The coexistence of different types of machinery within a single facility can make full interconnection a difficult task. Extracting data and accurately tracking total costs and energy consumption is crucial for implementing optimization and production efficiency strategies.

A company that produces standard and custom heat exchange solutions for commercial and industrial applications sought a solution to enable bidirectional communication between their machines and management system in order to improve the integration of information across Planning, Production and Control Management.

The goal was to monitor and interconnect 16 different types of production machinery, facilitating the automated transfer of batches and production instructions to the machines, and obtaining a complete view of the machine fleet, including data related to their operation and energy consumption.

Achieving full integration of the machines was essential in order to embark on a complete digitalization path and enable the Industry 4.0 transformation.

Zerynth’s team proposed a solution that involved the implementation of the Zerynth Industrial IoT & AI Platform. This has enabled a complete integration of information between the planning and management control departments, allowing for a comprehensive view of the active machine park.

By using an ammeter transformer, connected to Zerynth’s Edge Device, it becomes possible to extract valuable data related to the energy consumption of each machine. Production data, read from the PLC, is aggregated on the edge and sent to the cloud every minute. As a result, the management software already in place within the company is able to receive real-time information concerning the progress of the work and production processes.

With the help of Zerynth, in just a few weeks, the company was able to interconnect 16 machines of 10 different types within the same facility. This enabled active monitoring of production costs, energy consumption, and tracking of work orders.

The reliability of the Zerynth Platform ensures secure exchange of production data and persistence, as acquired data is stored on the cloud and temporarily archived on-the-edge in case of network issues.

The digitization of the machines in an Industry 4.0 perspective facilitated data exchange with the existing management system in the company and precise integration of information coming from machines with management systems.