The factory of the future, LEF, chooses 4.0 technologies: with the Zerynth IoT, SMEs renew their machinery in 3 hours

May 31, 2022

LEF (Lean Experience Factory)  is the world’s most integrated digital innovation hub, which also aids enterprises in digital transformation. Their goal is to show Italian manufacturing companies how to standardize their fleet view, regardless of the manufacturer or technological state of the fleet, and to innovate their shop floor by connecting it in less than 3 hours and with less than 30 minutes of machine downtime, in order to fully exploit the opportunities of the Industry 4.0 paradigm. 

Digitizing legacy machinery for careful and safe production monitoring is one of the current Italian companies’ main challenges, most of which use dated machinery that is still functioning from a production point of view, but not performing optimally. Particularly, some of the critical issues are the inability to connect to management and business intelligence systems, and renew their machinery. In fact, more companies are looking for solutions that can eliminate these technological barriers, allowing an easier transition to industry 4.0.

In this context, LEF (Lean Experience Factory) fits in as the most integrated digital innovation hub in the world that supports companies in digital transformation through experiential training and consulting services, which chose Zerynth technologies with the purpose of enabling SMEs to experiment with the use of innovative technologies, that are centered on reducing waste and inefficiencies, and thus allowing them to become more competitive.

LEF, in particular, was looking for a safe, non-invasive solution, quick to set up and being able to digitize both the old generation machinery present in the plant, and the new ones equipped with PLC, to collect data in real-time with easy and intuitive visualization. To meet these needs, the Zerynth team implemented a solution for LEF that allowed, on the one hand, a complete retrofitting action on the machinery present in the plant, and, on the other hand, a complete and uniform connection of new and legacy machines.

In just three hours of installation, it was possible to interconnect 4 machines at 2 different sites, with less than 30 minutes of downtime. Specifically, a 4ZeroBox Mobile industrial IoT device was connected to the older generation machinery, while a 4Zerobox device was used to interface with the newer ones equipped with PLC, in order to extract data, aggregate them and send them to the Zerynth Cloud platform, consequently, allowing a real-time display on customized dashboards. Furthermore, through a cellular connection, it was possible to connect machinery to the Zerynth Cloud in areas not covered by WiFi or Ethernet, allowing continuous transmission of data and their visualization on the appropriate dashboards, ensuring a more careful and secure production monitoring, as well as a reduction in consumption.

“Thanks to the use of the Zerynth IoT platform, it is now possible for us to have all the useful tools for actively monitoring the production of both legacy machinery and the new ones equipped with PLC”, explains Marco Olivotto, Managing Director of LEF. “Being able to obtain all the process insights and KPIs is one of the greatest advantages obtained in order to be able to adopt adequate strategies for optimizing consumption and thus obtaining real transformation”.

“We are proud to have implemented our technology in a model factory that all Italian companies should aspire to”, explains Gabriele Montelisciani, CEO of Zerynth. “The collaboration with LEF demonstrates the innovativeness of our solution and confirms our desire to make IoT technology easily accessible to all Italian companies, as we accompany them in their transition to Industry 4.0”.

About Zerynth

Zerynth helps companies digitalize their production processes and develop connected industrial products through a plug-and-play IoT platform designed to enable the 4.0 digital transformation of any industrial machine in a fast, flexible, and secure way.

Founded in 2015, Zerynth has grown steadily. Today it has 35+ team members with deep IoT expertise and industry knowledge with over 100 customers across many industries: from manufacturing to agriculture to energy to logistics. Zerynth is based in Pisa, Italy, and it is currently active in international projects, and foresees an expansion plan in EU and non-EU countries during the next three years. 

About LEF

LEF – Lean Experience Factory is the largest and most integrated digital modeling company in the world, founded in 2011 as an experiential training center from a joint venture between McKinsey & Company and Confindustria Alto Adriatico and other partners in the area. More than 3000 square meters recreates the processes, organization and roles and functions of the people of a company at different levels of lean and digital maturity. It is a real production environment with offices for training, consulting, creating test beds and producing orientation courses for schools.

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