Smart Automotive Industry: thanks to the Internet of Things it predicts malfunctions, optimizes processes and reduces production costs

September 07, 2021

100% remote monitoring, 50% less manual operations and malfunction prediction in 24 hours: this is what happens when the automotive industry becomes smart, as told by Vitesco Technologies Italy, a leading Italian company in the production of automotive components that has successfully optimized one of its production processes thanks to the Industrial IoT solution Zerynth provided .

Greater process productivity and more competitiveness: these are the objectives that justify the majority of companies in the automotive business sector to invest in industry 4.0 technologies. In particular, over 80% of Italian companies have opted for this type of investment or declare that they wish to invest in IoT. The benefits are huge: from the ability to analyze and eliminate malfunctions to the reduction of production costs.*

This has been confirmed by Vitesco Technologies Italy, an Italian company based in Pisa who for many years has been a leader in the production of components for combustion engines. In 2019  they embraced a “green” revolution by focusing on the development of cutting-edge technologies for sustainable mobility. They were able to reduce time, cut costs, and halt waste in production, thanks to the IoT system designed by the Italian company, Zerynth. Now, Vitesco can predict malfunctions in one of their critical production processes, as well as optimize the production of automotive components and significantly reduce operating costs. The system allows the company to predict pneumatic valve malfunctions within 24 hours, thus, reducing downtime tremendously.

In fact, the company uses several automatic assembly lines to produce fuel injectors. These lines include a test module that checks the previous assembly steps: if successful, the module proceeds along the line, otherwise it is rejected. However, it may happen that one of the elements of the module does not work correctly due to wear; therefore, before detecting a malfunction of the line, it produces many false rejects. So replacement of worn components is necessary. 

The system, developed by Zerynth, allows Vitesco to improve the quality of the automation processes and remotely monitor the status of the test module for each assembly line.

The solution, provided by Zerynth, is based on a control unit that collects the data available from the sensors of the machine and sends them to a connected cloud platform. The signals are then processed for early valve failure detection and displayed on a dashboard. All these details are displayed on a customizable dashboard. The system is able to manage all the connected devices, perform the temporal archiving of the collected data, view data and messages sent by the individual devices, and organize the latter by work area. It also allows the download of historical data in CSV format, the exchange of data with the end customer, and sending of push notifications in real-time.

“The ability to remotely control machines and continuously acquire data from any machinery is essential for companies like Vitesco, which saves time and resources”, explains Gabriele Montelisciani, CEO of Zerynth. “Our mission is to support companies in the digital transformation by connecting and digitizing their machines and demonstrating how any industry can benefit from the Internet of Things”. 

“For some time we were searching for a technology that could reduce downtime of a specific module within an assembly line. But thanks to our collaboration with Zerynth we are now able to predict malfunctions of pneumatic valves within 24 hours which reduces downtime tremendously,” explains Alessio Papucci, Chief Digital Officer (CDO) & Advanced Technology Leader of Vitesco Technologies Italy. “These advanced methodologies have allowed us to meet our deadlines and our goals.”

In order to talk about the importance of the digitalization of industrial processes, and the need to join the Industry 4.0 revolution, Vitesco will be a speaker at the webinar, organized by Zerynth, “IoT and Industry 4.0 to improve the efficiency of industrial processes: Armal and Vitesco Technologies Italy case studies” on Tuesday 21 September at 11.30 (the webinar will be in Italian).

Notes for the press

*Observatory on Italian automotive components 2020 created by the Turin Chamber of Commerce, ANFIA (National Association of the Automobile Industry Industry) and the Center for Automotive and Mobility Innovation (CAMI) of the Management Department of the Ca ‘Foscari University of Venice.

About Zerynth 

Zerynth helps companies easily get their industrial processes digitized and bring innovative connected products to the world. The Zerynth IoT Platform is a full set of hardware-software tools designed by IoT experts to enable digital transformation in a fast, flexible, and secure way. Founded in 2015, Zerynth has grown steadily. Today Zerynth has 30+ team members with deep IoT expertise and industry knowledge with over 100 customers across many industries. Headquartered in Italy, Zerynth provides support globally thanks to an extensive network of partners in Europe and pan-global locations.

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