Category: blog

Soap and Detergent Process

Soap and Detergent Process

Process Control

The process of controlling a series of events to transform a material into a desired end product is called Process Control.

Initially Industrial process control was performed manually by operators. Their sense of sight, feel, and sound were their sensors, which was making the process totally operator-dependent.

Industrial process control is now refined with computerized controls, automation, and accurate semiconductor sensors.

Soap Production Flow Chart

 

Soap Batch Process Dashboard

RM Section:

Ingredients are kept in DAY tanks and dispensed accordingly to Batch sequence as per selected Recipe by operator. User can Monitor and Control Both with the installed Load Cell as shown.

Dosing Process:

After Start Auto Batch / Auto Weighing time material discharge from DAY tank to fill weigh hopper and also controlled according to Batch step sequence as per selected recipe which is customized by user with specific Login ID.

Mixing Process:

All ingredients are mixed in predefined proportion and for particular time duration as per selected Recipe. Whole process controlled and monitored via SCADA or HMI.

Detergent Boon Mixer Process Dashboard

BOON  Mixer

In BOON Mixer, Auto Batch Process are totally depends on the customized selected and controlled recipe which are filled from customer R&D department depending on product. Because user can use these type of Mixer for more than 3 products.

All Ingredients are dispensed and controlled by the selected recipe. User developed the mixing steps from SCADA as per Recipe and also depends on environmental condition.

Final product after completion of BOON mixing are transfer to Packaging line through Multi discharge conveyors which are also work on Priority based concept as per no. of Packaging Machines.

Batch Report:

This is the sample Report format which are normally used in Batch Process Plant and also customized as per End user requirement.

 

What is Digital Transformation ?

Digital transformation

The incorporation of digitizing the data introducing digital technology to the processes is known as digital transformation.

As per the words of Greg Verdino,

  • Digital transformation closes the gap between what digital customers already expect and what analog business actually delivers.

Digital transformation is a matter of survival. Nowadays, every industry wants to digitize its processes since it will result in their growth and thus will increase the revenue.

Benefits of Digital Transformation:

  1. Technology is evolving at an exponential rate thus making the processes digitize will help to increase the revenue.
  2. Through digital transformation, the data has become more useful, predictive maintenance is one of the key factors.
  3. The importance is of data, not just big batches of data in fact real-time data, the data related to your ongoing processes and history of processes which helps the concerned person to make the right decisions which lead to innovation and success.
  4. By using the information from real-time data, industries have transformed their process for improved customer satisfaction.

Digital transformation depends on data but the informative data depends on the collection of data, proper analysis of data, data security and also the application. Thus, the steps for digital transformation are:

steps of digital transformationn

Reasons to leverage IIOT Solutions

REASONS TO LEVERAGE IIOT SOLUTIONS

IIOT refers to the Industrial system which connects machine, people, systems of an Industry. It helps to create a new prototype. IIOT is the basic concept for Industry4.0. It is not about connecting the device with individual users. IIOT is about creating a connectivity system between machines, users, data,inventory, processes etc.

This connectivity system is connected to cloud where data is saved and data analysis done for required reporting and analysis of data.

Data can be provided to multiple users from the cloud and when the analysed data is available with concerned persons they can take required preliminary actions for more efficient processes.

Following are few reasons to leverage IIOT solutions in the Industry:

1. It helps to make system sustainable:

Since the concerned persons get real time information, report analysis etc.,they can take preventive decisions much on time, which in turn will effect the sustainability of the system.

2. Improvement in Operations:

The information received help in changing the operations if required for better performance and high reliability.

3. Customer Satisfaction

When the process systems works smoothly and efficiently it leads to better productivity and thus gains customer satisfaction.

4. Maintenance- No issue

With the help of analysed data, one can do preventive maintenance. Preventive maintenance helps to reduce the uncertain shut downs which had a huge impact on cost and production.

The Historical data is also helpful for preventive maintenance.

5. Remote Access:

To check the process data, reports, one need to be there in plant near the desktop. With the IIOT Application, one can check the information from anywhere through any device say mobile, tablet, laptop, the only thing required is user id and password of the required portal. This relates to time saving.

