Optimizing manufacturing process management with data acquisition
The ability to gather specific data in a focused manner matters on today’s shop floor. It is critical to getting operational and strategic decisions right. With reliable data at their disposal, manufacturing teams can see how machine and processes are using resources and make informed choices about how to boost efficiency. Companies can analyze and interpret this manufacturing data to better manage operating processes and production lines to keep the competition at bay.
One of the biggest challenges: getting the factory connected
How do you connect an entire production line? This is one of the most daunting questions in today’s data-driven factory. Often entombed in silos, some of this data is hard to access and use. And that makes it difficult to connect other systems. This inaccessibility impedes digitalization projects. Engineers will struggle to maintain scripts and have to jump through hoops to adapt the system when requirements change.
It pays to think about how to capture the right data beforehand, when you are planning to deploy new machines or revamp the assembly line. If you want to use process and machine data effectively to connect the production line and scale data-driven use cases to size, this is the only way to go.
Also listen to our data analytics expert Marcus Weber in the Factory21 Pocast, talking about how companies can use data-based decisions to increase quality in production and reduce costs.
Let us help you meet this challenge head on. Opt for our customized solutions to connect your factory and boost its efficiency and productivity.
Cloud (IoT & connectivity): To make the most of data-driven innovations, you need solutions that break down data silos and link up the disparate systems of a heterogeneous IT landscape. We can build these solutions for you, putting relevant data at your fingertips for use with analytics tools and AI assistants.
Data engineering: Data is a rising force in business – we believe it is a make-or-break factor for business success. Taking a holistic approach to data engineering, our services cover the entire data lifecycle, from data acquisition at the sensor to data delivery and analysis in the cloud.
Data governance: Let us show you how to turn the requirements of the GDPR, the EU Data Act, and the EU AI Act into strategic advantages for your company. We are your go-to partner for everything from holistic strategy consulting to technical and organizational implementation.
Strategy consulting for smart factories: Let us join forces to develop a strategy tailored to transform your facility into a smart factory. And if you are looking to plan a new factory, we can help with that too. Our holistic, three-phase approach will enable you to put your strategy into action and maximize its impact.
Do you have a specific idea or project in mind?
Count on us to help you collect data and make the most of it for both operational and strategic purposes.
Experience teaches that efforts to connect and control systems and processes succeed when engineers take a holistic approach to gathering data. The first to-do is to address the pain-points in the process. For example, it may be useful to monitor machine utilization and adjust the order sequence to reduce set-up times. The next step is to select the right sensors to capture the appropriate data points for the identified metric.
Once sensors are in place, you need to verify the data and assure its quality. Then you can mine it to gain valuable insights and take appropriate actions. Adjustments after commissioning ensure that the recorded data can also be used reliably in the future to optimize production processes.
ITK’s Transparency Toolkit is a comprehensive solution for data collection that accommodates a wide range of sensors. This easy-to-use platform serves to collect, analyze, and visualize manufacturing data in real time. It also supports data quality assurance and provides the underpinning for scalable solutions.
Fast data acquisition and visualization with the ITK Transparency Toolkit
If you are looking for a quick, versatile way of capturing machine and process data on demand, your search ends with the ITK Transparency Toolkit. Portable and easy to set up, this prototyping kit is about the size of a toolbox. It features various components that use standard communication protocols – OPC UA, MQTT, AMQP, and DDS – to acquire data from multiple vendors’ machines and devices. The Transparency Toolkit can be tailored to suit your processes simply by integrating additional external sensors. Installation takes place right on site at the machine.
Value-adding benefits of the ITK Transparency Toolkit
Far greater transparency
Enables hypotheses to be tested based on collected raw data
Affords deeper insight into the system by visualizing internal cause-and-effect relationships
Smarter machines
Retrofit of legacy machines
Integrates into existing systems such as SCADA, MES, and ERP
Cost-effective prototyping
Affordable, easy to set up data acquisition system
Fast assessment of use cases’ potential in small projects
Do you have a specific idea or project in mind?
Count on us to support you with consulting services that address your specific needs. Let us tailor a data acquisition and processing solution that fits and creates maximum value for your business. Rest assured, we will factor your unique requirements, technical constraints, and legacy processes into the equation.
Determining OEE at the Bosch Rexroth plant in Lohr am Main, Germany
The challenge: The installed base of machines at the Bosch Rexroth plant in Lohr had grown organically over time. This is why there was no standard metric for assessing resource efficiency at the machine level.
The solution: An on-site analysis of processes determined overall equipment effectiveness (OEE) could serve as the key performance indicator. OEE provides a baseline for comparison with the perfect production line to rank equipment productivity and target improvements. The Transparency Toolkit served to track more than 40 signals from the machine control unit and to build a computation engine to determine OEE. Fault alerts were also factored into the equation.
The added value: The captured data provides the transparency engineers need to see how to best improve efficiency. The solution integrates seamlessly into the existing reporting system. Alerts notify the manufacturing team when events occur that require remedial action.
„ITK’s Transparency Toolkit is right for you if you’re aiming to boost production and gain valuable insight into your manufacturing processes. Working with the project team was a genuine pleasure – their collaboration and know-how was second to none. Their efforts resulted in an OEE calculation and visualization that delivered invaluable live data, which enabled us to optimize our operations and boost efficiency.“
Florian Patzolt, Digitalization Rexroth plant Lohr am Main
Energy monitoring at the machine level
The challenge: Our customer, a maker of packaging for the automotive, aerospace and many other medium and heavy industries, sought to measure energy consumption at the machine level.
The solution: Additional sensors were used to gather energy-related data across multiple shifts and production programs. With Modbus TCP serving as the communication protocol, this data could be viewed on the fly during operation. ITK experts also set up a module to visualize energy demand.
The added value: The solution pinpointed the main energy consumers on the production line and created a valid dataset for revamping the line and even for planning an entirely new factory. It fits seamlessly into the customer’s reporting system with zero integration effort.
Benefits
Create a database
Identify initial measures
Connect existing systems
Unsolved challenges? We look forward to your inquiry.
