Automation Solution for Manufacturing Industry (Process)
Cost Reduction Using Automation as a Tool
(Process Manufacturing)
Automation has revolutionized manufacturing industries by integrating advanced technologies such as Internet of Things (IoT) into production processes.
IoT enables seamless communication between machines, sensors, and software systems (ERP’s), optimizing efficiency and reducing human intervention. This interconnectedness allows real-time data monitoring and analysis, enhancing decision-making and predictive maintenance. Automated systems in manufacturing ensure precision and consistency in tasks ranging from assembly lines to quality control, leading to higher productivity and lower operational costs.
Manufacturing Industries Served
- Chemicals & Allied (Specialty Chemicals / Paints / Dyes)
- Pharmaceuticals
- Agro Chemicals
- Food & Beverage
- Plastics
- Oil & Gasoline
- Personal care products
- Alcohol
Need for Automation in Manufacturing Industry (Process)
Units of Measures
Material has to be measured in various units of measure - Kilograms, liters, numbers & even Bars. Often they are purchased in one measurement & consumed in another. Hence the accounting of materials needs to be done in more than one unit of measure. The conversion between different units of measures had to be considered.
Pricing
Pricing of the finished / semi finished products in not always based upon the cost of materials or market determined. Often additional processing is required to achieve materials of higher quality and associated costs.
Costing
Multiple end items may require that the cost of the entire process to be split based upon a percentage split of cost. The production of all items - intermediates, semi finished goods, finished goods etc is taken up batch wise. Hence the costs for various activities need to be consolidated Batch wise.
Input
Output Co-relation and process Yield is mostly required.
Batch tracking and Shelf Life
Mostly chemical industries produce products in the batches. The batches are required from the point of purchase to production and consumption. The inventory evaluation is also based on the batches. Further the batches would be associated with the attributes like the expiry date of the products, which requires to be tracked and it is a regulatory requirement.
Multiple versions of Formulations
It is possible that the finished material is produced according to the different rations of raw materials or some different raw materials are used in the process. The formulation definition has to be flexible to accommodate multiple versions.
Packaging
The finished materials are packed in a different variety of packing materials and in dispatched in different packaging combinations.
Damaged Stocks Management
For the sake of profitability, the management of the damaged stocks plays a critical both in terms or value as well in terms or logistics. The organization needs to manage & monitor the quantity & value of it’s damaged stock. The ERP system needs to track the damaged stocks at the various ware houses, locations etc.
Reprocessing, tinting and repacking
The reprocessing of non-conforming products, damaged products, damaged packing etc is an important activity in the Paint Industry. The management of packing materials damaged in transit etc directly adds to costs of distribution. Thus re-packing not only needs to be managed effectively, it also needs to be controlled & constantly analyzed
Warehousing and processing
The logistic requirements of the industry require stocks to be maintained at various locations (ware houses, stock points etc). This obviously puts additional pressure on the supply chain as well as on Working capital management. Further, the need to maintain the stocks as semi finished goods adds that extra work on the ERP & Supply Chain planning engine. Management & control of stocks across the value chain is an essential
Solutions
Industrial automation in manufacturing utilizes intelligent machines or industrial IoT solutions within factories to execute manufacturing processes with minimal human intervention.
It encompasses implementing diverse control systems that enable machinery to autonomously perform tasks demanding speed, endurance, and precision.
Various forms of industrial automation include mechanical, electrical, electronic, hydraulic, pneumatic, and computer-based systems, often employed in combination to optimize efficiency and productivity in manufacturing operations.
Industry Automation Solutions
- Goods Entry Scan by CCTV
- License Plate Recognition
- Data Integration
- Barcode/QR Code Scanning
- Vendor Document Scanning
- Quality Check
- Weight Feeder
- Production Data Gathering
- Movement Detection
- Delivery Tracking
- Energy Monitoring
- Predictive Maintenance
Quality Control Automation
Quality control automation in manufacturing involves the seamless integration of laboratory equipment with ERP systems, ensuring real-time data transfer and analysis.
