A new era of industrial innovation is here, i.e. industry 4.0. Industry 4.0 has become increasingly mainstream, due to the availability of affordable infrastructure from edge to cloud computing, the desire to gain production insights and improve performance and efficiency. Data has become a strategic asset in industrial environments. Using an IoT-based automation system, which employs a Node-RED interface and a message queuing telemetry transport (MQTT) broker to carry out an easy interconnection between different industrial equipment or machines. Coupling remote access with new technologies allows earlier detection, better diagnostics, and therefore facilitates faster service, resulting in better planning and an increase in efficiency.
Providing remote access to data and analytics to management will close the loop of continued improvement. Data collection and data analysis enabled by the Industrial Internet of Things may increase knowledge and allow predictions, but unless someone acts on these, there will be no effect on the operational performance and direct value to customers across various industries. Only when the knowledge is turned into actions and issues are resolved, then the results can be expected.
Log data in open format to MS SQL Server, MySQL, InfluxDB, SQLite, Access, SQL Azure, Google Firebase, and CSV filesLog events to open databases, and send notifications via SMS, email, and WhatsApp and connect to cloud-based IoT gateways such as AWS, Azure IoT, and MQTT.
Node-RED as a flow-based programming tool is rapidly getting popular in the industrial sector, as IoT devices from smart factories generate substantial datasets that need to be computed, stored, handled, and analysed. Node-RED is built on top of a Node.js / JavaScript stack. Node-RED is a development tool for visual programming established initially by International Business Machines Corporation (IBM) for wiring together hardware devices, application programming interfaces (APIs), and online services as part of the Internet of Things (IoT) and currently maintained by the open-source community. We can run Node-RED on the cloud or locally on a device like our MCU.
Node-red helps us to bridge the gap for Information Technology (IT)/Operational technology (OT). As the Node-RED is developed on Javascript stack, it lets us program unique functions with code. OT application engineers have used this schematic diagram for decades to program real-time control loops on hardware such as programmable logic controllers (PLCs), making the transition to Node-RED much easier.
Node-RED provides an option to develop a dashboard interface that displays different sensor information and can end devices using buttons. It provides nodes to quickly create a user interface with buttons, sliders, charts, gauges, etc. Thus, it allows for creating a spectacular interface without the need for special programming language knowledge, for integrating software and hardware components and may thus replace the SCADA system in the near future. Further, as Node-RED is a web browser-based application, it will allow users to access anywhere in the LAN without any license, thereby overcoming the problem of single display access of SCADA.
Our Solutions
Our Solutions
Remote monitoring and controlling
It is the process of supervising and controlling equipment and machines remotely via cloud or local network. The Industry 4.0-based system remotely monitors the health and status of each and every electrical equipment/machine in the plant, meaning that the complete manufacturing plant status will be available at your fingertips. This allows you to immediately and remotely diagnose and repair the equipment as well as reduce the time between detection and solution, thereby extending the uptime of your equipment/machine.
We provide an end-to-end remote monitoring solution which involves connecting to the sensors on in-service equipment through IoT, and then remotely tracking how and when the product is being used and how it is performing to generate reports, trends and insights. Our system is easily scalable with customized dashboards to monitor critical parameters.
Product Monitoring system
Production line monitoring is a method used in manufacturing plants to gain insights of a factory in real time. Before the revolution of Industry 4.0, many factories used to allocate a human resource to monitor their production lines to ensure that the products were being manufactured with the highest quality in stipulated time and update the same periodically to higher hierarchical management and cross functional teams for future planning.
To overcome the limited view, we provide solutions with the help of technological revolution i.e IIoT or Industry 4.0. The digital production monitoring system is capable of monitoring and collecting data endlessly. The management can not only monitor their plant remotely by sitting anywhere across the globe but also access historical data of production on previous days, weeks, months or even years for future planning and decision making. Our system not only provides insights to the management but also helps to improve efficiency of people who are involved in the assembly line by presenting real-time production data in front of them in an assembly line. This helps to optimize their production at the factory and also to identify areas for improvement.
