Any machine can generate data

Our new client, one of the polish pellet producers, appeared on the new markets, so it was necessary for them to increase the production volume.

The machine park was very efficient, but it was not computerized and did not generate any data that could be used to monitor and improve its work. All decisions were made on the basis of reports submitted by machine operators - these declarations were related to all events in the production: the amount of pellet produced, breakdowns, changeovers, etc.

Modernizing existing machines, or buying ones just for the sake of eliminating paper-based flow of information was not economically justified.

The management wanted to change the organizational culture - managers were to start managing the company based on real data, instead of the opinions of employees executing the manufacturing processes.

The consequence of this transformation was the introduction of management mechanisms known from the concepts of Lean Manufacturing and Industry 4.0.

Managers and engineers, based on the performance indicators measured (and not declared by the operators), were to optimize the factory's operation and increase the production volume without introducing new machinery.

FitMech sensors were sticked to the bodies of the pelleting machines and connected to the wifi network. By measuring the vibrations of the machines working, they began to provide data on their current status, true timing of work on individual shifts and downtimes.

The FitMech system, by analyzing data from all machines in real time, frees operators from the need to fill in paper reports, and gives the management staff on-line access to live production data.

The measured load of the pellet machines showed that the purchase of new machines is unnecessary. Knowing the causes and duration of each downtime, management could focus on implementing those improvements that improved the plant's performance the most.