In the highly competitive food and beverage industry, achieving optimal Key Performance Indicators (KPIs) such as availability, performance, and quality is essential for maximizing operational efficiency and profitability. A client operating semi-automated production lines was experiencing persistent underperformance in these KPIs. To address this issue, the company required a robust and precise data-driven approach to monitor production processes and identify the root causes behind its declining KPI performance.
Despite deploying a system that leveraged real-time data acquisition from machine controllers (PLCs) to calculate KPIs, the client continued to face significant inefficiencies, particularly in machine availability and overall performance. Preliminary data analysis showed that the downtime monitoring system failed to capture the full scope of the operational issues.
Upon closer examination, it was discovered that downtime events were disproportionately high during night shifts. This led to the hypothesis that procedural or operational inefficiencies specific to night shift management could be contributing to the overall KPI shortfall.
To address the client’s KPI challenges, a multi-faceted, technically advanced solution was implemented. The approach involved integrating real-time data from production machines and contextualizing it with shift information to provide actionable insights. Key components of the solution included:
Once the data collection infrastructure and advanced KPI analysis tools were in place, a clear pattern emerged: a significant percentage of unreported downtimes occurred during night shifts, which had not been flagged in the original manual reporting system.
Through the detailed correlation of downtime events with shift schedules, it was determined that these downtimes were frequently caused by non-compliance with standard operational procedures. Further analysis suggested that these events were largely “unintentional,” indicating a need for stricter oversight and adherence to established workflows during night operations.
Following the identification of the root cause, the following corrective measures were implemented:
While the client initially sought a solution for automated KPI calculation based on machine data, the introduction of advanced downtime monitoring and data contextualization proved essential for identifying deeper operational inefficiencies. The key insight was gained through correlating downtime events with shift performance, which revealed a management issue during night shifts.
As a result of the corrective actions, the company observed a marked improvement in operational performance. Machine availability increased, downtime incidents were significantly reduced, and overall KPI targets for performance and quality were met, leading to enhanced production efficiency and throughput.
An automotive company needed a solution to monitor production to improve the quality of final products. The key element was identifying issues by analyzing quality data correlated with production data. Special attention was given to the casting and cooling zones, where product quality was particularly variable.
A global company in the electrical accessories manufacturing industry used in automation faced the challenge of improving key performance indicators (KPIs), particularly increasing the availability and efficiency of production cells. Each workstation involved multiple stages of assembly and production across various positions and locations, requiring a coordinated approach to managing work, materials, and proper planning.
A client, a leader in the glass packaging manufacturing sector, identified the need to implement an integrated production data management system to replace outdated, manual reporting methods.
In the aerospace and defense industry, which is characterized by particularly high requirements for precision and reliability, key performance indicators in maintenance, failure prediction or machine condition monitoring, are crucial.
Industry 4.0, also referred to as the fourth industrial revolution, is a concept encompassing a complex process of technological and organizational transformation of companies, which began in 2013.
If you think OEE has no secrets to you and your plant maintain highest OEE results… think again. Harsh truth is that most manufacturing plants’ OEE land somewhere between 35 and 43%. They just don’t know about that.
You don't have to replace your machines with the new ones to make your production "smarter" and more efficient. Your shop floor is a data mine, and digitization is the key to unlock its value.
Whether you're a seasoned user or new to ThingWorx, overcoming these hurdles is crucial for IoT success. In this blog, we'll uncover the top challenges, offer tips for newcomers, discuss strategies to enhance your ThingWorx experience, and explore the importance of upgrading your ThingWorx solution.
Very often overlooked or accepted as-is due to being an integral part of the production – in times of crisis and cost-cutting, it can become a major factor that improves the bottom line of your organization. Where to look for significant energy savings to reduce energy costs? How manufacturers should focus on these goals to make an impact?
According to the German Federal Statistical Office, energy consumption by the industry for the production of goods hardly changed between 1995 and 2019. In 2019, it amounted to 3,874 petajoules. This means that it remains at the same level as in previous years. Germany plans to halve its primary consumption of energy by 2050, with the industry having to take part. In the era of the energy crisis, the drive to improve corporate energy efficiency is entering a new level.
In the manufacturing industry, efficiency is key to staying competitive and profitable. One way to improve efficiency is through data visibility. By having access to real-time visibility of the operational data throughout the manufacturing process, companies can identify bottlenecks, monitor production lines, and make data-driven decisions. In this article, we'll explore how data visibility can help manufacturing companies improve their efficiency and ultimately their bottom line.
Energy consumption bills have been a major focus in virtually all areas of industry for many years, and the current global situation is a factor driving up demand for solutions that make it easier to monitor energy consumption or save energy. In an industrial environment, where the cost of utilities has always been one of the main business drivers, the latest twists and turns in the global economy: inflation, natural resources supply challenges and the threat of fluctuating and unpredictable increases in energy costs – are arguably the most important economic factors these days.
The new opportunities associated with Industry 4.0 require companies to adapt to the new environment. In this article, we take a closer look at the current situation in the automotive industry, discuss the challenges it faces and the opportunities offered by digital transformation.
Digital transformation is reshaping the way how people, products, assets, data, and operations are connected to create an outcome for the customers and switch digital data into the customer experience. Digital technologies create new business opportunities across the globe and enable the evolution of enterprise, products and processes for valuable capabilities. The article describes the Internet of Things concept and shows how to use cloud infrastructure to take advantage of the digital transformation in business.
