Enabled IIoT Powered Remote Monitoring of Construction Machine’s Efficiency Parameters

Client

The client is one of the largest Asian construction companies. They were looking for a digital solution, which could provide real-time insights into machine utilization, parts servicing requirements, energy consumption, and more

Challenge

The client was facing various business challenges that included:

• Real-time monitoring of OEE (Overall Equipment Effectiveness) and equipment effectiveness.
• Analyzing productivity trends in order to handle breakdown alert management.
• Monitoring the conditioning of the key machines.
• Functionality to monitor energy consumption per operation for each factory remotely from the headquarters.
• Reducing unplanned downtime.
• Maintaining consistent quality of components.

LTM Solution

Our solution consisted of the below key solution components:

• The solution enabled data acquisition of machines by using sensors (level, temperature, and pressure) and from machine controllers (through OPC, MODBUS, and OEM’s (Original Equipment Manufacturer) Proprietary TCP/IP protocols) and wireless data transfer from machine controllers/- sensors to the central data store.
• Local interactive HMI (Human-Machine Interface)- for operators to trigger alerts (through Kaizala) to dedicated groups for production/maintenance related issues for immediate action.
• Andon display board- for consolidated plant information, the measured data was visualized at a local Andon in real-time for quick decision making at the shop floor.
• Intuitive dashboards- Visualized trends for utilization, energy consumption, operation efficiency, etc.

Business Benefits

The business impact of our solution was sudden and visible with the below achievements:

• The night shift productivity was increased by 2.5 times through insight-based intervention.
• The first output from the start of the shift was drastically reduced from 1.5 hours to 30 minutes.
• Our insights-based solution resulted in higher power saving, and the post breakdown response was brought down from 30 mins to 5 mins through digitizing the process.
• The most significant result was the streamlining of root cause analysis by replacing manual paperbased record keeping with HMI enabled recording of breakdown causes.