Customized Real-Time Monitoring Solution for Cold-Forming Machines

Introduction

Our client, a prominent player in the manufacturing industry with a focus on cold forming machines, faced significant challenges in monitoring and maintaining their complex machines. These machines, ranging from mono-layer to 7-layer extruders, are each equipped with multiple Variable Frequency Drives (VDSs) and four Programmable Logic Controllers (PLCs). Dissatisfied with their existing IoT solution, they sought a more reliable monitoring solution, specifically tailored for their industry.

The Problem Outline

• Multifaceted Machinery: The client operated various extruder machines, each with its unique complexity, making real-time monitoring a challenge.
• Size & Complexity: The sheer size and intricacy of the machines, coupled with multiple VDSs, posed difficulties in monitoring and maintenance.
• Automation Requirements: With four PLCs in each machine, the client required an automated monitoring system to streamline operations and reduce manual intervention.
• Unsatisfactory IoT Solution: The client’s existing IoT solution couldn’t meet expectations, prompting the need for a more reliable alternative solution.
• Predictive Maintenance: The client wanted a solution c offering predictive maintenance and comprehensive data gathering for informed decision-making.
• Customized Reports: Industry-specific customized productivity reports were essential for the client to optimize their operations effectively.

The Solution Summary

• Data-Driven Decision Making: Our IoT solution provided real-time remote monitoring of critical parameters, enabling data-driven decision-making for timely interventions.
• Improved Machine Quality & Lifetime: By analyzing machine performance in real-time, the solution contributes to enhancing machine quality and extending their operational lifespan.
• Trend Analysis for Faults & Improvement: The system facilitated trend analysis, allowing the client to identify patterns of faults and areas for improvement.
• Timely Reporting: Reports, which previously took weeks to compile, were generated within minutes, offering quick insights into asset performance.
• Real-time Monitoring: The solution allowed the client to monitor each machine’s running, and idling, providing a comprehensive view of asset health.

Results

• Enhanced Asset Performance: The performance of the assets significantly improved, allowing the client to proactively address potential issues.
• Reduced Customer Complaints: Customer complaints related to machine performance decreased, contributing to higher customer satisfaction.
• Elevated Brand Value: The overall brand value of the client improved as a result of optimized machine performance and reduced downtime.
• Improved Asset Visibility: The client gained improved visibility over their assets, leading to better control and management.
• Time and Cost Savings: The implementation of the IoT solution resulted in notable time and cost savings for the client.

In conclusion, the successful deployment of Trinetra’s data-driven IoT solution effectively addressed the client’s need for remote machine monitoring in manufacturing,