Production Monitoring System

Real Time Production Line Monitoring System for Intelligent Data Analysis and Industrial Digitalization

HELLENIC INSTRUMENTS offers a powerful solution for industrial digitalization, allowing automated monitoring and control of production lines. Using wireless data collection stations, the system can monitor performance statistics of the produced batches, including production times, breakdowns, downtimes, losses and operational activity. The system can be integrated on running productions with minimal integration overhead.

HELLENIC INSTRUMENTS’ solution differs from the conventional solutions available in the market, as it incorporates an extended list of IoT devices with the typical Industrial Surveillance and Data Collection Systems (SCADA), offering a complete data monitoring and analysis platform.

The system falls in the field of Internet of Things (IoT) Architectures and aims on the digitization of the conventional Factory. More specifically, intelligent IoT devices collect KPI data and send them over a wireless network to the central data collection & processing station. The interconnected devices are then connected using local networks, achieving the maximum level of protection during data transmission.

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Graphics, statistics, and analytics tools are combined together, displaying the results both in real time as well keeping history of events for future analysis. The main features of the  IoT system include:

  • Continuous monitoring of the main KPIs of the plant and its machines in real time
  • Personalized alerts and alarms for all types of data with user-configurable limits. Able to display alerts in the graphical user interface as well as send pre-configured emails.
  • The use of sophisticated IoT devices ensures a powerful and robust system that can precisely monitor and protect the infrastructure, allowing for future expansion of the system.
  • Local implementation of SCADA-IoT, protecting the privacy of business data.
  • Installation of the system does not affect the existing production flow and does not require any change in existing plant facilities.

The system can be divided into three sub-systems:

  1. A production process monitoring system
  2. A system for preventive maintenance of the machinery
  3. A system for monitoring environmental parameters

With this overall solution, Hellenic Instruments surpasses commercial SCADA solutions by providing a complete system that delivers all the information needed to get up-to-date and correct decisions.

Advanced Features

  • Tracking Stages of Production in Real Time
  • Automatic Reporting of Events
  • Monitoring 24/7
  • Location mapping of production Batches
  • Alerts and logging for reduced human error
  • Increase production efficiency
  • Statistical Analyses of collected data

 Applications

  • Packages & Building Materials Industries
  • Food, Beverage, Brewing Industries
  • Automotive & Aviation Industries
  • Pharmaceutics Industries

Software platform

The SCADA graphical interface represents real-time indications from the IoT sensors installed in the factory. The result is a dynamic monitoring system combined with advanced analytical and statistical tools. The main features of the platform include:

  • Graphic user interface with built-in and easily customizable calculations, including numeric unit conversion methods and trigonometric functions.
  • Incorporates widgets of different time periods, frequencies, and impressions.
  • Generates reports for all system parameters on request or on a specific schedule.
  • Reporting tools include bar charts, pie charts, bubble and scatter plot charts, historical data grids, and many other visual tools.

Hardware equipment

By using data collection stations compatible with IoT applications adds the ability to support a large variety of sensing systems by making each data collection station an individual tracking tool for the system. A list of available sensors includes: 

Temperature & Vibration

Industrial maintenance is the key point for keeping the manufacturing equipment running at peak efficiency inside a factory. It includes processes like scheduled cleaning, parts replacement and lubrication, as well as minor repairs. The field of industrial maintenance does not include only the repair of already existing malfunctions. Preventive maintenance typically is an important part of the field. As modern industrial machinery is expensive, it is usually important for businesses to ensure the upkeep of their investment. Preventive maintenance also may help ensure that machinery is safe, which can assist in maintaining the health of workers and equipment users. The process of monitoring these parameters allows reducing time and cost as well as maximizing production.

Humidity

Maintaining effective control of humidity is essential in industrial environments for both the health of the building and its occupants and, very often, supporting optimum performance of manufacturing processes. Humidity sensors are necessary because humidity influences the lifecycle of the machines and the product quality. Ensuring proper conditions in crucial stages of the production leads to uniform quality among production batches, expands production machine life and improves the production conditions of the products. Especially in the packing stage, controlling humidity levels during the food packaging process is important so that label inks or wraps do not adhere to the end product

Noise Pollution

Noise pollution is considered as more important environmental problem, especially in the industrialized and developed countries. Industrial noise is an important source of noise pollution, which annoys and disrupts the daily activities of workers. Environment pollution is a secondary and unwanted product of different industrial activities that has exposed the environment to further danger. Noise contamination is one of the extremely significant difficulties of the industries that influence the hearing procedure and other physiological factors of the human’s body, as well as bodies in sound exposure situations Furthermore, the monitoring of the sound level in combination with the vibration of a machine provide signals of a possible upcoming need of maintenance contributing to the overall safety of the plant.

Luminosity

From the workers’ perspective, poor lighting at work can lead to eye‐strain, fatigue, headaches, stress and accidents. On the other hand, too much light can also cause safety and health problems such as “glare” headaches and stress. Both can lead to mistakes at work, poor quality and low productivity.

Air Quality & Particle Matter (Dust)

The temperature, the relative humidity and the rate of CO2 in the indoor air makes it possible to obtain a good first approximation of the quality of the indoor air. These measures make possible the increase of the productivity of employees and the reduction of absences from illness. It also helps to increase well-being in the office.

The size of air particles is linked directly to their potential for causing health problems. Small particles less than 10 micrometers in diameter pose the greatest health risks, because they can affect the lungs and heart. Larger particles are of less concern, although they can irritate the eyes, nose, and throat.

Particles less than 2.5 micrometers in diameter are called “fine” particles. Sources of fine particles include all types of combustion, also motor vehicles (trucks and vehicles), power plants (power generators), and some industrial processes. Fine particles contains more toxic heavy metals and hazardous organic pollutants and can infiltrate directly to the lungs. They are easily attached to bacteria and viruses in the environment and thus have a greater impact on ecology and human health.

Watt consumption

 A continuous restructuring and re-engineering of the production line with upgrade of existed machines or new machines may leads to unpredicted and unwanted results, like higher power consumption than expected, breakdown of machinery, alter the production line and more. Real-time monitoring of the power consumption of the production process is a reliable factor for the verification of setting up the machines to the higher performance. An occurring machine event can be traced and prevented before it reaches the point of breakdown. Maintenance service of machineries can be predicted in a satisfied level with the monitoring of their power consumption.

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