Hetadatain

Typical problems with an Industry :

Machine up-time and down-time surge issues.
Idling and Minor stops.
Performance Loss.
Equipment failure (i.e. tooling failure, breakdowns).
High energy consumption but low efficiency of equipment's.

Who requires this ?

Production Team.
Dispatch Team.
Production Planning Team.
Breakdown / Preventive Maintenance Team.
Human Resource Department.

What is Monitored ?

Running status of each machine.
Breakup of Running time, Idle Time and Stop Time.

How this benefits the Top Management?

Factory production can be monitored from any time and location, to authorized user with the help of internet.
Post Production data can be analyzed without any input from any office staff.
PNo need to leave instruction for update on production status to subroutines.
Non Altered data available for analysis.

How this benefits the Middle Management?

Analysis of the machine status without visiting the shop floor.
Keep a track on Real Machine Breakdown status.
Inform the Material department in event of shortage of raw material or any machine
He gets a feel of the bottle neck in the production process, and utilizes his energies there.

PROCESS OF INTELLIGENT REAL TIME MONITORING SYSTEM

Energy, process and production data is extracted at regular intervals from the manufacturing machines.
Data retrieval by NON-INVASIVE TRANSDUCER does not intrude the running system and all the data is collected by our Embedded System.
Our intelligent system uploads the collected data to the cloud, where the requisite computations are done for the Energy Flow and Energy Loss at various locations.
Beyond the four walls of the confined production facility, the transfer to Cloud-Based software system allows employees and administrators to view the performance status of the manufacturing machines.
The graphical representations of the data can be viewed worldwide on our Web / Android / IOS applications.

Advantages of INTELLIGENT REAL TIME MONITORING SYSTEM

Invisible Supervision.
Predictive Maintenance.
Alert Maintenance and Production Team.
No Manpower Required to Run.
Integrated with ERP,SAP.
Can be Viewed on Mobile, Tab. Running status of each machine.
Breakup of Running time, Idle Time and Stop Time How this benefits the Top Management?
Factory production can be monitored from any time and location, to authorized user with the help of internet.
Factory production can be monitored from any time and location, to authorized user with the help of internet.
Post Production data can be analyzed without any input from any office staff.
No need to leave instruction for update on production status to subroutines.
Non Altered data available for analysis. How this benefits the Middle Management?
Non Altered data available for analysis. How this benefits the Middle Management?
Analysis of the machine status without visiting the shop floor.
Keep a track on Real Machine Breakdown status.

How this System is installed?

Real Time Data of Machine Status, Production, Stoppages etc are logged through Non-Invasive Sensors to a Embedded Server.
he Data is uploaded to the Cloud for Analysis and Storage

The Front end Dashboard on any Authorized User can then see the following :

Status of the Machine
Trends of machine Production through the day
Production and Down time details of the day
Any predefined KPI of the system
Predefined Alerts are sent to concerned departments when the Machine / Production is not in the set limits.

Information deduced by Intelligent Real Time Controller (Mother) from the data collected by Intelligent Real Time Detector (Daughter)

Working Time of the Machine
Idle Time of the Machine
Efficiency of the Machine
Cycle time of Machine (optional) Reports which are generated by the Intelligent Real Time Controller (Mother)
For the Machine
Time Analysis
Trend Analysis
Productivity Analysis
For the Shift / Operator
Working Time Analysis
Cycle Time Analysis
Machine Efficiency

Power consumption of each Line (if Feeders are logged - optional). This can be linked with the production, and we can get KW/unit of production for each line.

Shift wise
Day wise
Month wise

Deliverable by the system

Dashboard showing near Real Time status of each Line and its components, on any computer
Graphical trends of each line in any time frame
Reports of each line in any time frame
Display provision on any Smart TV showing the status of the lines shift-wise and day-wise
Daily Data in SQL / CSV database format for integration to your ERP / SAP

System Deliverable:

a) Energy Flow in the Factory with the following values
i. Voltages
ii. Current
iii. Active Power
iv. Power factor
v. Reactive Power
vi. Energy
b) Graphical 24 hour trends of any of the above parameters for all the feeders in the Factory
i. This will be available in JPG, XLS, CSV, PDF formats
c) BI Reports for hourly trends for any of the above parameters for all the feeders in the Factory
i. This will be available in JPG, XLS, CSV, PDF formats
ii. The BI report can be sorted on any of the above values, i.e. the report can be sorted on the basis of Active Power etc.
2. A dashboard will be available for ANY ONE FEEDER
a) Graphical 24 hour Trends for any of the above parameters
i) This will be available in JPG, XLS, CSV, PDF formats
ii) The BI report can be sorted on any of the above values, i.e. the report can be sorted on the basis of Active Power etc.
i) This will be available in JPG, XLS, CSV, PDF formats
3. BI Report for any of the above feeder in any time frame, i.e. hourly, daily, weekly, monthly etc.
4. An ANDROID APPLICATION showing the above trends for registered users.
5. DATA of all parameter of each feeder will be stored in the cloud in a SQL Database, for analysis for future action by the user.

Productivity Optimisation

Process