C03: Connected Smart Factory
Installation
PlantConnect SFactory deployed across multiple plants for real-time shop-floor monitoring.
- Implemented on assembly lines, discrete machines, and manual operations.
- Centralized architecture enabling multi-plant monitoring from a single server.
Customer
- A leading manufacturer of consumer electrical goods looking to implement a connected factory solution to gain real-time production visibility, improve operational performance, and enable seamless integration with enterprise systems.
Use Cases
- End-to-end production tracking: Raw Material (RM) → Semi-Finished Goods (SFG) → Finished Goods (FG).
- OEE monitoring for machines and production lines.
- Loss analysis including downtime and rejection tracking.
- Integration with enterprise systems for automated data exchange.
Challenges
- Limited real-time visibility into shop-floor production.
- Difficulty in monitoring productivity and identifying losses.
- Need to connect legacy machines and manual processes.
- Accurate production counting in manual assembly operations.
Connectivity
- Hybrid connectivity architecture combining machine signals and sensor-based tracking.
- Electrical signals from machines captured through micro-PLCs and transmitted via DATCon Edge Gateway.
- Sensor Tunnel solution implemented to count products in manual assembly lines.
- QR code scanning devices used for tracking finished products.
- Energy and gas meters integrated using Modbus RTU.
Key Outcomes
- Real-time production tracking from RM → SFG → FG.
- Machine and line OEE monitoring.
- Loss analysis across 16 TPM loss categories.
- Dashboards for Plant Efficiency, OEE/OLE, PPH, and UPPH.
- Energy monitoring and optimization (electrical and gas).
- Reports including production reports, OEE reports, Pareto analysis of losses, machine performance, and utilization.
Sensor Connectivity
Smart touch Screen
Enterprise Integration
Profibus Connectivity
Industrial HMI
Interlock
Enterprise Integration
PlantConnect Sfactory connects all departments of a consumer electrical goods manufacturing unit. Main use case is to track production from Raw Material (RM) to Semi-Finished Goods (SFG) to Finished Goods(FG) in real time.