Seamless collaborative working sets out simplified, risk-free path to IIoT-enabled production facilities

INTRODUCTION

Estimates from leading analysts such as BCG (Boston Consulting Group) suggest that the value of the IoT market is today around €250 billion. Moreover, the fastest-growing and largest segment is IIoT, which is expanding at a compound annual growth rate of approximately 30%. With this thought in mind, industrial product manufacturers are striving to offer leading-edge IIoT solutions as they seek ways to generate new revenue streams and differentiate themselves from competitors.

More and more companies are leveraging the benefits of digital IIoT tools to tap into a connected environment of information, processes, people, services, systems and IoT-enabled assets. The choice of supporting technology providers in this area is wide. This white paper demonstrate how astute decision making can pay significant dividends, when made up-front rather than retrospectively.

COLLABORATE TO ACCUMULATE

IIoT solutions are not homogenous, there is no one-size-fits-all approach to suit every manufacturing facility regardless of its products or core business. Instead, factories must set out what they want to achieve, and choose solution providers according to their specialisms.

Of course, selecting more than one technology supplier can sometimes prompt concerns over a lack of integrated working, but this need not be the case. When identifying solution providers, manufacturers should enquire about the potential and willingness of shortlisted technology specialists to work collaboratively. The best way forward is to focus on those that respond positively and can demonstrate successful examples of previous co-operative IIoT projects.

There are many benefits to this strategy, but most notably, appointing a collaborative IIoT partnership is akin to receiving two perfectly harmonised, simplified architecture solutions from a single entity. The process is easier, smoother, more controlled and often faster, as Shiratech can testify from its numerous collaborations with IIoT platform providers. Its iCOMOX™ device is an intelligent condition monitoring platform for IIoT applications, and take-up is growing fast.

Another clear strategic benefit is that FabMetrics, an IIoT and AI platform connected different sensors, PLCs, and different manufacturing equipment, is continuously optimizing its connection capabilities.

COLLABORATION IN ACTION: ELECTRIC MOTOR MANUFACTURER

Striving to simplify the next stage of its evolution, an electric motor manufacturer recently asked Shiratech and Innoppia to collaborate on a major IIoT/AI introduction project at its factory. The concept would apply to production operations, testing processes and products. In turn, the project would also serve to reduce downtime at the motor manufacturer’s customers.

The scope of the project, which focused on the FabMetrics factory analytics IIoT/AI solution from Innoppia and iCOMOX™ from Shiratech, included two main areas:

  • Fully connect the company’s production machinery and processes
  • Connect the products and offer value to the company’s clients through digital services

FABMETRICS: CONVERTING DATA INTO VALUE

FabMetrics is a solution that unlocks the full potential efficiency of production lines. The system’s developer, Innoppia, creates systems to collect data sets from production floors and convert them into business value. As a cloud-based SaaS, FabMetrics does not require big hosting investments, and offers both accessibility and flexibility. This flexible framework means solutions are possible for any type of production line or machine.

A four-step process helps projects get underway:

  • Analyse the factory
  • Connect to/locate sensors
  • Configure the FabMetrics gateway
  • Provide access to real-time reports

In short, FabMetrics makes the IIoT accessible for any size of manufacturer thanks to the power and efficiency of cloud computing. Many companies are guilty of underutilising valuable data from machines and sensors, but this issue is easily addressable with FabMetrics.

ICOMOX™: INTELLIGENT CONDITION MONITORING

By adopting the intelligent iCOMOX™ condition-based monitoring solution from Shiratech, customers can increase their OEE (overall equipment efficiency), save costs and improve the safety of employees using existing machines.

As an open, embedded sensor-to-cloud platform, iCOMOX™ monitors operating conditions from the surface of equipment for early identification of potential faults, subsequently reducing the risks/costs associated with system operation and maintenance. This capability extends the lifetime of equipment, reduces unplanned downtime, cuts maintenance costs and unlocks potential energy savings. iCOMOX™ offers:

  • Multi-sensing: vibration, magnetic field, temperature and sound sensors
  • High dynamic range and exceptional SNR for vibration analysis
  • High-performance acoustic emission detection
  • Non-invasive current sensing for motor current signature analysis

Three standard iCOMOX™ modules are currently available: iCOMOX™ with PoE (Power over Ethernet), a wired solution for industrial applications; iCOMOX™ with NB-IoT (Narrow Band Internet of Things) for remote cellular communications; and iCOMOX™ with SmartMesh IP for low-power wireless communications.

APPLYING THE SOLUTION

At the electric motor manufacturer, implementation of the unified FabMetrics/iCOMOX™ solution has led to the connection of production processes and the tracking of machine data. In addition, the testing of motors has become a connected process.

But the work did not stop there; connection has also been achieved for the company’s motors. In all cases, MQTT architecture provides the messaging protocol. MQTT is an open OASIS and ISO-standard lightweight, publish-subscribe network protocol that transports messages between devices to create a connected world. Furthermore, it is simple to integrate existing systems into this solution, ultimately delivering an IIoT digital service platform with AI capability that provides outputs about product health and production quality.

iCOMOX™ is used by the electric motor manufacturer to record the basic characteristics of each motor during production and final testing. Delivering 100% control, iCOMOX™ records vibration, sound, heat and magnetic field data. Furthermore, connecting the motors to the cloud provides round-the-clock control of products in the field, detecting any anomalies that may occur.

NEW INCOME STREAM

The electric motor manufacturer can now offer digital services that help reduce the downtime of its clients’ production operations, in essence generating a new income stream thanks to connected motors.

A further advantage for the company is faster problem-solving cycles in manufacturing, which again equate to direct cost savings. Notably, the solution makes the impact of production variables visible on product quality. In total, the FTP (first-time pass) rate at the company’s final quality control stage has climbed by an impressive 15%, while the required amount of rework (re-assembly) time has reduced by around 12%.

The new IIoT platform with integrated iCOMOX™ condition monitoring has also improved the quality-control process itself. Techniques such as spectrum analysis now provide valuable insight into any potentially problematic mechanical components. This data sets out decisions about process/product redesigns to overcome any technical difficulties.

IN CONCLUSION

There are many advantages that result from collaborative working, not least increased creativity and out-of-the-box thinking: after all, two minds are better than one. More flexibility in project direction, increased learning possibilities and enhanced stakeholder relationships are among further benefits of this strategy.

Seamless simplicity was central to the project at the electric motor manufacturer where, thanks to the proven technical partnership and optimised project management between Innoppia and Shiratech, a fully functional IIoT production facility has been created that not only benefits the company’s own operations, but those of its customers too.