Machine monitoring system
Machine monitoring in factories is the method of collecting and analyzing data by collecting from machines with the help of advanced technology in the factory. The process of machine monitoring consists of collecting data from machines, transferring that to local or cloud servers to analyze the data to improve performance. With the help of a machine monitoring system, the manufacturers can predict abnormal behaviour of machines and reduce downtime and also identify areas for improvement.
Manufacturers can use machine monitoring system to capture one or more details mentioned below:
● Machine status
● Machine downtime
● Operator efficiency
● Waste
Making informed decisions based on available real-time data helps to reduce cycle times and machine downtime, limit maintenance, resulting in increased production and operational efficiencies.
● Real time automated data logging
● Data transparency and data manipulation
● Error free and on-time report
● Eliminate manual reporting
● Maintenance prediction
Energy monitoring system:
Energy monitoring systems are in demand to decrease the energy expenditure from the businesses. Smart energy monitoring system technique tracks the usage of energy of different areas of the plant round-the-clock.
The energy monitoring system is accomplished through the use of energy meters, along with data loggers. Multiple energy meters are linked to an RS485 network. A data logger is utilized to get this data from energy meters via RS485 protocol. Efficient energy monitoring provides the basis for your energy management.
The energy consumption data is processed and reflected within the datalogger, which then transfers this data to the cloud server or to local server via LAN. An authorized person can access the data. The data plays an essential part to comprehend the behaviour of energy consumption and also to rectify the undesirable energy use in the business.
● Detect abnormal patterns that can indicate potential failures and help with risk mitigation
● Provide centralized monitoring with the ability to monitor and control
● Helps organizations to reduce expenditure on energy usage by optimizing and preventing wastage
● Amalgamation of this system reduces maintenance and operations costs, which results in continued savings
Pick to light system:
Pick-to-light systems are simple but robust systems designed to streamline material kitting operations in assembly lines, thus increasing efficiency, productivity and picking accuracy, while simultaneously reducing time inturn costs.
Pick to light is a type of paperless kitting fulfillment technological system designed to improve picking accuracy and efficiency, while simultaneously lowering your labor costs. It employs alphanumeric displays and buttons mounted at item locations on flow rack, shelving, workstations or other storage media to guide operators to the correct item locations and quantities required for the assembly at hand. Pick-to-Light systems increase pick rate productivity and kitting accuracy by reducing the walking and reading associated with paper-based methods.
Advantages:
● Ease of use
● Increased efficiency
● Paperless: Saves trees hence is environmentally friendly.
● Reduced costs through the elimination of paper-picking lists
● Lower operational costs
● Improved kitting accuracy
● Shorter kitting cycle times and hence increased throughput
● Reduced employee training time
● Reduced errors or rework
Pick to light system
The Customer: Automotive Manufacturing Plant, Karnataka
The Challenge: Picking up appropriate materials from the inventory rack while handling mixed mode production in the same assembly line
The Solution: Implementing our Pick-to-Light system
The Theme: Pick-to-Light is a type of order-fulfillment technology designed using our own IIoT products to improve picking accuracy and efficiency, while simultaneously lowering your labor costs. Pick-to-light is paperless, it carries an alphanumeric display and buttons with inbuilt lamp at storage locations, to guide a person in light-aided manual picking and refilling.
The Implementation: This system is semi-automated and implemented using mixed technologies such as wired and wireless. Initially, the system was implemented with wireless technology. As there were a lot of parts to be brought under this system in a small area of real estate, we switched to mixed technology.
Results:
● Reduced picking material time and increased productivity
● Reduced human error while picking with respect to material and its quantity and increased efficiency
● System can be integrated with ERP
Production monitoring system
The Customer: Toy manufacturing factory
The Challenge: Improving performance of gun assembly line and automated production insight to management
The Solution: Industry 4.0 based production monitoring system
The Theme: Industry 4.0-based production monitoring system is an order-fulfillment solution developed using our own IIoT products and integrated to monitor and improve production
Results:
Reduction in waste of time hence, increased the efficiency of production ~10%.