By directly reading data from instruments such as spectrometers or chromatographs into the ERP, companies can automate the collection and processing of quality data.
This integration eliminates manual entry errors, accelerates decision-making, and enhances overall production efficiency. It enables manufacturers to uphold rigorous quality standards consistently, fostering improved product quality and customer satisfaction.
Energy Conservation
Energy automation entails the direct integration of energy meters with advanced systems capable of real-time data collection and analysis.
By reading data directly from energy meters, organizations can monitor and analyze energy consumption patterns across their facilities. This enables proactive energy management strategies, identifying inefficiencies and opportunities for optimization.
Moreover, such systems can detect anomalies that may indicate energy theft or unauthorized usage, thereby enhancing security and reducing operational costs. Overall, energy automation empowers businesses to optimize energy usage, improve sustainability efforts, and ensure compliance with regulatory standards.
Predictive maintenance
Predictive maintenance automation leverages advanced sensors and data analytics to monitor equipment in real-time, predicting potential failures before they occur.
By continuously collecting and analyzing operational data such as temperature, vibration, and performance metrics, these systems can identify patterns indicative of impending issues. This proactive approach enables timely maintenance interventions, preventing unexpected downtime and reducing repair costs.
By optimizing maintenance schedules based on actual equipment condition rather than fixed intervals, predictive maintenance automation improves overall equipment reliability and operational efficiency. This results in increased productivity and minimized disruptions, ultimately enhancing the competitiveness of industrial operations.
What makes us different
emerging world of the industrial ecosystem requires contactless, intelligent solutions for the businesses to achieve concrete results.
Quality & Quantity check
The system measures the quantity & quality of semi-finished and finished goods using special industrial sensors or information from the PLC’s and updates it in the ERP system. This makes it easy to track the produced goods and consumption of raw materials with no scope for manual data entry errors or loss of data.
Inward Material QC
The Inward material, which is placed in designated areas, is now inspected for quality control. The parameters for quality check are fed into the System once the material is checked using Video cameras, sensors (replacing visual inspection), or Lab equipment for its various properties, the results are automatically captured in the ERP system, comparing it with the standard parameters & sent as alerts to the in-charge to approve or reject the goods
Contactless Inward Goods Storage
The system automatically captures the vehicle details such as the Vehicle number at the gate using the security video cameras. Further, the truck is directed to the weighbridge, where the truck’s weight is captured and linked to the ERP’s gate entry system without any manual intervention.
The raw material (inward material) is automatically fumigated, weighed, packed, and are transferred to the designated warehouses.
Contactless Production Process
The production system fitted to the Machines is fed with the standard recipe. The raw materials added to produce semi-finished and finished goods are scanned, weighed by the system using various sensors on these machines; if the weight doesn’t match the standard recipe, the production process will NOT begin.
Barcoding
The goods are also tagged with identification tags such as auto-generated QR codes; once weighed, these QR codes will be used for tracking their movement within the plant and give alerts for auto replenishing the exhausted stock. The tagged QR codes capture the Quantity, Weight, batch number of the incoming goods and integrate it automatically in the gate entry system of the ERP.
Contactless Dispatch
These goods are now packed & installed with QR codes or RFID tags and transferred to the Dispatch area. This system helps in the smooth dispatch of the packed goods by tracking the vehicles inside the plant and send the details of the vehicle to the Gate Exit system of the ERP
Predictive Maintenance
The system constantly monitors the machine parameters such as temperature, pressure, current, vibration & compares them with the permissible range of operating these machines to predict any criticalities, thus avoiding machine breakdowns. A service call is automatically created in the ERP system, and an alert is sent to the designated maintenance engineer to take early action.
Energy Management
The system makes energy management in manufacturing plants efficient and automatic.
The machines can be automatically turned on/off, and respective energy savings made will be alerted in the dashboard.