Guarni&Med needs to interconnect a hundred machines for traceability, to know the cost per batch, to have production control and the possibility of applying artificial intelligence algorithms to avoid machine downtime.
Guarni&Med is specialized in the design and production of gaskets for the medical sector and for the most diverse industrial sectors.
The challenge is to interconnect about a hundred machines of different brands, functions and ages, with the company management system and the MES. The goal is to automate data collection, track downtime, know the cost associated with each batch and have traceability and control of production.
Another requirement is to know the machine states, the number of pieces produced, the good parts, the waste parts and the operating temperatures of the ovens in real-time and through dedicated panels.
Last but not least, another objective pursued is to seize the opportunity offered by the Italian National Industry 4.0 Plan for a small subset of machinery and to be able to take advantage of State incentives. It is, therefore, necessary to respect all the requirements of the legislature in this regard.
To satisfy the need of Guarni&Med we used our long-tested software for Industry 4.0: iDaq, Digital Factory 4.0 and Lilium, achieving all the pre-established objectives with a complete and scalable solution.
The machines, which are a hundred and of different types, are connected to the company MES and a percentage of these machines directly receive the active order code and the article number to be produced. These are displayed on the panel on the machine.
iDaq deals with data collection directly from the field. It’s in fact used to communicate with the machines via Modbus protocol, FINS and through other dedicated protocols. For each machine, moreover, iDaq conveys more signals taken from the machine itself, providing a single quantity that summarizes the operating status.
The main data acquired are:
Digital Factory 4.0 collects all the data acquired by iDaq. It provides a global view of the data acquired by the plant's machinery and sends the batch codes and the article to be produced to a percentage of machines according to what the operator has chosen from the MES.
The data can be viewed in real-time from different locations, each customizable according to criteria of subdivision of machinery or type of data.
Digital Factory 4.0 interface for the control of the various production areas of Guarni&Med (7 areas)
The user interface presents three-dimensional images colored based on the state of the machinery and graphs, tables and clear numbers.
Lilium transfers data to the company database, from which the MES extrapolates the information for viewing and archiving, and the transfer of data from the database to Digital Factory 4.0 and iDaq.
Diagram of company interconnection
All the pre-established objectives have been achieved, thus allowing Guarni&Med to obtain significant benefits:
The solution is completely scalable. From the point of view of the field, it allows both to acquire new quantities, and to connect new machines quickly, ensuring minimal impact on the existing system.
Moreover, thanks to the modularity of the solution, it’s possible to interconnect machines with technologies and functions that are different from those already connected.
From a management point of view, the solution is open to interfacing with third-party software for visualization, data analysis, and business intelligence.
Finally, the solution allows to apply artificial intelligence algorithms, such as Machine Learning, predictive analysis and process drift control for each machine and plant. This makes it possible to foresee downtimes and breakages in order to promptly intervene and thus reducing downtime and production costs.
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“With the T4SM team we have finally found the technology that will allow us to make a very important step in terms of quantity and quality of data collection, so we can aspire to enter into highly specialized and sophisticated markets where the tolerances of the gaskets to be produced are really very narrow.
Moreover, the willingness and competence of the T4SM CEO Mr. Vivante will stimulate us further to look for solutions to boost performances of our products more and more.”