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Production monitoring with complete visibility on processes

Monitoring production and providing complete visibility on operations: seamless integration between production and planning.

Production monitoring with complete visibility on processes

Monitoring production and providing complete visibility on operations: seamless integration between production and planning.

Metal industry company: Production efficiency and order tracking

The Challenges

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.

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

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.

machine monitoring
machine monitoring

The Results

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.

The company 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.

Metal industry company: Production efficiency and order tracking

The Challenges

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.

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

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.

machine monitoring
machine monitoring

The Results

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.

The company 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.

INDUSTRY:

Metal Industry Company

ASSETS:

Lathes, milling and welding machines

THE RESULTS:

Increased productivity
Complete visibility of all work orders remotely

Work visibility
Integration of data from production machinery of different types

Process monitoring
Accurate estimate of actual production time compared to planned time

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