Project Overview#
As the project lead for the implementation of a Shopfloor Visualization System, my goal was to create a service that provides real-time machine data for process optimization. The system enables the real-time visualization of machines—especially production machines in the form of Digital Twins. Users can monitor relevant machine parameters and production processes in real-time, enabling swift responses to any changes.
The flexible processing of these data messages plays a key role in enhancing process control efficiency and achieving quicker reaction times, ultimately resulting in more efficient manufacturing processes.
On-Site Work in Italy#
As part of this project, I spent two weeks in Crema, Italy, working with the leading Digital Twin team. My key responsibility was to analyze their manufacturing developments and processes. Using the insights gained during this time, I collaborated with the local team to implement optimizations in both software and hardware, aiming to make the data collection for Digital Twins even more efficient.
Solution: Introduction of a Second Network#
A significant milestone was the establishment of a second network running parallel to the existing production network. This additional network ensured that our systems were continuously supplied with real-time data. This step was crucial for enabling the Maintenance 4.0 concept and fully leveraging the power of the Digital Twin. It allowed for significantly improved monitoring and maintenance of production processes.
Results#
The project led to a notable increase in efficiency within the manufacturing processes by integrating real-time visualization and data management. Key outcomes included:
- Real-time Visualization of Machine Parameters: Critical machine parameters can now be monitored in real time, providing better process control and swift issue resolution.
- Flexible Data Message Processing: Adjustments in production control can now be made immediately and flexibly.
- Efficient Maintenance: By introducing Maintenance 4.0, we were able to reduce downtimes and optimize maintenance cycles.
Conclusion#
The collaboration with the Italian team and the establishment of a second network parallel to the existing infrastructure were key to the successful implementation of the Shopfloor Visualization System. With the integration of Digital Twins and the introduction of Maintenance 4.0, we achieved a significantly improved process monitoring and much more efficient control of manufacturing processes. This project laid the foundation for further optimization and automation within production.