Implementation of IIoT-based Digitization Solution for Epoxy Moulded components manufacturing Company | India.

Project Name:?Implementing IIoT-based Digitization Solution for a leading Epoxy Moulded components manufacturing Company?| India.

?Scope: Consultation, gap analysis, detailed design & engineering, supply and commissioning of IIoT-based Digitization Solution for implementing?OEE, Production/ Downtime monitoring of moulding and press machines including monitoring of Process KPIs.?

Background: ?

The customer has been engaged in manufacturing a full range of epoxy moulded components, Thermoset, and Thermoplastic products for more than 30 years. With numerous plants located in various locations, the industry is working to become an Industry 4.0 Role Model through digitizing plant operations.??

The customer was looking forward to implementing an open and scalable IIoT Architecture by implementing various digital use cases across the entire organization.?The objective was to enable management to make data-driven decisions and enhance the products' quality. ?

Our Approach: ?

The approach was to use a dedicated Data Acquisition Panel (DAQ) for each machine considering the scalability. By this method, we can considerably reduce the engineering efforts, implementation complexity and field work as it’s a plug-and-play model. It was decided to retrofit the existing machine panel with a few components that bifurcate the signals from the field, along with adding a couple of sensors to measure additional important parameters. All the critical Parameters required were fetched from exiting machine controllers and new sensors/transducers were installed to collect additional data.?

System Description: ?

The following solutions are implemented moulding, pressing and riveting machines at the facility.?

• OEE to give productivity, availability & quality insights??
• Energy Consumption and analysis? ?
• KPI that are Critical to Process (Temperature, Heater Current, Tonnage, Curing Time, Charge weight etc) ?
• Integration with ERP system.?

All the DAQ Panels are connected to the plant network via LAN port using Ethernet communication. To enable operator alerting, we have provided a 10” HMI on the DAQ panel which will give real-time monitoring and alerts to the operator, furthermore an audio-visual alarm system is installed on the DAQ panel to get the operator notified.

The machine’s collected data are then integrated into?IIoTNext Metaware, the flagship middleware software solution offering from CONSYST Digital.?The middleware pushes the data to the IIoTNext platform for further visualization and data analytics. The?IIoTNext Platform?enables customers to access various Dashboards and Reports for Energy Monitoring & Analysis, Production Monitoring, OEE Calculations, and Process parameters monitoring & analysis. ?

The management/production head has access to the platform to view necessary dashboards and data that the individual hierarchy needs access to. The plant supervisor has an Android App wherein the necessary info they want is made available. The same data can be accessed from outside the plant remotely. ?

Result: ?

• Customers can now access OEE for each machine by getting insights on Productivity, Availability & Quality. ?
• All critical process parameters are monitored and logged which will enable the customer to track the quality of each product being manufactured. ?
• The system logs all the required data associated with each machine, which will help customer to forecast maintenance schedules. ?