Manufacturing companies have been and, continue to make significant investments in Digital Technologies yet, derive very little returns from data. Every action on the shop floor creates data, creating an ever-growing need, to derive actionable insights and, to deliver tangible outcomes.
StatPort, a product for Industrial Digital Transformation, with core strengths in IT – OT convergence, builds a holistic picture, enables early detection and resolution of problems, to deliver sustainable bottom-line impact.
Industry 4.0 Trends
- Up to 60% savings in manual data management, invested in problem solving
- Transform from firefighting to continuous improvement
- Evolve from ‘after the fact’ diagnostic analysis to real time, early detection and predictive
- Emerge from People Centric work practices to Process Centric work culture
- Take a holistic view of operations with convergence of data from machines and manual ops
- Go towards ‘Zero Dark Data’ in your shop floor
- Revive your Enterprise Systems with reliable and real time data role up
The triangle feeds on problems, nourishes on distances and time and, it grows. The triangle represents the zone that burns your budgets & effort.
It’s also an opportunity for transformation.
StatPort simplifies the process by collapsing the triangle of challenges through early detection and actionable insights. This enables stakeholders to align on a shared “Common Language,” facilitating collaboration and decision-making.
Digital transformation collapses the triangle across space and time, enhancing problem-solving and enabling continuous improvements. As a result, solutions become not only impactful but also sustainable. Ongoing problem-solving and continuous improvements drive long-term profitability.
Industry 4.0, also known as the 4th Industrial Revolution, is the integration of digital technologies to create an ‘intelligent’ system.
The objective is to promote connected manufacturing through Digital Convergence of: Industrial systems, Workforce & Processes.
Industry 4.0 is the ‘coming together’ of existing and new systems in your value stream.
It is also the integration of locations, stages, departments and functions.
In this era of global opportunities, with stringent focus on capabilities and competitiveness, CEOs expect manufacturing functions to speak the language of the customer.
It possible for different functions with different systems, data structures and KPIs to be in sync?
How can we come together and use ‘a common language’ without losing individual focus?
The core of any Industry 4.0 initiative, is the technology to create convergence across Information Technology (IT) and Operations Technology (OT). It is based on Mechatronics and Cybernetics leading to a Cyber Physical Interface.
Technology First – is a key reason for failure in Digital Transformation. It should be Business First – Choose your goals before you start your Industry 4.0 journey and focus on the outcomes.
Pictogram shows the impact of Digital Transformation: Streamlining of Data Collection, Reduced effort in Data Management, to get Real Time & Reliable Insights from data.
Impact on Problem Solving: Improved Focus & Sustainable Outcomes.
Industry 4.0 Use Cases
IoT – Machine Monitoring
Shopfloors comprise of different generations of machines with varying digital capabilities. With our IoT interface box and StatPort, you can bring I2.0 and I3.0 machines along with your latest I4.0. The outcome – real time and reliable view of availability, productivity and production count. With StatPort and D-App you can get a transparent view of your Digital Work Centers wherever you are.
IT - OT Convergence
Value streams have old generation and state of the art machines working side by side. Often, old generation machines are not capable of delivering the data points needed to meet your Digital Transformation objectives. Where machines fall short, StatPort can interface with users and collect data from External Events. These could pertain to job type, customer, raw material grade, tool ID and more. These External Events are closely knit with the internal events, the data we get from machines. You get a holistic picture of your operations.
Overall Line Effectiveness
Does your OEE score translate to actual throughput and revenue recognition? Does your Finance reflect the efficiencies you show with OEE – Probably not. The real deal is the movement of material, without bottleneck and zero defects, from incoming material to the end of the line. StatPort, with its holistic approach can give you Overall Line Effectiveness. OLE means efficient cost control and real outcomes.
Process Monitoring with PLC
PLC – SCADA systems bring in highly reliable data, in vast volumes. Such data streams can be read and understood by trained users, near the operation. StatPort can consume the rapid streams of data from your PLC systems, distil through the volumes and give you essential, significant and actionable insights. Process Monitoring with StatPort is a must, especially for those with multiple locations and 24/7 operations.
Telemetry
Investing in Best-in-Class measurement systems to meet customer expectations, is only the first good step. You now need to ensure that observations and evidence of quality are created in line with Control Plan. You also need a system of monitoring to identify abnormalities and abnormal statistical patterns. With StatPort you can integrate with measurement systems and translate data feeds into statistical process control in real time. Combined with Daily Works Management, Activity Management and CAPA modules you are ready to establish your capabilities to your customers, at any time.
Visual – Touch Systems for QC
QC inspections in on fabrication, project-based manufacturing and assembly lines are contrastingly different from component manufacturing lines. StatPort presents Visual – Touch based inspection systems where traditional checklists will not suffice. These systems present a visual depiction of the job under inspection, users touch the visual to bring up a list of possible defects and select those that apply. In terms of analytics these defects are grouped in Heat Maps helping you identify operations that are driving defects.
One Line – Many Products
Fluid lines, short batches, rapid changeovers are becoming the norm in the industry. Each production line is re-configuring to support different types of products – when the value stream is constantly changing, the data stream becomes dynamic. Your Industry 4.0 strategy should ensure responsive and elastic systems that can work with varying data streams. As an organically built product, StatPort delivers just that.
Andon Systems
Andon is a Japanese word that roughly translates to ‘Lantern’, hence the popular concept of Andon Lights. The Andon, conceptually, are calls made from the work centers to alert the supervisors about potential or actual causes of production losses. StatPort transforms these time-tested practices by raising Andon calls for cycle time losses, queue times, fault alarms, inventory shortages, and any other calls from the operations. In addition, StatPort delivers Andon calls to targeted functions, monitor mean time to respond and drive productivity.
Gauge Rooms
StatPort A & M is a product for gauge rooms with specialized features and data models for R & R study, Measurement Systems Analysis along with workflow for calibration and service management. The product is available as standalone, network and hosted with apps and dashboards. The maintenance module enables digitalization of preventive and breakdown maintenance with dashboards for assets with MTTR and MTBF.