When the Industry works hand in hand with digitization, it brings to innovative changes in Industry which are Industry friendly as well as gains customer satisfaction.

BENEFITS OF IIOT

Digital Transformation: Technological Revolution in Manufacturing Industry

Digital Transformation : Technological Revolution in Manufacturing Industry

Digital transformation has brought a new era of technological revolution in the manufacturing industry. Digital transformation helps in utilizing data of every activity of manufacturing process.

Digital transformation impacts all the process from raw material to finished goods. It helps in making the process systematic and helps in generating a revenue.

Benefits of Digital Transformation

There are tremendous benefits of Digital transformation, brief is as follows:

  1. Quality:

    Machine learning algorithms are applied in the process of production from where production process data is generated. This helps in predicting the defects in the production line, also it helps to predict the root cause of defects if any.

    Thus, it helps in maintaining the quality in production line as well as it helps to save a lot of time which can be used for productive process.

  2. Cost:

    Capturing and analyzing data at all points of the manufacturing line which includes production line and manufacturing data. Analyzing data helps to identify new cost saving opportunities.

    Inventory management can be done with the help of IIOT. Inventory management helps to further reduce the wastage in the industry which indirectly impacts the cost of production.Safety & Security

  3. Safety & Security:

    For digital transformation sensors are to be placed at different points of a process to analyse the data which can intimate in advance of any irregularity.

  4.  Customization:

    Nowadays customization is a key to unlock the requirements of customers. It can be easily achieved with digital transformation. With digitization manufacturing lines can offer a wide customization options to customers while remaining competitive in price.

  5.  Productivity:

    Analysing of data helps in better and faster processes. Since real time data is available with the help of IIOT which further is used for reducing the downtime and increasing the production rate.

    Pre information of data is helpful for preventing malfunction in the production line.

  6.  Cloud Computing Platform:

    Industrial cloud applications are used for capturing and accessing the data which is fast, helpful for easy updates and can be accessed on mobile or desktops as per the convenience.

  7. Advanced Analytics:

    IIOT has the ability to receive constant information from sensors and respond with analysed data in real time. It makes machine learning very powerful tool in providing benefits in production through IIOT.

    IIOT has helped with predictive maintenance, the behaviour can be very well understood of machines with their real time data. The machines can be well identified with accuracy for the errors and malfunctioning.

    Digital transformation is vital aspect for IIOT implementation in a manufacturing process. The digitization should cover all the aspects of Industry which includes production, development, delivery, quality and analysis.

Solution to Big Losses of Manufacturing Industry : OEE

Solution to Big Losses of Manufacturing Industry :OEE

What is OEE?

OEE is basically the metric for benchmarking progress, improving effectiveness, improving the productivity and identifying losses. It is calculated as :

OEE= Availability x Performance x Quality

There are six big losses which occur in manufacturing units while production. It is considered that OEE is used to minimize those losses. The major losses are:

  • Availability Loss

a. Unplanned Stops

b. Planned Stops

  • Performance Loss

a. Small Steps

b. Reduced Speed

  • Quality Loss

a. Production Rejects

b. Startup Rejects

How to Improve Production Losses?

OEE basically aids to increase the efficiency and effectiveness of the manufacturing system. By OEE we can take the reporting in a manner that no manual intervention is there and the system is calculating the real time report of manufacturing.

By OEE we can calculate the performance of individual alongwith availability of raw material.

In Brief:

  1. OEE helps in reducing the cost of quality manufacturing in a stipulated time.
  2. It increases the effectiveness of the production.
  3. Production rate also gets improved.

How OEE works?

Sensors are placed on the machinery and they measure the relevant parameters such as temperature, pressure etc while the production line is working.

There are two ways:

  1. OEE
  2.  IIOT

    Benefits:

    OEE is useful when it helps to take the better decisions regarding how and when production line should progress.

    The concerned person can check the relevant data at any given point of time and take the decision as per the same.

     

    Direct Analysis:

    The data reaches the concerned person without manipulation and in the format as desired. No more heavy files to access for analyzing the data.