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Industrial automation & measurement

ripplesiotData visualisation, IOT asset tracking, IOT in factories, IOT in manufacturing

IOT & activity based costing

Industrial automation - wireless sensors, retrofit solutions

How Condition Monitoring solutions can lead to a higher ROI

Activity Based Costing is widely used in the manufacturing industry. However, it comes with its fair share of criticism because it is difficult to correctly estimate the amount of resources required to perform a task efficiently. 

Two of the key performance indicators (KPI) in the manufacturing industry are MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair). MTBF is a performance metric that measures the time elapsed between when a failure occurs and the next time it happens. MTTR is the time spent to conduct repairs once a failure occurs. Both these KPI’s are calculated by dividing the total time taken respectively by the number of failures. While these are good indicators of performance, they are flawed. Failures cannot be foreseen as they are not uniform and can occur at any point of time. In the case of repairs, it may take longer for some than others. That is why these metrics lack real-life accuracy. 

Using condition monitoring solutions, it is possible to successfully obtain operational information from machines which are variable in nature. The actual operational times of the machines can be analysed and resources can be allocated accurately. Maintenance can be scheduled based on the number of hours used. This eliminates the need to estimate KPIs like Mean Time Between Failures and Mean Time To Repair by providing us actual figures of usage. No excess resources will need to be allocated . This will in turn improve operational efficiency and ultimately lead to a higher Return on Investment (ROI).

IOT solutions can help to improve the audit and scheduling of pro active maintenance schedules by gathering operational data such as hours used, operating environment, power consumed and abnormal handling of equipment by users. Helps to ascertain Mean Time Between Failures (MTBF) and Mean time Between Repairs (MTBR)

Most of factories and warehouses employ technical staff to conduct periodic check and repairs to ensure the asset equipment are up and running all the time. Unexpected breakdowns can lead to loss in revenue, opportunity costs, unsatisfied customer etc.  Using our IOT in maintenance solutions, your own technicians will be able to remotely monitor the fixed assets to help prevent breakdowns.

IOT industrial automation & maintenance

Implementing a retrofit IOT solution with non invasive sensors and integrating data visualisation tools can help businesses to improve equipment uptime,  track and trace of critical plant and machinery in factories, shipyards, airports, supply chain environment, warehouses etc, which otherwise takes many man hours of unproductive work.

Anomaly detection solutions for industrial automation can help businesses improve the operational excellence by pro active maintenance, optimising spares inventory and reducing energy consumption of various heavy industry equipment.

Call us at the following numbers to more on how IOT industrial automation sensors and IOT in maintenance management using anomaly detection solutions can help improve asset efficiency and reduce breakdowns.

Industry 4.0 & asset visibility

ripplesiotIOT asset tracking

Asset monitoring solutions are driving Industry 4.0 revolution

Asset monitoring solutions Singapore. Industry 4.0

Asset monitoring solutions in IIoT involves attaching or embedding IoT-enabled devices (i.e. sensors, RFID tags etc.) to machinery or other pieces of industrial equipment to make them “intelligent”.

These intelligent devices can then be connected to back-end systems, applications or cloud services via wireless connectivity in a mesh or star network. This makes it possible to continuously collect and analyze data generated to actively monitor pre-determined asset-specific information.

This enables users to continuously monitor conditions related to high value asset:

  • Quality
  • Performance
  • Damage of breakdown
  • Other environmental conditions

It provides asset monitoring solutions to users by allowing them to collect and analyze IoT data regarding pre-determined conditions.

Manufacturers can implement predictive maintenance based on equipment condition analysis and performance trends.

Predictive maintenance will help companies save $630 billion by 2025 by:

  • Reducing unplanned equipment downtime, which can cost upto $260K per hour
  • Cut the number of unnecessary maintenance tasks associated with a  schedule – based process
  • Minimise levels of wasteful production associated with sub-optimal operation
  • Providing access to new, actionable insights uncovered using advanced IoT data analytics

30% of manufacturers have already implemented IoT technologies for predictive maintenance and analytics while another 30% are interested in joining this new chapter of modern manufacturing, the 4th Industrial Revolution.

Are you ready ? Talk to our experts in Singapore and learn how to deploy asset monitoring solutions in your manufacturing unit and leapfrog to adopt Industry 4.0 practices.

Asset tracking in Industry 4.0

ripplesiotIOT asset tracking, IOT in factories, IOT in logistics, IOT sensors, IOT solutions, , ,

Factory asset management systems

Industry 4.0 valuable asset tracking, equipment monitoring in factories

Emergence of Industry 4.0 and smart factories have made it a necessity for manufacturing industries to adopt modern practices to optimise their production processes. Valuable asset tracking and monitoring wireless technology are being adopted by leading industries for asset intelligence –  tracking and monitoring of critical assets, their location and working environment.

These wireless monitoring technologies can also be classified under factory asset management systems in which industries leverage such sensor technologies to prevent equipment failure and to significantly improve asset performance and extend their life. This digital transformation technology is playing an important role in many mainstream industries such as as logistics, warehousing, healthcare, fleet management, shipping, and factory automation.

“Wireless (Active RFid tag) temperature sensing of a 33 KV high voltage transformer. Thrilled to see the performance and the immense opportunity it opens for asset tracking & condition monitoring of critical assets like transformers and electrical panels,” says Mr. Balasubramaniam Somasundaram, plant Engineering & Maintenance, ZF Windpower

With manufacturing industries aiming to adopt Industry 4.0 and smart manufacturing, product-life cycle management,  efficient production process  control,  supply  chain visibility, and just in time logistics have increasingly become a necessity.

Owing to this platonic shift, high value asset tracking solutions are being adopted by leading corporations practicing Industry 4.0, and are anticipated to greatly impact the growth of various industries in the coming years.

This disruptive technology allows manufacturers to track a high value asset through the entire stage of production, their real-time location and status, and generate various reports which help them to monitor and take important actions accordingly.

Technology Adoption in valuable asset tracking

These unique wireless asset tracking solutions also helps in monitoring real time data regarding plant & machinery and equipment to plan maintenance activities and reduce preventive maintenance costs, besides. Industries involved in warehousing, distribution & supply chain logistics, who are the main adopters of cold chain / asset tracking solutions, are able to track truck location, movement, tilt, temperature, shock & environment condition. These key forces pave the way for the adoption of wireless asset tracking technologies in smart factories and warehouses.

Currently, wireless asset tracking technologies are in perpectual developmental stage and undergoing enhancements due to the emergence of 5G, Sigfox, LoRa, Narrow Band IOT (NbIOT) etc that are telecom industry driven disruptions.

The asset tracking technoliges need to balance between ease of deployment, battery autonomy, transmission range, device size, wireless protocol, security and safety norms.

Some industries use active RFid, the highly proven, widely deployed technology for asset tracking, equipment  monitoring, and physically securing high value assets. Ripples IoT provides best in class, tamper proof, miniature sensor devices, dashboard software and data visualisation tools for valuable asset tracking.