Overview:
The manufacturing industry, especially small to mid-scale units like plastic pipe manufacturing, often lacks smart connectivity and automation. Machines such as extruders, cutters, and heaters operate in silos, monitored manually by operators. This traditional setup not only increases the risk of downtime but also limits productivity, scalability, and process visibility. With IOTnarad, these challenges are addressed head-on through smart, affordable industrial IoT integration.
Problem Statement:
In typical manufacturing plants:
- Machines are standalone and not digitally connected.
- Operators must manually check heater temperatures, motor speeds, and production counts.
- Faults such as overheating go unnoticed until serious breakdowns occur.
- There is no way to monitor shift-wise productivity, making performance evaluation and planning difficult.
- Plant owners and managers have no real-time insights unless physically present on-site.
Challenges Created:
- Unplanned Downtime: Equipment failures that are not detected early can halt operations.
- Higher Maintenance Costs: Maintenance is reactive, leading to more frequent and expensive repairs.
- Human Dependency: Skilled operators must constantly monitor operations.
- Low Productivity: No benchmarks or metrics to track performance and improve efficiency.
- Lack of Process Visibility: No centralized monitoring leads to information gaps.
Our Solution:
IOTnarad transforms traditional manufacturing into a smart factory by:
- Connecting directly to heaters, motors, encoders, temperature sensors, and counters.
- Enabling real-time monitoring of all machine parameters from a single dashboard.
- Automatically generating detailed shift-wise reports, production statistics, and downtime logs.
- Sending instant alerts in case of temperature breaches or equipment failures.
- Allowing remote control over machines (e.g., emergency shutdowns).
- Upgrading existing legacy machinery to Industry 4.0 standards without requiring complete overhauls.
Key Features:
- Edge device connectivity
- Dashboard with real-time data visualization
- Alert systems and analytics
- Customizable controls for remote intervention
Impact:
With IOTnarad, manufacturers can:
- Prevent downtime through predictive maintenance.
- Improve productivity by analyzing performance trends.
- Make data-driven decisions for process improvement.
- Minimize operational costs by reducing energy consumption and unplanned repairs.
- Gain full visibility and control of their production lines remotely.
