Collaboration with a market-leading beverage bottling manufacturer to develop a cloud-based solution that predicts equipment failure with advanced analytics
Client: Vitaqua is a market-leading beverage bottling manufacturer and distributor in Germany. Vitaqua produces natural mineral water bottles and non-alcoholic soft drinks under the brand names of renowned retail chains.
Challenge: Production plants with bottling lines usually undergo various challenges when it comes to mechanical efficiency of the machines. It is important to ensure optimum machine efficiency which can be achieved with proper preventive maintenance to minimize losses, maximize output and simplify changeovers. Data from machine sensors can be collected at the assembly line to interpret operational efficiency and to identify any faults.
Vitaqua was seeking a powerful and flexible leak-detection and notification system that can use this data to detect the leakage within the assembly line and notify relevant users through alarms or buzzers; helping VitAqua be proactive in their maintenance.
Solution: Strategic Systems International (SSI) was contracted due to our extensive experience in providing cutting-edge solutions to the manufacturing industry. Vitaqua was impressed with our deep domain expertise in architecting customized Industrial Internet of Things (IIoT) solutions that provide predictive machine failure tools to similar businesses.
Engineers and data scientists at SSI built a cloud-based application to detect, record and track the leakage with timely alerts.
The key features of the platform include:
- Mathematical model implementation that uses real-time data generated by the assembly line to detect leaks
- Calculate leakage to annual operational loses and risk to the manufacturer
- Live 2D view of assembly line with the health and status of machines
- Error/warning indicators
- Real-time visualization of KPIs
- Historical data trend for KPIs
- Mobile application for remote monitoring
- Real-time alerts and notifications
Result: The solution developed by SSI has helped the client make probability-driven and multi-scenario informed decisions before critical problems occur. This, in turn, has saved Vitaqua operational costs which otherwise would have occurred due to machine failures. It has also helped the client streamline their production processes and operations and provide a real-time pulse on its efficiency.