Overview

A leading tractor manufacturer in India needed an IoT solution to monitor the KPIs of their final assembly line. They wanted a new solution based on IoT/Industry 4.0 concept that can use their existing PLC, sensors, and hardware and provide data-driven actionable insights by remotely capturing accurate shop floor data; 24 x 7 real-time in a secure way.

Client Profile

Our client provides a technologically superior range of tractors. They are pioneers in farm mechanization in India. Their Agri Machinery has in the last seven decades, committed itself to enhance India’s agricultural productivity and adding value to farmer’s life.

Problem

One of the biggest tractor manufacturers in India was looking for a replacement for their existing SCADA system. They had an outdated SCADA system that was no longer supported. They wanted a new solution based on IoT that can use their existing PLC, sensors, and hardware. One of the key requirements was to monitor the Overall Equipment Effectiveness (OEE) of the assembly line.

Solution

Datakrew delivered MADS as a solution to replace their current SCADA. A total of 39 screens were made with 7 PLCs, 15 drives, 4 oven controllers, and 280 tags for the site. Dashboards were shown on large plasma TVs, desktops, and mobile phones. Email alerts were given for any data that has gone over or under certain thresholds. MADS is Datakrew’s IoT and Big Data Platform ​​with a layered stack for Data Ingestion, Data Cleaning, Data Processing, Data Storage, Data Query, Data Visualization, and 3rd party Data Integration.

Results

1. The main screen for production ANDON shows the overall OEE of the production line and hourly achievements. Data such as actual shifts, days, and months are also shown.                                                                            
2. High-limit and low-limit alerts are sent via email to the respective PLC of the equipment. The status of the machine such as running, standby, and stopping is also shown.                                
3. Each machine has a detailed screen that shows all its parameters. Each parameter is stored in a time-series database to show historical data of machine operations.                                                                                            
4. Each parameter can be viewed in a historical chart view. This helps with diagnosis and troubleshooting.

Benefits

1. OEE data is visualized by everyone giving better cooperation to solve plant floor issues; excel sheets are no longer needed for OEE calculation and plotting
2. Dynamic graphs & drill-down make the analysis of trends and history easier
3. Anyone with a web browser can access it; no need to install additional software
4. 24×7 email alerts give plant awareness and quick diagnosis of issues
5. Lower downtime and faster time to spot anomalies in production
6. Better UI/UX design enables everyone to understand the main KPIs that are needed