Gaining insights and Visibility into Operations using Observability, ML and Industry 4.0
A distinguished manufacturing firm operating globally, renowned for compressors catering to global markets. Even slight downtimes in specific sections halt assembly, incurring significant production losses.
The Challenge
- The absence of real-time machine status visibility
- Dependence on human reporting
- Absence of alarm histories
- Traditional manufacturing practices hindered productivity.
- OEE prediction
- Operational View (Operator, Line manager, Production and Plant manager)
What did ACTIN do?
Employing the MES system across eight milling centers and vertical turning lathe machines, we seamlessly integrated machines to Cloud hosted platform.
The Solution stack was able to ingest timeseries data from the IOT gateway and then Store, Process, Analyze it for Insights.
This enabled real-time machine status monitoring and data visualization, extracting accurate insights directly from the machining floor.
Coupled with Observability Solution and ML in tandem helped in predicting OEE and providing Operator level dashboards, Line manager Dashboards, Production manager Dashboards and Plant manager Dashboards. So, each stake holder had a view and insights of operations.
The application facilitated digital breakdown slips, recording real-time downtime and repair specifics, empowering operators to manage unplanned downtimes effectively.
Impact Made
- MES system enables traceability, accurate data, reduced non-conformance, paperless operations, shorter setup times, minimized downtime, precise economics, and enhanced OEE.
- Boosted output by 27%, eliminating the need for a third shift.
- Enhanced operator productivity by 18%.
- Provided high-level real-time visibility of the machine shop for efficient monitoring.
- Implemented a system for comprehensive performance monitoring.
- Transitioned to paperless operations, reducing production stationary costs.
Technologies used
- IOT gateway, MQTT, Cloud native development in line with CNCF, AWS IOT core, AWS Sage maker, S3, RDS Columnar DB, AWS TimeStream Timeseries DB, AWS Lamda, Responsive Frontend and backend tools, WAF , observability tool etc.
Latest Insights
4 Cybersecurity Takeaways from Chinaâs Largest Data Breach
Cybersecurity drama strikes again as human error leads to Chinaâs biggest data breach and perhaps the most significant hack of personal information in history.
Top 5 Tips for Solving the Email Security Problem
Ever review your email in the morning and wonder why there is so much spam coming through? It takes time to differentiate between the emails…
What You Shouldnât Be Doing with Your Cybersecurity in 2023
Most people believe cybersecurity is highly complicated, ever-changing, and technical. Theyâre not wrong.
