IoT in shop floors
The advent of IoT in manufacturing industry has efficiently catered to the challenges of obtaining regular and accurate information of manufacturing resources across the shop floor. The real-time data driven monitoring and tracking of equipment and machines have improved the productivity and quality of the shop floors, most noteworthy point is that it has reduced the wastage of manufacturing resources to a large extent.
A shop floor is divided to various zones or areas. Each zone is critical towards the overall working of the industrial plant. It is extremely crucial to monitor and track the machines and the staff inside each of these zones. With Ripples IOT asset monitoring and tracking solutions, shop floor managers can obtain better insights into the working of the resources and can take actions to improve efficiency and accuracy across the production lines.
IOT energy monitoring
One of the major contributors towards the operational costs in a shop floor is the energy consumption by the machines. Due to the increasing awareness towards the optimum usage of non-renewable resources and tightened environmental regulations, it is extremely important to keep check of energy consumption by each machine in the shop floor. In most shop floors we had visited, they would be just taking a summary data of monthly power consumed, whereas the need of the hour is real-time visibility of the energy information from each of these machines.
But, it tells you lot more than just energy consumed…
Tracking power consumption by each machine can tell you an unforeseen story. I remember one use case when our client wanted to monitor the power consumed by a motor that powered a mixer. The manager said that this mixer is consuming way more power than it should. When we implemented a real-time IOT energy monitoring system, it was interpreted that the motor drew more power when there was an increase in the load. It became clear that the motor was due for maintenance.
Another use case we can remember with the same client was that they found out one machine on the shop floor drawing excess power than it should. It’s when they found that the filter in a pipe leading to the machine was clogged and this was forcing the motor to draw extra power.
Tracking power consumption data live can also give indication of the usage time of the machines and whether the machine is operated correctly and as said in the manual. Improper handling can also lead to maintenance issues and by tracking energy consumption correctly; this can be avoided to a certain extent. In developing countries, there is always problem of erratic power supply, the voltage levels can fluctuate a lot, which is not good for machines at all. Such issues can be proactively taken care of using our real-time energy monitoring solutions.
If you want a demo of how our solutions using IOT energy monitoring enables to reduce possible downtime situations and reduce possible energy wastage on the shop floors, do contact us.