Factory Modernization Using Industry 4.0

At HashStudioz, one of our key virtues is to redefine simplicity. We believe in helping industries modernize their 3Ps: products, processes and people. HashStudioz Advantage Services delivers an automated, in-house-designed and in-house-developed kit that’s customized as per the customer’s pain point.

When we undertake projects of modernizing a factory, we inherently work on developing solutions which not only enhance its capacity or productivity drastically but also enable our customers to challenge any leading industry giants technologically. This case study revolves around one such example.

TASK OVERVIEW

Business Use Case

This case study highlights a live project consulted and undertaken by HashStudioz to reduce manual work of Factory Supervisors pertaining to testing of mechatronic components and reporting of results. This not only resulted in facilitating increased production capacity and manpower capacity but also led to freeing up of skilled supervisors from monotonous labor-like tasks for their better utilization in more self-fulfilling, decision-making and intelligent purposes.

The organization belongs to the manufacturing factory domain and essentially manufactures bottles on a large scale. It started facing hurdles for its large-scale Asia-Pacific expansion plans as it required more manpower owing to its manual nature of supervisory jobs.

On reviewing the issue, we found that the strategic decision wasn’t at fault, but the process needed a major revamp for optimization. Being a team experienced in Industry 4.0 and IoT projects, we undertook this project and designed an industrial automation solution to eliminate the manual part and reduce skilled man-hours considerably.

Solution Approach

We designed an ICT-enabled embedded system to test various parameters like Inductance, Resistance, Holding Currents and Feedback Voltage from the Motor.

Factually, testing these parameters of the motor took a fair amount of time (20-30 mins), and supervisors had to do it manually and write down all the observations at the end of every 30-minute cycle.

To address this, our in-house-designed and developed kit automated the testing of the motors, completing end-to-end testing of all parameters in a mere 2 minutes, recording these observations and displaying them in a readable GUI format. It could also be saved locally in spreadsheets by end users/supervisors.

This reduced testing cycle time from 30 minutes to 2 minutes and facilitated dual operation-improvement methods for our customer:

1) Increased process productivity by reducing testing time.

2) Increased skilled man-hour capacity utilization by displaying response in custom-tailored GUI and making it downloadable.

Process Implementation

The customer’s success in mitigating growth barriers and paving an entry into a large-scale market could be attributed to a timely realization of the urgency and need to remodel its legacy processes in part or in full. Simple Integral can help you to identify the best-suited channels and embark on the journey of your digital transformation to be a global leader.