At one of the largest manufacturers of Industrial Ceramics products in the world, StatPort enables productivity improvements, delivering system-based operations management. The value stream comprises Raw Material, Mixing, Ball Mill, Slurry, Spray Dryer delivering Ready to Press Ceramic powder.
Across stages and functions, StatPort delivers 150 workflows – replicating human oversight, instincts and thumb rules. These workflows primarily focus on productivity and process adherence delivered 2000 person hours of saving s in a year and also removed 22,000 sheets of paper from the value stream.
As a result of improved monitoring and actionable insights, the company achieved 1.8% improvement of efficiencies per month.
- Popular use cases for Industry 4.0 are based on condition monitoring and predictive maintenance. The outcome is reduced downtime of machines. This can be called the ‘vertical approach’ to Digital Transformation, to focus on specific data points. However, experience has taught us, that machine uptime does not equal line effectiveness.
- Factories with 85% utilisation of machines often achieve 65% of throughput. Solving this problem, needs the ‘horizontal approach’ to Digital Transformation. StatPort is based on the horizontal approach – that means, we work with a wide range of data sources and structures. We have 50+ Machine Learning – Parsers built for Industrial use cases.
- This section show cases a sample of use cases delivered by StatPort across different types of manufacturing.
IoT & Smart Quality for Heavy Engines
- Data integration with CMM, Air Electronic Gages, Profile Projectors and more to acquire data points pertaining dimensional measurements, organise the data for different sub components, engine types and deliver statistical stability and capability of 1000s of parameters.
- Outcomes include quantification of product characteristics, validation of machine capabilities and shortening of review cycles across functions and stakeholders.
IT – OT Convergence for Electric Vehicle
- Starting with Cell Orientation, Welding and Sealing intercepted with manual operations, integrating with Cycle and Management System tests, StatPort brings all the data together to bring up a Go – No Go for battery assembly
- In assembly line, StatPort integrates with the PLC based conveyor to look at cycle times, production losses and enable line balancing.
- Outcomes include improvement of line speed from 7.5 minutes per cycle to less than 2 minutes.
IoT & Smart Quality for Foundry
- Characterised by short batches of a large variety of – 1300+ components – StatPort is used for digital transformation of quality control across 6 different pillars of inspection including IoT integration with data loggers for process characteristics.
- Characterised by short batches of a large variety of – 1300+ components – StatPort is used for digital transformation of quality control across 6 different pillars of inspection including IoT integration with data loggers for process characteristics.
- Achieving demonstrable capabilities and compliances required for a value stream emerging from automotive to aeronautical standards.
IoT & Statistical Control for Passenger Cars
- MQTT based integration with measurement systems across machining line of engine components, StatPort acquires and translates raw data into control charts and statistical capability
- Data from across stations in the line are consolidated into a dashboard at the plant level
- Data is delivered via Web APIs, every hour, into servers at the Corporate
Monitoring for Process Manufacturing
- PLC based systems are characterised by the creation of large volumes of data. While near operation visibility is flooded with data, there is very little, in terms of actionable insights and enterprise wide visibility.
- StatPort can translate raw data points to KPIs, map them against thresholds, and deliver actionable insights to targeted users.
IoT & OEE for Machining
- Modern machines can relay loads of data, however, Industry 4.0 systems need to integrate the old with the new.
- Our IoT interface products (hardware) can integrate with old machines to get ‘Internal’ events, combine them with Apps to capture ‘External’ events.
- Outcomes include real time production monitoring, enforcing operation sequences, identify production losses, process bottlenecks and deliver workflows to resolve losses and improve Equipment Effectiveness (OEE) & Line Effectiveness (OLE).
IoT & Smart Quality for Heavy Engines
- Data integration with CMM, Air Electronic Gages, Profile Projectors and more to acquire data points pertaining dimensional measurements, organise the data for different sub components, engine types and deliver statistical stability and capability of 1000s of parameters.
- Outcomes include quantification of product characteristics, validation of machine capabilities and shortening of review cycles across functions and stakeholders.
IT – OT Convergence for Electric Vehicle
- Starting with Cell Orientation, Welding and Sealing intercepted with manual operations, integrating with Cycle and Management System tests, StatPort brings all the data together to bring up a Go – No Go for battery assembly
- In assembly line, StatPort integrates with the PLC based conveyor to look at cycle times, production losses and enable line balancing.
- Outcomes include improvement of line speed from 7.5 minutes per cycle to less than 2 minutes.
IoT & Smart Quality for Foundry
- Characterised by short batches of a large variety of – 1300+ components – StatPort is used for digital transformation of quality control across 6 different pillars of inspection including IoT integration with data loggers for process characteristics.
- Characterised by short batches of a large variety of – 1300+ components – StatPort is used for digital transformation of quality control across 6 different pillars of inspection including IoT integration with data loggers for process characteristics.
- Achieving demonstrable capabilities and compliances required for a value stream emerging from automotive to aeronautical standards.
IoT & Statistical Control for Passenger Cars
- MQTT based integration with measurement systems across machining line of engine components, StatPort acquires and translates raw data into control charts and statistical capability
- Data from across stations in the line are consolidated into a dashboard at the plant level
- Data is delivered via Web APIs, every hour, into servers at the Corporate
Monitoring for Process Manufacturing
- PLC based systems are characterised by the creation of large volumes of data. While near operation visibility is flooded with data, there is very little, in terms of actionable insights and enterprise wide visibility.
- StatPort can translate raw data points to KPIs, map them against thresholds, and deliver actionable insights to targeted users.
IoT & OEE for Machining
- Modern machines can relay loads of data, however, Industry 4.0 systems need to integrate the old with the new.
- Our IoT interface products (hardware) can integrate with old machines to get ‘Internal’ events, combine them with Apps to capture ‘External’ events.
- Outcomes include real time production monitoring, enforcing operation sequences, identify production losses, process bottlenecks and deliver workflows to resolve losses and improve Equipment Effectiveness (OEE) & Line Effectiveness (OLE).