertake the necessary tasks needed for such machines, including trenching, rock breaking and demolition. These same motors are also used in cranes, wheel loaders and general construction equipment. Though not a new product, the designs of such motors and control valves have been around a few decades, the overall method for manufacture has changed rapidly over the last few years to take account of the need for more modular designs, manufacture and just-in-time manufacturing. Kawasaki Precision Machinery (UK) Ltd based in Plymouth, UK is one of the leading manufacturers of such motors and pumps. They approached Industrial Vision Systems Ltd to come up with a solution to provide automated inspection of such pumps for their semi-automated assembly process. The pumps requiring inspection are at a sub-assembly stage when they are due for the inspection process to take place. Due to the highly modular nature of the construction each part of the pump can have many different derivatives which overall have a different effect on the pump in industrial use. It is therefore critical for the manufacturing process to check all components are the correct type and number for the construction of the pump to begin. Once built it is difficult and costly to rework such units if a fault is detected later in the manufacturing process, therefore automated visual inspection is critical for the success in building quality motors and pumps.
Like many organizations, Anaren had a homegrown work order application that had basic asset management functionality. “It was menu driven, so quite cumbersome,” explained Bill, “reporting was limited and it still relied heavily on paper transactions and records. We looked at our business needs going forward and decided this was one area that could be modernized.” On launching the Manufacturing CMMS project, Bill, the business analyst of the company identified three major areas for improvement:
1. Improve efficiency by eliminating paper.
2. Improve the control of preventive maintenance.
3. Improve inventory management.
Ready2Wash IoT solution is built on top of WolkAbout IoT Platform, which is a heart and brain of all technology and business processes. All data (operational, financial, data about customers) is now collected and available for usage here. WolkAbout IoT Platform uses robust and reliable technology with PLCs, industrial PCs and Modbus as a communication protocol. Given it is vendor agnostic, it can connect all diverse machines seamlessly and provide an end to end solution, right from the machine connectivity to data acquisition and processing, with business relevant applications on top of WolkAbout IoT Platform. It is designed to have reliable two-way communication between the platform and carwash facilities in order to measure, monitor and control all operational aspects of those facilities. Web portal aimed at self-service carwash owners helps carwash owners or managers to manage multiple stations from any location and monitor all their work processes, malfunctions and services. The key feature is controlling, as WolkAbout platform allows remote actuation of switches, relays, and water pumps. Lastly, monetisation module of WolkAbout IoT Platform enables mobile payment for carwash customers and participation in the loyalty program, which are available through Ready2Wash customer iOS and Android apps.
SeeControl partners designed a wireless access control unit that operates over GSM and Mobitex wireless networks to control access to a room. This same solution is also pre-built onto industrial lockers that can be dropped-shipped anywhere globally. Via keypads and keycards, they only allow access to authorized users, or temporary users who have the correct disposable PIN number or keycard. The solution is optionally married to a barcode scanner or RFID reader so that the manager knows with certainty who has accessed and used/returned materials. A central web application controls and reports on access and also records inventory control and management activity at remote sites.
Information transparency is key to get to the root cause of profit losses in manufacturing. The Industrial IoT unleashes the data silos in productions lines, and turns data into real insights. relayr’s Smart Manufacturing Solution allows you to collect, manage, and analyze data straight from production line machines, regardless of the level of automation. With relayr Smart Manufacturing you can easily change your current IT production line environment into a predictive model.
Tetro factory implemented the LeaderMES system to tackle the aforementioned challenges. The LeaderMES system with its plug-and-play modules were deployed across the production floor became instrumental to Tetro's operational success and long term vision of a fully visible, connected and knowledge-based factory. Being open and flexible, LeaderMES was configured to integrate with Tetro's internal business intelligence and validation systems to meet its specific traceability and analysis requirements. LeaderMES gave Tetro full visibility of their floor operations and material management enabled the team to monitor and track the entire plant's day-to-day operations and resource usage in real time. It also enabled predictive maintenance that reduced unplanned downtime.
PTC offers a framework to evaluate and implement the technologies that enable manufacturers to realize results. The approach consists of three distinct stages: understand, advance, outperform. 1) Understand: Make smarter decisions by analyzing service and product data in real-time 2) Advance: Differentiate service offerings by improving and expediting the way products are serviced 3) Outperform: Completely redefine value with new service offerings and business models
Time Sensitive Networking (TSN) is a set of new capabilities being added to the IEEE Ethernet standards. TSN ensures that end nodes and switches have a common understanding of time and there is tighter time synchronization in these systems. TSN also ensures that packet transmission from a sender to a receiver is scheduled end to end and follows a repeating cycle. A consistent mechanism for network configuration also helps meet application needs.
The first part of the project involved systematically defining how each part could be presented on a fixture to the vision system, ideally fitting all components onto one large fixture design in order for multiple cameras to view all components in one inspection position. Once the final design for the travel board fixture was defined the final camera position and lighting position could be confirmed. The machine incorporates a central roller feed conveyor system and incorporated into the conveyor are pneumatically-driven stops. The cameras, optics and lights are mounted from individual doweled fixtures mounted inside the main inspection canopy. The whole system was shielded from ambient lighting to stop this affecting the vision system result. Machine vision inspection functions were then selected from standard routines available in the IVS software and deployed to check the six main components on the fixture board in sequence. The main pump inspection and the associated valve plate and cover checks were completed via the use of a match against a trained template of the relevant type. Due to the precise positioning of the products on the board no rotational movement of the templates was required. After the software has examined all the characteristics of all the components, it then determines whether the pump manifest meets all the tolerances that have been specified, or whether the parts must be reworked or rejected.
