Case Study: Converting to Industry 4.0

Posted by Kari Grosser on Jan 29, 2018 11:00:00 AM

A global partner for the automotive industry who develops products for transmissions, engines, drivelines and fasteners started a company optimization program with the support of Net Surfing to optimize internal industrial asset management and energy consumption starting from the existing machinery and infrastructure by combining the asset management system with IIoT energy saving technology.

System Requirements

After a deep analysis of available technology, the client stared to apply high-tech sensors on ovens and compressor rooms for heat treatment and consumption analysis, but furthermore they needed to acquire all production data from the existing equipment and machines (from PLC and dedicated counters) in the field to get physical parameters in order to put in place a predictive maintenance and an energy saving system. Another challenge was to create a type of bridge between OT field data and IT asset management data. In order to do this, they needed an open technology for data acquisition, collection and monitoring, that can support different equipment and machines without the existing HW and be user friendly for operations with an easy dashboard to be shown also with a smartphone, table or QR-Code.

System Description

The entire project was implemented by integrating an asset management system based on the Infor EAM platform together with an IoT and energy saving technology based on the Advantech WebAccess platform with a redundant architecture on a virtual machine. In general, the overall system included: acquisition monitoring of energy consumption data acquisition of production data from each machine/piece of equipment (from PLC and dedicated counters). Acquisition of physical parameters: temperature, pressure, flow and vibration. In particular, from the compressor room the acquisition included: compressors remote control air flow pressure and temperature, air extraction from buildings, fire alarms, technical alarms, electrical energy consumption cooling system, pressure monitoring, temperature monitoring, pump monitoring and remote control.

System Diagram

After a deep analysis of the available technology, the client started to apply high-tech sensors on ovens and compressor rooms for heat treatment and consumption analysis, but furthermore they also needed to acquire all the production data from the existing equipment and machines (from PLC and dedicated counters) in the field to get physical parameters in order to put in place a predictive maintenance and en energy saving system. Another challenge was to create a type of bridge between OT field data and IT asset management data. In order to do this, they needed an open technology for data acquisition, collection and monitoring that can support different equipment and machines without the existing HW and be user friendly for operations with an easy dashboard to be shown also with a smartphone, table or QR-Code.

diagram.pngWebAccess/SCADA - Browser Based HMI/SCADA Software

ADAM-4570 - 2-port RS-232/422/485 Serial Device Server

 

Conclusion

In practice, the production process monitoring in addition to the energy consumption saving allowed the company to program half-yearly stops for ordinary maintenance, but also to allow them to replace worn parts before they broke. Further results included a production waste decrease and the possibility to apply a remote control to some machines, especially in the compressor room, which allowed for remote assistance. The project allowed the company to improve the overall performance of 4-5% without changing all the existing machinery and therefore offering a suitable investment in terms of costs and an increased ROI with an estimated amortization time of approximately one year. Thanks to the expertise of our new technology partner Net Surfing Srl, we were able to reach our mission by enabling an intelligent planet.

 

Technology Partner: Net Surfing Srl

Country: Italy

Topics: Remote I/O, Automation Software

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