Data Science saves €18 million per year in energy costs In IIoT, Data Science is often associated with predictive maintenance - clever algorithms that predict when machine parts wear out, go out of alignment or otherwise will be in need of repair. This is then used to schedule maintenance to avoid unnecessary downtime, thus keeping machines up and running and earning their keep. But Data Science is a broad field that can bring more advantages to your operations than this. As an example, consider a well-known, large, European cement producer. For them, energy consumption is a matter of profit or loss, as 30% of the cost of cement is due to the energy consumed during its production. Recognizing this fact, the company went to great lengths to optimize, and standardize operating procedures. However, ei3's team of Data Scientists noticed that some plants, sometimes, were doing significantly better than the overall average, showing an up to [...]

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New Analytics Shows New Ways To Make Machines Run Better Broad Frequency Spectrum analysis might hold the key to getting ahead with predictive maintenance. For years data scientists have been grappling with the problem of predicting machine failures based on conventional process data, and have made significant advances: Today, vital insights can be told from increased oil consumption, slowing machine speeds, sluggish motor acceleration data. But the quest is open for more insights with more sensors and more data! New methods based on frequency spectrum analysis give surprisingly accurate information about the inner workings of your machines. The technique is similar to what a human engineer might do: listen to the sounds of the mechanism to spot any unusual patterns. Except, when done electronically, a sensor can improve upon the human ear by listening to a much broader frequency spectrum, be placed inside the gut of the machine where an offending frequency would be much more pronounced, [...]

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Time to focus on your most important asset on the shop floor What might it be - the spot welder? The injection molding machine? The shrink wrapper? The cash register? No.  It’s your operators. Plant and line managers spend a great deal thinking about how to improve production, i.e., making it faster, eliminating bad products, or reducing cost. We will continue to find such improvements but how much better can we really get? Think on the other hand about your human capital. A good, well-trained, and well-motivated operator will be the best guarantee for a well-running shop floor, while any mistake made by a tired, distracted, or overworked operator will cost you dearly. In the end, the skill of the operators makes or breaks the success of the operation, yet we still rely on old-school methods to ensure they are as good as they can be. Best operating principles manifest themselves in the machine data that your [...]

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Solve the Downtime Challenge with Data Science
Is it? Your data shows when your machines are down. Look close and data will also tell you how to avoid it. Manufacturers and machine owners know that every minute that a machine is not running costs money in missed production, lost revenue, lost customer confidence, and possibly lost future business. So machine makers and owners are working hard to make their machines as dependable as possible. Rigid, redundant designs provide for long term reliability. Operating procedures ensure safe and efficient operations. Regular maintenance ensures the grease stays on where it needs to. Yet, invariably the unexpected happens: parts fail, go out of alignment, or quality issues force unplanned downtime, despite best maintenance practices. Many of such failures can be predicted, and their impact therefore avoided by carefully watching machine parameters. For example, failing motors or gears develop unusual current draws or vibrations long before going kaput. Let us show you how to make Data Science a reality by tackling [...]

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Andon Display gives multi-site awareness
IoT Custom Enterprise Dashboard Gives Multi-Awareness Coming from the Japanese word for “Paper Lantern”, Andon display boards visually broadcast the status of a line or machine for everyone in the plant to see.  It works so well that lean manufacturing experts will make this one of their top priorities for a shop floor. The Internet of Things provides a perfect dashboard solution for machine data capture, analysis, and display.  In the cloud, Machine production data can be converted into OEE and other KPIs, and then Web TVs can be used for the display. ei3 brings innovation, experience, and design to create beautiful and informative shop floor displays. In a typical project, we show you some reference ideas and then work together to create a custom display that exactly meets your needs.  Jobs, Shifts, Machines, Recipes are individually tracked and compared to your targets. Once the design is ready to run, ei3 can host the display in the [...]

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Benchmark machine’s Overall Equipment Efficiency (OEE) to find improvement opportunities
Benchmark machines to find hidden production capacityKnow the machines that benefit the most from improvement efforts It’s hard to identify which machines need attention on a plant floor because there’s so much going on. If your plant is like most, you might have both new and old machines, they’re running simple and complex jobs, and each one has different specs and features.  It may feel nearly impossible to tell which machines are running well and which ones need urgent service. Production Tracking from ei3 is a great way to visualize the good, the bad and the ugly of machine performance. It makes a real-time list that shows all your machines and how they are doing, by shift, job and day.  These numbers tell you the story of how each day is going for meeting production targets. Put web TVs on your shop floor and the machine operators will know how they are doing compared to targets. This [...]

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