Project Details
OEE or/ Overall Equipment Effectiveness is a method of analysing the performance of a machine or piece of equipment compared to its theoretical maximum capacity. OEE includes three main factors i.e. Availability, Performance, and Quality. So, a production line which has an OEE of 100 percent will manufacture only good products with no defects (quality), production will run as fast as it can (performance), and there will be no stop time, even for short periods (availability).
-
Client
One of the world's largest paper manufacturing company -
Project
Manufacturing OEE
Status
- Phase 1: Solution Implementation
- Phase 2: Data Analytics & Deep Learning
- Phase 3: Recommendation Engine
Customer/Solution Requirement
Challenges Involved
- Human entered data is always prone to tampering, human errors, delays and bias.
- Whereas on the other hand, the machine generated data is very high in volume, it requires high compute power to analyse the data. The flow of data from the manufacturing floors to the dashboard requires a highly robust, responsive, and accurately engineered Data Pipeline.
- Other than that the high volume of data generated needs to be captured and stored efficiently, securely, with minimal cost and highly available for different dashboards.
- The solution including infrastructure, software modules, dashboards and reports needs to be configurable per client and its on-boarding needs to be automated as much as possible.
Our solution
- As a standard practice, there are three infrastructure environments i.e. Dev, Stg, Prod. The Dev environment is generally a sandbox environment or a replica of actual production environment but with less resources or different configuration. The Stg environment behaves exactly like the Prod (production) environment, or Stg and Prod are exactly same except that there is no client specific data on Stg and it is accessible to the internal team. Whereas, on Prod there is client sensitive data and only client has access to this environment.
- The agile methodology allows us to develop new features or improve existing feature on the Dev environment. Typically, the release cycle of each sprint is 2 weeks. Wherein, along with the feature development, different test cases are also implemented as part of automation testing. Every deployment to Dev environment is followed by Automation Testing and then Manual Testing. Once the feature is approved on the Dev branch it is ready to be pushed to the Stg environment. Similarly, on Stg after automation and manual testing the features are approved to be pushed to Production environment.
- The solution included IoT sensors places to the manufacturing machines. Which stream data to the cloud PubSub (MQTT) service every second. The data is then analyzed in blocks of 5 minutes. The analyzed data is pushed to SQL databases for further report generation and dashboarding.
- The dashboards are user role specific and hence every user role has access to different KPIs. For this case we implemented Duroid based Grafana dashboards.
- Different technologies, tools are used to implement automated DevOps. As automation reduces cost of implementation and deployment for every new customer, it was our obvious choice.
Value Delivered, benefits for Customers
- Highly accurate and reliable OEE measurements.
- Realtime dashboard with 100% automated data entry.
- Fast turnaround time for new feature development.
- Fast turnaround time for new client on-boarding.
- Reduced roll-backs due to automation testing.
- Highly reliable solution due to cloud-based server-less infrastructure.
- Low cost of system maintenance because of fully managed cloud infrastructure.
Our Process
Customer Vision
Creating a Great Customer Experience is All About Communication.
System Design & Analysis
Software Consultation, Digital Strategic Planning, System designing as per the customer's satisfaction.
Define Feature & Milestone
Prepare a complete project plan, set timelines and deliverables.
Project Delivery
Project delivery through continuous integrations and deployments.
Some of our most creative, hi-tech, and challenging works
KNOWLEDGE INDUSTRY
Team Collaboration and Project Delivery Tool
MANUFACTURING
Smart Manufacturing using IoT Sensors
WAREHOUSE MANAGEMENT
IoT based Warehouse Management System
SEARCH ENGINE
Documents Classification and Data Lake
What Happy Customers Say About Us
Anonymous
US based Taxi App Ampam
GoldKeys mPedgree Retail Management Mohit Ahuja
Accenture Media Management Suresh Mansharamani
Entrepreneur Baljit
Health Care AI Product Vandana Chadha
Product Manager at ClearTrail Technologies Anonymous
Fake Product Identification Projectt
Let's Talk
If you want to talk us and discuss your project contact us here. We treat your information with respect, and we will never sell it to other companies. This information is collected out of necessity for reaching back to you.