Production and planning are the two main areas to monitor in order to make production more efficient and start a complete digitization 4.0 process.
CPS D’Auria, an Italian company that specializes in the design and construction of molds for the mechanical machining and energy sectors has turned to Zerynth for assistance in integrating its production and planning management systems and digitizing production processes, enabling real-time remote monitoring.
The company needed to digitize 120 heterogeneous production machines (both legacy and modern) present in the shop floor of 7 different plants, and integrate them with the two pre-existing management systems (master data and planning) with the aim of obtaining complete, real-time visibility and remote monitoring of all processes.
The solution proposed by the Zerynth Team involved a phase of integration tests with the management systems already in place at the company, as well as the translation of data extracted from the machines. After these initial steps, the team connected all machines across the various plants.
The data of interest, extracted from the machinery or through declarations by the operators, concerned the tracing of all the states of the machinery (on/off/waiting/production in progress), reference to the part-program, phase and order, energy consumption, estimation of the machinery operating speed through “override” knobs, alarms and machine stops.
By automating all processes, the company is now able to monitor all programs associated with the machine and the traced work orders in a simple and real-time manner, with a particular focus on the machine status, energy consumption and program of the orders processed by the machine at any given moment.
CPS can now easily access data on actual processing times for each machine to compare and analyze them with the times defined in the planning phase. This way, the company can obtain a precise estimate of the processing times for each machine, even for long processes, from the first hours of operation.