IoT Implementation Case Study

Connecting People & Machines

Assessing & Implementing Digital Transformation in the Manufacturing Industry & Making Production More Reliable

IoT Implementation Case Study

Digital change has been more pronounced in recent times across all industries and in our daily lives. In order to succeed in this hyper-competitive world, it has become the greatest necessity in the world. Digital transformation strengthens our companies’ overall effectiveness, improves our corporate values, and creates income. We offer customized IoT solutions for the adoption of digital transformation to elevate the manufacturing companies which strive to attain greater heights. The following IoT implementation case study explores the tangible benefits that our customer has garnered.

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Precision Machining

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Metal Injection Molding

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Batch Processing

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Assembly

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Quality Inspection

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Traceability & Digital Twin

precision machining

Precision Machining

Automatic acquisition of the Availability, Downtime, and production count from the machines / PLCs for all kinds of precision machining processes like Grinding, Milling & Turning machines. The customer has been producing components for the Aerospace industry where the precision and the quality of the part are highly important. Granular planning and output comparison is done at the machine, department, and unit level.

Metal Injection Molding

The mix of raw material along with the binder is passed on to the Molding tool using the molding machines. Each mold tool has a different count of slots changing the parts per cycle. A few operations like mold close, metal injection, settling time, mold open, and Robot picking molded pieces to combine to form the complete process. These process has been captured using our device for the production data. In parallel, we have configured the molding machines to send the quality parameters to our server to correlate with the critical limits to understand mold quality.

metal injection molding
batch processing

Batch Processing

Binder removal, heat treatment, and hardening process at the Injection Molding factory were done in batches. Complete tracking of what are the different parts that go into a particular batch in relation to the individual part tracking code. Planning with the maximization of the Capacity utilization of each batch. The process parameters like Pressure, multiple temperature points, and speed in relation to time have been measured and associated with each batch for quality analysis.

Assembly

Three components have been assembled to create a single product that has been shipped to the customer. A centralized Software has been built to control the robot arm that picks and places individual components on a 4 stage process over a gang tray to press to combine to form the part.  The process has a 3 stage quality check with visual dimension and quality checks based on which the rejection is triggered and the data of the quality is logged for each component and co-related.

assembly
quality inspection

Quality Inspection

The medical tools component assembly process combines two parts into a single piece to create the process. The process has both assembly and quality inspection. Our device sits monitors the signals using Digital IOs and captures production, accepted, and multiple rejections to report the overall production and yield data on a live and historical dashboard. Quality inspection is done on Load testing and the assembly line.

Traceability & Digital Twin

The parts in the MIM process go through multiple processes and are exposed to a different set of process parameters ( Speed, Pressure, Temperature, Displacement ) in relation to time. The combination of these parameters across multiple processes influences the quality of the usage environment. So the parts produced are grouped and associated with a tracker number inside the plant. These tracker numbers are in turn associated with the process parameters and the process at each stage to review and reanalyze based on the performance in the field.

Traceability

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