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IIoT and Smart Factory System Design Solution:

Unlock your potential with us, using the latest technology, we can help you with your digital transformation strategy. Using the plant floor Data to enhance your company decision making and visibility on your production areas.

IIoT and Smart Factory System Design Solution

We are service provider for IIOT in Faridabad Based in India. The IIOT is also known as the Industrial Internet of Things. It brings together amazing machines, advanced analytics and people at work. It is a network of many industrial tools connected by communication technologies, which become systems that can monitor, collect, exchange, analyze and disseminate valuable new insights like never before. Following this information can help industrial companies make smarter, faster business decisions.

As with other areas of your business, see where your needs are in reality. Where is your pain If it is in throughput, see how you can use your data in the OEE / FIS app, which gives you a better understanding of the constraints, starvation stations, and machine performance. If you’re adding value to defective products or running a product recalls, consider where you can implement IIOT for traceability. If you have unacceptably high scrap rates, look for IIOT options for error proofing.

IIoT and Smart Factory System Design Solution:

1: IIoT refers to the network of interconnected devices, machines, and systems in industrial settings, enabling data exchange and automation.

2: Smart factory system design harnesses IIoT technologies to create intelligent manufacturing environments.

3: IIoT devices, such as sensors and actuators, collect data on equipment performance, production processes, and environmental conditions.

4: Data analytics and machine learning algorithms are used to optimize operations, predict maintenance needs, and improve overall efficiency.

5: Smart factories aim to enhance productivity, quality, and agility by enabling real-time monitoring, remote management, and autonomous decision-making.

Predictive maintenance in process and component assembly in plants

Predictive Maintenance in Process and Component Assembly in Plants

Predictive maintenance in process and component assembly in plants

Empower your production team to predict & prevent production losses, with ready-to-use AI. Maximize asset uptime & enhance its lifecycle. Discover our reliable sensor solutions for condition monitoring and predictive maintenance. Reckers Mechatronics – Driving decarbonization and digitalization. Integrated Circuits. Reference Designs.

Predictive maintenance seeks to prevent equipment failure and downtime by connecting IoT-enabled enterprise assets, applying advanced analytics to the real-time data they deliver, and using the resultant insights to inform educated, cost-effective, and efficient maintenance protocols. Component assembly is the assembling of components or subassemblies into a functional end product. Component assembly is a broad term in the manufacturing techniques of industrial companies and is used for the composition of complex assemblies in small and large series.

OEE and Machine downtime calculations

Before we do anything else, let’s define machine downtime. Machine downtime is any (usually unexpected) time during which an asset/piece of equipment is not running.

There are 2 types of machine downtime:

Unplanned downtime – undesirable, typically a result of malfunction
Scheduled downtime – necessary, used for repair and maintenance

Production lines are, in their essence, delicate clockworks. To work, all the equipment and its parts need to function flawlessly.

If anything throws a wrench into the works (literally or figuratively), the whole system fails. And, we probably don’t have to tell you this, that’s not something you want.

According to research, an hour of machine downtime costs a company on average $260,000. That’s not to mention the lost time and staff productivity, besides the revenue hit.

Energy Management Systems:

1: Energy management systems (EMS) help organizations monitor, control, and optimize energy consumption.

2: Energy management system in Logistics implies choosing the right means of transportation, routes, performing load optimizations, using fuel-efficient vehicles, and opting for clean fuels.

3: EMS can identify energy waste, inefficiencies, and opportunities for improvement, leading to cost savings and environmental benefits.

4: These systems often integrate with building automation systems, HVAC (heating, ventilation, and air conditioning) systems, lighting controls, and renewable energy sources.

Predictive maintenance is an advanced maintenance strategy that involves constant monitoring and automated learning of the equipment condition and aims to address all the above challenges by leveraging historical and real-time data to predict failures and allow just-in-time maintenance and repairs. Industrial maintenance plays a vital role in sustaining reliable equipment performance, safety, energy efficiency, regulatory compliance, and warranty protection.

Vibration and Temperature Based Machine Condition Monitoring Solution

Reckers Mechatronics provide Vibration and temperature based machine condition monitoring solution Faridabad, Haryana Based. Accurate, highly reliable, easy to use, and cost-effective real-time condition monitoring solution. Our condition-based monitoring solution is ideal for any kind of rotating machinery such as electric motors, gearboxes, pumps, etc. Measure and monitor vibration, and temperature with the greatest possible precision and get the right results. Vibration monitoring is very essential for the dynamic as well static machines in the industry point of view. In a running plant over the same platform every machine feels vibration under the tolerable limits. Hence monitoring of such vibration is very much required for long term use of machinery. Vibration and Temperature based Machine Condition Monitoring.

Highly integrated hardware and software that just works out of the box.

Vibration Based Condition Monitoring (VBCM) is a technique used to monitor the condition of machinery and equipment by analyzing vibrations. It is a non-invasive method that can detect faults and defects in machinery before they cause damage or failure. While vibration is recorded using frequency and amplitude, it is measured in terms of acceleration, velocity and displacement. These characteristics can be monitored with sensors and vibration analysis equipment. This equipment can vary regarding the elements it measures, as well as how it is measured. The five key elements of condition monitoring are data collection, data analysis, alert generation, maintenance planning, and continuous improvement. Data collection involves gathering information from sensors or monitoring devices.

Displacement of shaft with respect to its real axis, rotaional path displacement, x-axis/y-axis displacement of turbine shaft are very critically observant parameters for any rotational machine and we provide all such monitoring and control in our CONDITION MONITORING SECTION.

Vibration and Temperature Based Machine Condition Monitoring Solution

We provide condition monitoring in following type-

Solution

Developed a highly flexible & cost effective, designed for real time monitoring of overall (direct) vibration levels & we guarantee measurement accuracy within ± 2 microns with Allen Bradley world class Automation control system.

Hydropower(horizontal/vertical) turbine
Thermal power turbine
Extruder machinery
FMCG industries
Blower in heavy industries
Power motors
Diesel Generators turbines

An Ability to Track and Trace : Traceability

Traceability is the ability of a system to track and trace the every single part, product or batch through the complete manufacturing process. It starts from the movement when a raw material is entered into the manufacturing unit/ factory to the movement a final and finished product is ready for shipping.

This process of Traceability helps/allows the manufacturing units to digitally connect their each and every single part, product or batch to the Sub-assembly, the Main assembly and finally to the Final assembly. This is required and very much in need of the industries to maintain their products quality to save their brand image along with the sustenance in the markets competitive environment and to gather Customers Loyalty.

In Manufacturing Traceability systems are found in both part and batch production. There are four elements connected to the design of a lot-tracing system or batch-tracing-system:

Physical lot-integrity – This refers to the size of the batch of raw material and how good the integrity of the considered batch is maintained. This will determine the the perfection of the traceability solution considered.
Data collection – For Data collection there is requirement of Two types of data. One is Process data which will provide the process information and second is Lot-tracing data that will provide the information related to the movement of product batches.
Product identification – This refers to the connection of identified product data and process data.
Reporting – It is the use of generated data and visualization of same .

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.