IIot – Reckers Mechatronics pvt. ltd.

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 .

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.

Traceability

Traceability is the process of maintaining records of all the materials and individual parts from raw material to a finished product where a UID helps to identify a part, a batch or a finished good. In manufacturing process, the activity of collecting and managing information is known as traceability. The information is collected right from the acceptance of a raw material to shipment of that product.

We provide Automotive Industry Solutions. The solutions are provided for the following lines say Production, Inventory, Vendor etc.

Let’s take an example of Production line. On a assembly line, there are various parameters which are calculated:

From the above parameters Efficiency and Automation is further divided as:

Here by smart monitoring we refer to making the data digital through digitization or digitalization. When we convert the data from reports to computer, it is said digitization. When we convert the data from hardware such as push buttons to HMI , it is called digitalization.

Whether it is digitization or digitalization , it depends upon the ground level equipment available on the assembly line. Now a days the digitization process is done with the help of Industry 4.0.

In the production line , when we talk about a particular section, there are different factors on which production depends, these are:

1. Material available

2. Operator Efficiency

3. Record Maintenance

1. Material Availability

We have developed a software , named , VM Tool which takes the input data through ERP or manually in its Library. This Variant Management Tool is also helpful in Inventory Management of the plant.

Say, we had raw material , x

Now , after production the raw material left is y

Thus,

2. Operator Efficiency

Operator Efficiency is calculated through different factors, like OEE/ANDON & Efficiency. OEE is defined as addition of following factors:

3. Record Maintenance

Reporting is done in various ways:

Thus, tracing can also be known as tracing in the internal system. Every product is marked with UID, and thus when a product is traced back , one can track the raw material of the product and this is called genealogy.

track and trace

Variant Management

Challenge:

Now a days the products are becoming customized , it leads to increase in no. of variants. Manufacturers have to manage assembly lines , features for customized products which is resulting in increased errors, delays in meeting customer requests and extensive rework. This all is related to Variant Management in assembly line.

Every manufacturing unit manages variants, it can be with the help of Excel Sheets or Manually. It result in long working hours, chances of errors are more, variant may get interchange with other design which in result hampers the quality of the final product. Thus, arranging multiple variants on single assembly line is becoming a challenge.

Solution:

We offered our Variant Management Solution , through which the software will enable to keep the check on production with its correct components. This is done when barcode is scanned and matched with the RFID tag. In this the comparison is made via Plan v/s Actual.

Why Variant Management?

To preside over the power of reuse, reduce errors and delays and increase productivity.

In this manufacturers need to define Bill of material of a component and manage the variable in one structure rather than having individual structure. Reckers Mechatronics has designed the software, named VM Tool , which enables one to save the variants in one structure called ‘LlBRARY’ which can save upto 5000 metrics.

Here is the dashboard of Variant Management:

Advantages for the same are as follows:

Plan vs Actual can be easily checked and verified.

2. It helps to reduce the Rework.

Options for each BOM is ready with the operator and can be checked also with the help of Tool.

Implementation

Firstly the data is saved in the ‘Library’ , which is build during development. It consist of the specification as per the design of the product. The Library fetches the data either through ERP or manually prepared reports.

There are various steps in implementation of VMS (Variant Management Software ). The steps are as follows:

Order in a sequence.

2. Appropriate Information to concerned Individual.

3. Comparing Plan v/s Actual.

ERP is fed with the production plan, which is then fetched in Library , which is build during development of VM Tool. When the component comes on assembly line , the signal is transmitted to VM Tool , the matrics related to the product comes on the screen, if it qualifies then marked as OK. Plan vs Actual is checked.

The barcode is placed on each component of the machine which is scanned and matched with the pre defined specification. ( present in the Library)

The RFID tag is placed on each fixture which carries the unique identifier is related to the machine.

Component assembly takes place on one assembly line and engine assembly takes place on another assembly line. Further, both the components are combined to form a final desired product, which is on each stage qualified with Plan v/s Actual.

ROI

The benefit of Variant Management system is to stop the Rework procedure which was time and cost consuming. Generally , customization can no longer be transferred to the customer, therefore the impetus of these losses comes on manufacturer.

IIOT for Industries in Noida Delhi Chandigarh Punjab

IIOT for Industries

IIOT stands for Industrial Internet of Things. It facilitates manufacturing zone of various Industries.

It basically implies the digitization of all the elements of production process efficient and cost effective since it leads flow of data from end customer to manufacturing system and then to individual section of the process involved. IIOT for Industries in Noida, Delhi, Chandigarh Punjab.

With the help of IIOT we take all the elements of production on to the digital platform where it provides integration between software, machines and human in order to respond effectively towards the shift of standards.

IIOT due to its extended feature of modularity and connectivity modernize the production process by adding on to various features like customizing of vehicles.

It collaborates human efforts and robots and made them to work together that will enhance the production speed of the industries and thus increase the profitability.

In todays time the majority of automotive manufacturer have more than one plant for production and that too are located in different countries, thus companies interconnect their plants over different location through this technology.

It enables to monitor the production cycle, calculate the down time , production efficiency in the form of reports.

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