Where You Are
As a manufacturer, you are constantly facing challenges. In addition to competition from within and outside the country, new technologies and evolving consumer demand put additional pressure on you. Much like smartphones, users today are demanding products with improved features year-on-year.
Cost cutting, improved productivity, and quality, are time-honored ways of making yourself more competitive. Evolve and transform before you are left behind.
Where You Should Be
Industry 4.0 will take the centre stage and will transform traditional manufacturing methods.
What is Industry 4.0? The extreme version is a completely robotic production floor where the machines talk to each other, transfer data, and manage the production based on predefined inputs. A simpler version is semi-automated processes where the production data from one process moves to another through what is termed as Machine-to-Machine, or M2M, communication.
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What You Can Do
Of course, the easiest solution is to junk your existing production methodology and build a shiny new fully robotic production factory. This may not be feasible for everyone as the investments are huge. Secondly, such a production facility makes sense only if your production volumes are fixed and not dependent on market forces.
A more gradual process is to slowly and steadily bring in automation in as many processes as possible over a period of time. When you do that, you need to understand the advantages that automation brings in. In processes where automation may not be possible or too expensive, you must find ways of gathering data from existing processes. Some of the process machines may be generating data in analog formats. You need to understand that and find a way of sensing and converting all data to digital formats for uniformity and processability.
Either way, data is the key. Industrial IoT will help you identify and reduce wastages, optimize production costs, and help you achieve predictable productivity and quality. Machine to Machine (M2M) communication will deliver accurate data in time for you to take effective action. When you design new products or product features, data makes it easier to understand what changes you need to make in the production processes, and how to shift to the new product with least disturbance and lowest possible investment.
How Sosaley Can Help
We start by simply enabling you to capture data at as many critical points as possible. We then transmit the data through the best viable communication protocol to another process, to the cloud, or to your smartphone. In the cloud, we help you analyze the data, create alert points, and generate information dashboards, all in real time. In the smartphone, we can create alerts and messages that help you take immediate action.
The 8 transformational steps are shown below.
The Sosaley Legacy
In just 12 odd months, Sosaley Technologies has delivered jaw-dropping solutions to problems in the automotive, healthcare industry, safety, and industrial automation sectors. Working with companies such as Armstrong, MIT/DST, and Vodafone, we are pumping out multiple solutions every month. Look at some of what we have done recently.
1. Flow Meter
A Flow Meter that is used to monitor the flow of air, water, or steam in an industrial environment. Uses DPT, pressure, and temperature sensors to calculate the flow rate.
2. GSM Gateway
A universal GSM Gateway that cuts wires and enhances data movement reliability in large factory areas. The GSM gateway senses erroneous data and raises real-time alerts. Can send data to a smartphone and the cloud.
3. Universal Scanner and Data Logger
A 24 channel scanning device. Displays values of multiple sensors that measure temperature, pressure and RTD. Designed to withstand temperatures up to 500 degrees. Stores encrypted data for security.
4. Remote Pressure Calibration
Can remotely monitor pressure calibration process using a smartphone. The device communicates via WI-FI. The results are stored in PDF format for validation and data collection.
5. Test-Bed Automation
Enhancement of R&D and engine test-bed facilities for a Tier-1 car manufacturer. The enhancements cover air exhaust, air quality, water level management, and fuel flow management.
6. PID Controller
PID controller to regulate speed, temperature, flow, pressure, and other process variables. Sosaley’s PID controller is being used to control pumps, switches, and valves based on analogue and digital inputs. Delivers significant improvement in parameters, transient response characteristics, and in the reduction of errors.