End To End Capability To Implement Smart, Simple, Systematic And Structured Solutions
For a manufacturer, smart manufacturing is expected to handle the following key indicators and aspects of manufacturing.
- Safety and Sustainability
If the cost of manufacturing and quality of the output are in control inspite of variation in the volume demand and frequently changing market and customer need, manufacturers will be able to plan and run their operation better.
Smart systems and solutions should be able to help suggest and execute the most optimum plan under the given operating environment. Dalisoft intends to help customer with capabilities from sensor to datacenter and from signal to its compete analytics
Smart Manufacturing is achieved by having Smart Machines giving Smart Data on Smart Network which is used by Smart Application to drive Smart Analytics which can then provide deep insights into operations for better quality and productivity while optimizing cost and improving customer satisfaction.
Make Machine Smarter
In any manufacturing, Smart Machines are the foundation for any integrated and coordinated operation which can smartness
- Automated and Flexible
- Connected on Plant Network
- Self-aware and predictive
- System Aware and manageable
- Real time Data Enabled
- Energy Saving
- Structured and Standard Data
- Process Parameters
- Product Parameters
Dalisoft intends to help customers convert their existing machines into smart machines and hence helping them achieve their digital transformation goals.
Design And Implement Smart Connectivity For Plants And Machines
Smart Machines have to be connected with smart, reliable and rugged network to ensure data integrity and security. It is important to understand that Plant Network and Office Network handle different kind of data for different purpose. Manufacturing data has to be near deterministic with hundreds of devices and user stations connected.
In addition to this there are different devices communicating on different protocols but still operating in an integrated manufacturing environment. Missing of a small information can cause huge errors which can have cumulative effect and hence data has to be handled through a proper by handshake wherever possible.
A smart network will have wired and wireless network in a structured and at times unified network for office and plant. Wireless Network is increasingly being used in Manufacturing for mobile devices and handheld terminals.
Dalisoft Technologies intends to help customers with secured, scalable and reliable Manufacturing Network.
Design And Implement Smart Data Management For Real Time Manufacturing
Smart Machines and Smart Network will help in creating a strong foundation for Smart Manufacturing. Once the data is on the network it has to be handled in a scalable manner. Some of the machine data had to be handled at machine level. Line, shop and plant level data has to be handled at the system level. Large amount of data and data over a long period of time will be handled at the Enterprise Level and analyzed in conjunction with other non-manufacturing, supply chain and field data.
Every information either from the machines or collected manually has to be put at the right place and analyzed. There will be both relational and time series data depending on the nature of use and requirement of the process. Following types of data are handled in a typical manufacturing plant.
- Critical and non-critical data
- Slow and high speed data
- Real time and historical data
- Process and Product data
- Raw and Calculated Data
- Actionable Control & reporting data
- Compliance Data
- Manual and Automated Data
Dalisoft Technologies understands the importance of structured and scalable data management in the process of achieving the digital transformation goals. We bring the right capabilities to help customer manage the data in most optimized manner.
Develop And Implement Smart Application
Once the scalable and reliable data is in place, it has it be used by right applications to drive benefits across different functionalities key to achieving manufacturing excellence. Smart Applications in manufacturing should bring intelligence to the plant by tightly integrating man machine, material and methods. They should be simple yet comprehensive, user friendly yet robust and result oriented to ensure effective utilization of the complete solution.
Some of the Key applications required in manufacturing delivered by Dalisoft Technologies are listed below:
Production Order Management: Order Execution, Hold or Expedite Orders, Production and consumption booking, Routing of serialized units, Part Grouping
Genealogy / Track & Trace: WIP and Material Tracking, Take-In/Take-Out, Test Data Collection, Process Data Collection, Unit and Lot genealogy
Quality Management: Quality Inspection Display, Quality Buy Off, Defect data and Rework, Hold, Quarantine, Release, CAPA
Material Management: Just In Time (JIT) calls, Material Call/eKanban (Pull System), Kitting (offline part pick), WIP of components, Goods Receipts from ERP
Performance Management: Equipment & Alarm Monitoring, OEE at cell, line, and shop level, ANDON, Reporting and Dashboards
Maintenance Management: Maintenance Workflow Management, Preventive Maintenance, Machine Predictive Maintenance, Reliability Data: MTBF, MTTR, Escalation Matrix.
Error-Proofing: Part Pick (Line Side), Component Verification, Test Equipment Results, Work Instructions
Energy Management: Optimize usage based upon cost of energy, Predict energy consumption
Workforce Management: Skills Management, Labor Management
Create Smart And Outcome Based Analytics
Manufacturing processes have improved a lot in the last few years driven by competition and market demand. Many plants are running at capacity level but there is always an optimization that is possible, Quality that can be improved, Energy that can be saved and inventory that can reduced. In an integrated manufacturing environment, it is not easy to identify bottlenecks and areas of improvement in real time without using some simple tool for analysis. Analysis can be looked at it two ways.
Detailed analysis of a specific machine or area of the Plant in real time.
Machine Analytics: Performance, Alarms, Process Control, Breakdown
Plant Analytics: Line Performance, De bottlenecking, Genealogy/ Traceability, Process vs Product
Enterprise Analytics: Month and year Performance, Product vs Supply Chain, Product Cost plant to plant
Operations Intelligence: Executive Dashboards, Critical KPIs – Safety, Quality, Cost, Outcome of the Analysis Process
Descriptive Analysis: Providing the information on what actually happened. This important but action taken to handle the issue is people dependent.
Diagnostic Analysis: Here the user gets the root cause analysis of why the issue happened. Hence narrowing down the solution.
Predictive Analysis: Smart Machines are now able to provide health data in addition to operational data. This data is now allowing users to look at the third state of machine other than the running and breakdown state called the Abnormality State. In this analysis, the user is informed on the potential problem if the abnormality state ins not rectified immediately.
Prescriptive Analysis: The most advanced state of analysis is prescriptive where the tools are able to suggest the action to be taken to handle an abnormality state. Sometime in an advanced closed loop operation the machine takes the corrective action based on the system advice.