Internet of Things systems have one huge advantage – they can collect lots of data. Temperature, items produced, amount of remaining liquids, humidity, machine uptime, damaged products, vehicle routes, electricity used. Based on this, we can get even more value by calculating KPIs to indicate how close to perfect our system is. Going manually through an endless stream of numbers changing every couple of hours is impossible and inefficient. The simple solution is to visualize the data by using a carefully selected chart type, that will exponentially increase its value. In this article, I want to show you the benefits of good data visualization and explain how it can be applied in your solution.
The sudden epidemic of SARS-CoV-2 coronavirus and the COVID-19 disease has affected every sphere of the modern world. Caused by an epidemiological threat, the restriction of the flow of people, goods and services has already negatively affected the continuity of production processes in many industries, and each day this situation persists, without credible forecasts of a return to normality, will pull others into the spiral of detention threats.
Scalability in web applications has become crucial in the past years. An ever-growing number of devices and clients, connected to the Internet, makes it difficult to handle the traffic by a single server. Scalability is a characteristic of a system that tells if expanding the resources of a server(s) will make it run faster (or handle more load).
Modern web applications that serve data and content to millions of users run in clustered environments. Dealing with a huge amount of connections at the same time requires many resources. That resources are CPU time and RAM. Each and every connection produces an additional load on the server. Having just one server would require a vast amount of resources and we already know that Moore's Law is no longer valid. That said we need multiple servers ready to respond to users’ requests. Web applications use HTTP(S) protocol which works in the request-response communication method. Upon user's request, the server will prepare the response and send it back. Every response needs to be processed by the server and that's the key factor in provisioning resources for the server - requests may be different, starting from simple static data like CSS or images to more demanding like requesting data from database, filtering or calculating certain data.
The ThingWorx IoT Hub Connector is the bridge that connects the ThingWorx platform to the Azure cloud (more specifically to Azure IoT Hub). It provides secure (certificate-based) communication, thanks to which we can use the enormous possibilities of cloud computing. It is also a very extensive, but generic solution.
Synergy, this is how you can define this natural combination of technologies that will significantly affect the appearance of the future of production. Recently, in addition to the Internet of Things (IoT), artificial intelligence (AI) is gaining more and more popularity. The connection of these two technological trends heralds a real revolution in industry 4.0.
This year's Liveworx, due to the global situation caused by the COVID-19 pandemic, has exceptionally been held only online. On the very first day it was announced that a new version of ThingWorx - the most popular platform maximizing the potential of the industrial Internet of Things - will be released for commercial use. According to the announcements of Joe Biron, CTO responsible for IoT technology at PTC, it is supposed to be faster, cheaper and more effective.
The evolution of artificial intelligence, as well as machine learning has gained momentum in the last few years. The constant drive to increase the computing power of computers has given the opportunity to use algorithms and mathematical apparatus created in the second half of the 20th century on an unprecedented scale. With the imminent arrival of a commercial quantum computer, we can slowly become afraid of scenes from the movies with Arnold Schwarzenegger as Terminator. However, without going too far into the future, and focusing on the present, I decided to check the possibilities offered by the technology available today and whether it can be used to predict the spread of COVID-19 disease.
The Industrial Internet of Things changes our view on the classic concept of production today. The largest manufacturing companies are eager to reach for technological solutions that streamline and increase the efficiency of production processes. With the development of subsequent technologies, interest in the concept of industry 4.0 increases, and thus, the number of connected devices. To meet the demand for infrastructure with adequate capacity and speed it was necessary to evolve towards the next generation of networks - 5G. How will 5G affect the development of Factories of the future and why is this crucial from the perspective of the Internet of Things? You will learn everything from the article.
The Internet of Things is being used more and more, and even global giants are already using the optimization or information gathering solutions. All this to improve existing processes, acquire, process and report more data, or even introduce new services for their clients, thereby increasing sales revenue. How is the Internet of Things changing the reality of the aviation industry?
Following up our partnership with Rockwell Automation, our team of business and technical experts found their way to Munich, Germany to participate in TechED EMEA. It is a unique event during which you can listen, talk and test the latest news in the field of industrial automation and directly participate in the next industrial revolution.
Nobody would be surprised by a statement that the Automotive industry is innovative in its nature. Cars are machines that historically revolutionized many areas of industry themselves, and today we can’t help but notice that the industry has not slowed down even for a moment and has always been focused on technological growth that serves both the business and its customers.
It might seem that the Internet of Things is dedicated only to industry. However, transport and logistics are closely connected to it, and they can also take advantage of the ongoing revolution. In the end, every industry uses transport services or logistic processes to some extent.
As every time for the last couple of years, our strong team of representatives was present in Boston to attend one of the most important IoT events of the year – LiveWorx, 2019 edition. Get the ball rollin’ And even with 10 participants from various business areas, actively seeking new information and presentations, […]
Industry 4.0 and its foundation, the Internet of Things (IoT – especially in industrial version: IIoT), in the last years have dominated the way of thinking of advanced management concerning manufacturing business resources.
PTC is phasing out its Axeda platform. Although they look similar at first sight, Axeda and ThingWorx differ very much in capabilities.
While ago, PTC announced a new release of ThingWorx Platform (8.4). Among other exciting features, this release has OOTB support for integration with InfluxDB.
The approach that has been underestimated for a long time is nowadays spreading its wings and becoming a crucial set of solutions for global corporations. However, not only for them as medium and small companies are following the biggest ones as well. Thus, the advantages of the Internet of Things have been recognized by everyone. […]
Recent years were hyped about the Internet of Things (IoT) and how it was supposed to re-shape the whole industry. However, so far we’ve seen many more people talking about it than actually implementing it enterprise-wide. Is IoT mature enough to be “the real deal” and bring measurable value to businesses? The term IoT […]
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