Turning conventional into super factories with IoT 4.0 (Industry 4.0)
What is Industry IoT 4.0?
Industry IoT 4.0, also known as Industrial Internet of Things (IIoT) or Industry 4.0, is the fourth industrial revolution. It is characterized by the convergence of physical and digital technologies, the use of data and analytics to drive decision-making, and the increasing automation and autonomy of machines and systems.
The concept of industry 4.0 involves the digital transformation of the industry. This helps to gather and analyze data across the machines, work faster, flexible and organize processes to produce high quality goods at low costs. The continuous collection of real-time data from enabled IoT devices, make assets tracking, behavior monitoring and manufacturing efforts more effective.
Currently, most of the manufacturing industries are monitoring their machines manually. If there are any breakdowns or wastage, there is no way to track them, and reasons are not traced. If there is a variation from output to input of resources, the reason for loss needs to be identified. But, due to the manual works, it’s difficult to find the stage of loss (whether it's in printing, cutting or laminating etc.) and find a remedy (come to a solution whether to change the machinery or upgrade it or any human error). Sometimes, the machines can consume more power and it directs to the huge loss. So, it’s essential to track the energy consumption as well.
The below data needs to be gathered in the package printing industry.
- Length measurement of reels
- Weight measurement of reels
- Machine operating time
- Package count
- Wastage weight measurement
An admin enters the job number with details into the ERP system. The Tablet shows the task allocated each day and the person assigned to do the task.
The required data are collected from SenzMate gateways. Encoders installed in the machines will measure the input and output reel rotations. The users will get threshold-based alert triggering, real-time alerts, time series-based data visualization, report generation and multiple user roles.
Individual tablets installed in machines will minimize discrepancy in results, allow for double checking, and job entry information to correlate with data. If wastage occurred, the reason for wastage is entered in Tab. Also, the status of the process can be tracked.
Example: Machines are monitored from morning to evening (workhours) to ensure that they are working properly and consistently. This helps to track whether there were any breaks (intervals) taken and the number of breaks taken, machinery breakdowns, reason and how long it took to solve the issue.
Also, the power consumption is tracked. Power status of the machine is detected and updated in real-time. This includes alert notification when there is a power failure. Even, the fraud and theft are monitored in the manufacturing industries after the industrial revolution 4.0.
This revolution in manufacturing industries will increases productivity, competitive advantage and enrich industrial growth.
SenzMate has partnered with automation companies and integrated with their system to achieve industry 4.0.