Data availability to all the hierarchical management
Data history view in a convenient way by selecting the date
Can be accessed from any corner of the plant as long as the user is in the same wired/wireless LAN
Energy monitoring and saving
The Customer: Bus building factory
The Challenge:
Wastage of power at blower units in bus body-building plants
Human error in energy data collection
Periodical report generation
Turning the machine OFF in a congested place is tedious
The Solution: Remote monitoring and control of the blower using our Modbus to IIoT
Results: Monitoring system is very helpful to fulfill the needs of the environment management system and if management wants to implement ISO 50001.
Pick to light system
The Customer: Automotive Manufacturing Plant, Karnataka
The Challenge: Picking up appropriate materials from the inventory rack while handling mixed mode production in the same assembly line
The Solution: Implementing our Pick-to-Light system
The Theme: Pick-to-Light is a type of order-fulfillment technology designed using our own IIoT products to improve picking accuracy and efficiency, while simultaneously lowering your labor costs. Pick-to-light is paperless, it carries an alphanumeric display and buttons with inbuilt lamp at storage locations, to guide a person in light-aided manual picking and refilling.
The Implementation: This system is semi-automated and implemented using mixed technologies such as wired and wireless. Initially, the system was implemented with wireless technology. As there were a lot of parts to be brought under this system in a small area of real estate, we switched to mixed technology.
Results:
● Reduced picking material time and increased productivity
● Reduced human error while picking with respect to material and its quantity and increased efficiency
● System can be integrated with ERP
Production monitoring system
The Customer: Toy manufacturing factory
The Challenge: Improving performance of gun assembly line and automated production insight to management
The Solution: Industry 4.0 based production monitoring system
The Theme: Industry 4.0-based production monitoring system is an order-fulfillment solution developed using our own IIoT products and integrated to monitor and improve production
The Implementation: This system is semi-automated and implemented using mixed technologies such as wired and wireless. Initially, the system was implemented with wireless technology. As there were a lot of parts to be brought under this system in a small area of real estate, we switched to mixed technology.
Results:
- Reduction in waste of time hence, increased the efficiency of production ~10%.
- Data availability to all the hierarchical management
- Data history view in a convenient way by selecting the date
Can be accessed from any corner of the plant as long as the user is in the same wired/wireless LAN
Energy monitoring and saving
The Customer: Bus building factory
The Challenge: Wastage of power at blower units in bus body-building plants
Human error in energy data collection
Periodical report generation
Turning the machine OFF in a congested place is tedious
The Solution: Remote monitoring and control of the blower using our Modbus to IIoT
Results:
- Results: Monitoring system is very helpful to fulfill the needs of the environment management system and if management wants to implement ISO 50001.
Efficiency monitoring system
The Customer: Blanks manufacturing factory
The Challenge: Improving performance of machine operator and automated production insight to management
The Solution: Industry 4.0 based production monitoring system
The Theme: Industry 4.0-based production monitoring system is an order-fulfillment solution developed using our own IIoT products and integrated to monitor and improve production
Results:
- Reduction in waste of time hence, increased the efficiency of production ~10%.
- Data availability to all the hierarchical management
Data history view and report generation in a convenient w.r.t date, time, operator, product, shift etc…. - Can be accessed from any corner of the plant as long as the user is in the same wired/wireless LAN
Efficiency monitoring system
The Customer: Blanks manufacturing factory
The Challenge: Improving performance of machine operator and automated production insight to management
The Solution: Industry 4.0 based production monitoring system
The Theme: Industry 4.0-based production monitoring system is an order-fulfillment solution developed using our own IIoT products and integrated to monitor and improve production
Results:
Reduction in waste of time hence, increased the efficiency of production ~10%.
Data availability to all the hierarchical management
Data history view and report generation in a convenient w.r.t date, time, operator, product, shift etc….
Can be accessed from any corner of the plant as long as the user is in the same wired/wireless LAN
Our Customers