“We learned about Fiix from one of our subsidiaries, and when we tried it we liked it immediately,” recalls Bill. “We wanted an application that could work across all our facilities and Fiix seemed to fit all our requirements. Training staff was easy primarily due to the inline videos on each screen. I gave a class with a brief overview; we then watched the support videos followed by a Q&A session. It worked very well. The guys then went away and spent a few days experimenting with the new CMMS on their iPads.”
Ready2Wash is a company founded by experts with 20 year's experience in car wash manufacturing and software development which is specialised in providing an integrated IoT solution for the self-service carwash.
ABB is one of the largest engineering companies as well as one of the largest conglomerates in the world. ABB has operations in around 100 countries, with approximately 135,000 employees.
OVERVIEW: - Owner-operated company founded in 1997 - Mid-sized manufacturer with 5 plants in Europe - Each plant runs approx 150 production lines, running 800 spindles per production line - Produces high quality textiles across entire value chain (aerospace, hospitality, fashion) - €90 million annual revenue (approx.) OBJECTIVES: - Identify potential fault conditions to reduce unexpected downtime - Reduce waste due to quality issues - Reduce energy consumption, and enable reporting in accordance with legal standards and requirements (EEG-Umlage) - Improve effectiveness of maintenance planning - Identify future opportunities to improve the value chain with suppliers and operations
All manufacturers who want to transform service to avoid commoditization, maximize customer satisfaction, and increase revenue.
Customers are mainly production and manufacturing engineering companies whose manufacturing processes involve a lot of machinery. In addition, a number of industrial suppliers are now working to support TSN functionality in their operations.
Kawasaki Precision Machinery, Axial Piston Motors
Anaren Microwave is a high-tech manufacturer and supplier of custom microwave and RF technology for various industries around the world including US space and defence.
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|Use Cases||Manufacturing System Automation||Inventory Management||Factory Operations Visibility & Intelligence ||Factory Operations Visibility & Intelligence ||Machine Condition Monitoring||Process Control & Optimization (PCO)||Manufacturing System Automation||Predictive Maintenance|
- Connection of all parts of the carwash system, regardless of the fact that they are heterogeneous;
- Near real-time automation, monitoring, and control of carwash facilities remotely over a Web portal;
- Notifications in case of threshold breach, warnings, and errors
- Online service utilisation and financial reports;
- Definition of marketing campaigns and multiple loyalty programs;
Cloud solutions enable aggregation of 'big data' to generate valuable intelligence about when to sell a new product, based on excessive part replacements.
Full Visibility into the key metrics that are impacting the production line and need to be communicated per machine in real-time: right rotation of spindles, direction of rotation, and power consumption.
Real-time monitoring of resource consumption helped the firm to save costs.
A manufacturer of integrated cancer therapy systems is using remote monitoring and access to identify issues and complete repairs without on-site visits.
Allowed a more modular approach to production to be adopted and a great degree of flexibility to be offered to their customers in the future with regard to the modular designs and functionality offered.
"Any findings out of the ordinary recorded during the PMs are now logged into the system so they can be addressed quickly."
Real-time monitoring of dust and humidity levels, to ensure the environment does not exceed acceptable thresholds that impact yarn quality.
Predictive maintenance reduced costly unplanned downtimes.
A global manufacturer of high quality welding, cutting, and joining equipment, ensured that parts could be delivered seamlessly to technician and customers.
“We’ve collected baseline data over the last six months so we can start identifying those areas that can be improved,” says Bill, be that more preventive maintenance.
Accumulating manufacturing data allows the firm to manage their "SWOT (Strengths, Weaknesses, Opportunities & Threats) process" to maximize advantages and reduce risks.
ABB acquired an additional 100 customers over the first two years of service and increased core products sales 150% over prior years.
A 5% reduction in total waste.
In less than a month of using the LeaderMES system, the firm's overall energy efficiency improved by more than 30%.
For every dollar in equipment sales, upward of 12 dollars in service revenue is realized for a world leader in air conditioning systems, services, and solutions.
Provides a method for the 100% inspection of the pump product prior to assembly of the complete unit.
Time to market was also reduced by 25%.
Mean time to respond for equipment problems in cancer therapy medical devices decreased 50%, and site visits costing roughly $2,000 per event, declined 42%.
A global manufacturer increased service efficiency by decreasing service costs by $1.2 million and increased parts revenue by $2 million.
IoT Snapshot: Hardware
|Processors & Boards|
|Sensors & Actuators|
IoT Snapshot: Software
|Software as a Service|
|Platform as a Service|
|Infrastructure as a Service|
IoT Snapshot: Service
|Construction & Buildings|
|Equipment & Machinery|
|Logistics & Warehousing|