Machine Health Monitoring System for Real-Time Insights & Improved Efficiency

A remote monitoring service gives your customers instant visibility into the performance and health of their equipment/machine while simultaneously providing you a new recurring revenue model.

Introduction

The client here is a well-known manufacturer of machine tools with a large customer-base spreading across the country. They specialize in in manufacturing original equipment machines and came to Trinetra for a solution. The company required a solution to monitor their machines in real time to improve on performance and capabilities, besides saving costs and time by remote diagnostics.

The Problem Outline

The client a leading manufacturer of machine tools, needed a centralized solution or system to continuously, remotely monitor their machinery installed in an industry. They wanted to improve machine capabilities and be unique from competitors

They required a unique skill-set for the organization and needed to monitor the assigned critical parameters over a time period, using sensors, such as temperature or pressure and energy usage and understanding the equipment’s controller.

They envisaged real-time visibility of data to take proactive decisions, leading to better efficiency and productivity of their machines. This is to ensure that the machines be able to maintain optimum production and performance in the manufacturing plant. It reduces Turn Around Time for service executives with quick fault detection features.

Therefore, the software application they were seeking would run on 24×7 basis. It must be accessible by multiple users in real-time on the Industrial IoT platform provided by us, built on the Particle IoT Platform. This software will help them connect to various platforms and to automate functions. It supports Data Management, comes with predictive analysis to Improve the efficiency, save time using remote diagnostics and is ready for future forecast solutions.

The Solution Summary

What the client needed was a single unified software to monitor all the machines parameter they considered important and which will improve their production, performance, technical capabilities and thus be really unique from competitors. The solution we developed, brought about in maintaining all assets in a single platform that reduces Manual Intervention and improves data security. The other benefit is it reduces Turn Around time for service executives with quick fault detection.

Overall improved brand value ensures the uniqueness in a competitive market. The automated solution with Sensors installed for tracking key parameters for analytical information, has sensors for monitoring efficiency and production of machines from a remote location, with features for triggering Instant fault notification using remote diagnostics.

The Modular Solution helps achieving real-time visibility of data and for monitoring is enabled with reliable secure, bidirectional communication, built on a robust data management system & architecture. The remote monitoring service would send real-time alerts to the customer to reduce the service cost. It gives Value Addition to maintain the machines performance and improve its life time.

Outcome / Result

• OEM Software built by in-house developer matches customer requirements
• A tailor-made and customised solution, specific for your business needs
• Data-driven results and trends for timely, quick decision-making
• With domain expertise, the solution experts work closely to offer value addition to your business
• Expertise in 3rd party device integration and on single unified powerful platform
• The system offers expectation based monitoring & custom based reporting

Takeaways

• Improves assets’ performance by monitoring 24/7
• A 60% improvement in knowing about machine trends
• Improves data security and safety aspects
• Help know current status through automated process in real time
• Reduces Service TAT by 70%, by knowing about error’s in advance
• Reduces Service request by 65%, by improving product quality

Conclusion

When provided on a single unified software, customized for all their needs, the highly automated IIoT solution installed works to monitor numerous parameters remotely in real time and generates data for remote diagnostics and data analysis. It helps quick go-to-market advantage for products developed by an Original Equipment Manufacturer, besides improving on post sales experience of customers.