Manufacturing

Optimize machine health, productivity & energy consumption

The machinery in discrete and process manufacturing industries is decades old, operated in isolation and expensive to repair with little or no communication between different equipment.

IoT is beginning to change this, by connecting devices and machines to each other and the cloud and recording critical data in real time. This gives manufacturers the ability to collect data from all parts of the production process, and use it to improve quality control, identify bottlenecks, and predict maintenance needs.

IoT devices can measure the smallest of parameters like gear mesh frequency, gear tooth misalignment, current and voltage trends, electricity consumption, and furnace temperature. By analyzing this data, factories can identify problems and make corrections before they cause downtime or product defects or chalk up to high repair costs.

As a result, IoT is beginning to transform the discrete and processing industry, making it more agile, efficient, and responsive to change. Datakrew’s MADS IoT platform offers dedicated Industry 4.0/Industrial IoT solutions for the manufacturing industry. It provides a complete analysis of trends, with predictions and recommendations on intuitive dashboards, WYSIWYG reports, and interactive 2D/3D digital twins making sure you are always informed and therefore always prepared.

Usecases

Automotive

Implementing IoT solutions at an industrial level, can save costs and improve efficiency with benefits that extend all the way down to commercial usage.
Predictive maintenance helps lower operating and capital costs in the automotive industry. Proactive servicing and repair of assets help to prevent unexpected downtime, with available resources being used more efficiently.
IoT-led solutions can save vital resources by reducing the need to purchase replacement parts for asset components before they fail. This is especially important now, as the cost of labor and parts continues to rise. This solution can also reduce the out-of-service time for an asset by determining when maintenance must be completed in order to minimize asset failure.

Steel and Cement

In the steel and cement industry, most of the equipment used is at least 40 years old – meaning the chances of machines failing is on the rise as is the cost of replacing these soldiers lost in battle. Spare parts for older machines are hard to find, and once found, are expensive to acquire.
There are frequent failures in cement and steel plants due to poor lubrication, roller bearing faults, spikes in temperatures and electricity consumption. Flying in experts for diagnosis is expensive and these consultation can snowball into even larger expenses over time. Even then, the risk of repairing or monitoring equipment with high temperatures or electrical activity taking place inside them is prevalent. A furnace, for example, is dangerous to manually monitor from close quarters.
IoT sees these problems 24×7 under a magnifying lens and offers quick, cost-effective, scalable and complete `proactive` solutions. Variables like electrical consumption, voltage trends, temperatures in rotary kilns and preheaters are carefully monitored. Any deviations are recorded in real-time and sent to the concerned team immediately by way of email, SMS, or WhatsApp messages.

Agro (Palm, Rubber, Tea, Sugar)

When it comes to industries like palm, rubber, tea and sugar – there are two concerns you have as a business owner. Are you producing consistent, quality output? And are you taking care of your critical assets at the same time? While these are two entirely valid problems themselves, your output quality is tied to your asset health at the end of the day.
If the parameters for your machinery, e.g., motors and pumps, are not set optimally – you would be producing outputs of varying quality. This is a problem when you manually do this, as machine malfunctions or voltage spikes can alter outputs that the end consumer may complain about. In an industry where taste buds are involved, this is a real problem. At the same time, not having set parameters or being able to compare real-time values with those set parameters means you will not have an estimate of the remaining machine life or upcoming failures.
IoT-enabled solutions can gather data through accurate and robust sensors that keep you informed about various parameters, withering temperatures and durations, and motor temperatures. This data can then be analysed to understand what works best for your product by helping you identify ideal durations and temperatures.
What MADS also does is monitor your critical asset health round the clock. By monitoring real-time values, like electricity consumption, voltage, furnace temperatures, and measuring against parameters, MADS is able to quickly detect and alert you about potential problems, giving you a solid headstart on taking care of them.

Our Customers

Smart Agriculture Success Stories

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Customer Speaks

Smart Agriculture Blogs

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