Industries
Industry and manufacturing
Overall equipment effectiveness is calculated from three measurements: availability, performance and quality. Without instrumentation, all three are estimates.
Stakes
What weighs on the trade
- Unplanned stoppages and lost production
- Machine performance estimated rather than measured
- Traceability of batches and non-conformities
- Maintenance that is mostly curative
Critical operations
What must not stop
- Production scheduling
- Running the lines and machines
- Quality control and traceability
- Equipment maintenance
- Management of materials and work in progress
Why digitalise
What technology changes here
Instrumenting a line makes it possible to tell unplanned stoppages from organised ones. That is the first step before any improvement work, and it often produces unexpected results.
What can be automated
- Production counting and effectiveness calculation
- Work orders triggered on a threshold or an hour counter
- Recording of stoppage causes
- Batch-by-batch traceability
- Alerts on quality drift
Capabilities
What we put in place
Software
- Production tracking and OEE calculation
- CMMS with preventive and corrective maintenance
- Management of material and work-in-progress stock
- Quality control and non-conformity management
- Shop-floor and management dashboards
Data
- Overall equipment effectiveness by line and by shift
- Distribution and duration of stoppage causes
- Energy consumption per unit produced
- Maintenance cost per piece of equipment
IoT
- Counting of parts and machine cycles
- Vibration and temperature measurement for predictive maintenance
- Electricity consumption tracking per machine
- Statuses and alarms read from controllers over Modbus or OPC-UA
- Monitoring of workshop conditions (temperature, humidity, dust)
Artificial intelligence
- Anomaly detection on vibration and temperature signals
- Forecasting drift before a threshold is crossed
- Analysis of recurring stoppage causes
Integrations
- Existing controllers and SCADA
- ERP for production orders and stock
- Measurement and quality-control systems
Security
- Strict separation between the industrial and office networks
- Read-only access to controllers by default
- A unique identity per gateway and per sensor
- Logging of commands sent to the field
Our approach
A typical path in this sector
Pilot line
One line instrumented for a few weeks, to measure before acting.
Measured OEE
Calculation of real effectiveness and ranking of stoppage causes.
CMMS
Work orders triggered by counters and thresholds.
Extension
Rollout to the other lines once the method has proven itself.
Related services
The services we bring in
Solutions
Related solutions
Work
Related work
Africa Tech Services
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