Digitisation: A core element of innovation

June 29, 2017 3:28 pm

As measuring technologies evolve, digitisation has become a core element of innovation. As a result, an intelligent measuring device or sensor provides more than just accurate measuring values.

In an interview with OEM Update, Rajashekar Venkat, General Manager – Industrial, PI, SCM & Manufacturing, Mettler Toledo India Pvt Ltd explains the importance of digitisation in manufacturing process highlighting details on their products for ‘smart factory’.

Digitisation in manufacturing process:
As measuring technologies evolve, digitisation has become a core element of innovation. As a result, an intelligent measuring device or sensor provides more than just accurate measuring values. In addition they can provide qualified real-time status information about the manufacturing process, collect measuring results and steer production equipment. Measuring devices, such as weigh modules, platforms and terminals, can be built into highly modular assembly lines and conveyor belts. There they can be either automated or operated manually. Despite increasing automation, manual work will not disappear in modern factories. Assembly, quality checks and material handling is still done by operators on manual workplaces. Manufacturers are now looking for equipment that allows them to integrate these workstations into their systems.

Product for ‘smart factory’ and its salient features
Mettler Toledo weighing terminals with embedded InTouchSM Remote Services connectivity can send alerts to remote service technicians or internal personnel. Performance issues are immediate addressed, which means more uptime and fewer unforeseen expenses. Protected by proven IT security measures, InTouch securely improves your performance and uptime by keeping production running, avoiding unplanned downtime and planning repair at the right time for your business.

Efficient equipment management
• Real-time equipment status information
• Fact-based timing of preventative maintenance activities
• Abnormal condition change triggers email alarm notification.

Improved performance control
• Ongoing monitoring of measuring performance
• Avoid overnight downtime surprises
• Expiration of calibration is monitored to ensure compliance
• Periodic asset status reports to optimize processes.

Remote services for weighing equipment
Examples of events monitored to ensure the health of weighing assets include:
• RAM battery critically low
• Calibration expiration or test dates
• Control limit failures or capacity issues
• I/O communication errors
• Low-level load-cell excitation
• Zero captured during calibration.

Smooth production logistics
For internal logistics to keep pace with assembly, precise delivery to different production stations in the factory is required. Therefore, it’s necessary to accurately supply batches of thousands of plastic parts, weighing only a few grams each, and to deploy them for further processing at the right time. Additionally, the medical technology sector is particular regarding the data provision and the label printing to guarantee traceability along the complete supply chain of sensitive products.

Custom solution
Mettler Toledo developed PC terminals to meet the requirements of their customised piece counting system and also created a software solution based on the IND890. The software was designed for the specific needs of the company and adapted to the existing production system. Four counting workstations consisting of an IND890 terminal, barcode scanner, attached printer and a KA32s weighing platform are distributed throughout the plant.

Label creation and SAP input
At the end of the counting process, a label with the item or batch numbers, the number of parts and the associated barcode is printed. The employee attaches the label to the container and the production data is collected via barcode scanner and sent to SAP. Production logistics staff has an ongoing accurate inventory count and the ability to easily plan for future needs.