SMART MANUFACTURING BUNDLE FOR SMEs

SMART MANUFACTURING BUNDLE

4 Smart Apps Enabled by BorgConnect $^{\textcircled{2}}$ Hub and BorgConnect $^{\textcircled{3}}$ Nodes Across 5 machines

MATERIAL COUNT / ACTUAL PRODUCTION	MACHINE AVAILABILITY (%)	QUALITY (%)	PRODUCTION YIELD (%)	OVERALL EQUIPMENT EFFICIENCY
2100	93	88	84	76

Real time Visualization of the Plant
Track Key Performance Metrics such as OEE, Utilization, Wastage, etc., of the 5 connected machines on a smart phone or a tablet.
Elimination of Paper Records
Whenever necessary, barcode and/or user entry of data of process, product, material root causes of failures, etc., via an intuitive user interface to eliminate paper records.
Benchmarking
Smart benchmarking of process/production for different dynamic conditions and identification of anomalies and threshold crossings. Alerts of such anomalies delivered in real time!
BORG CONNECT®
Smart tracking of deviation from plan in three dimensions - production time, production volume and materials usage.
Elimination of Non-Value-Added Costs
Smart vertical integration of production to corporate/enterprise systems for automated reporting of real-time production performance.

Tracking Availability
Tracking planned and unplanned downtimes, idle times, breaks, product change times, etc., to compute and track Availability against Planned Availability for each of the 5 assets or a combination of assets.
Tracking Reliability
Tracking component MTTFs, MTTRs and computing MTBFs of the 5 connected assets. Pareto tracking of the failure rates leading to the tracking of the reliability of the 5 assets.
Prediction of the "Next" Failure
Estimating the probable time for the "next failure" of a component across all 5 connected assets - using machine intelligence. Automated generation of predictive maintenance actions to reduce or eliminate unplanned downtimes based on failure predictions. Generate preventive maintenance work orders on the fly from a tablet!
Elimination of Non-Value-Added Costs
Automated integration of production equipment to enterprise asset management systems or CMWS for generating predictive, preventive & corrective maintenance work orders.

Elimination of Errors and Omissions in Quality Inspections
Recording quality measurements directly (objectively) from sensors and measuring instruments against established Quality Plans. Elimination of data input errors and/or omissions.
Tracking Process Stability & Process Capability
Automatic generation of X-bar, $C_{\mathrm{p}}$, $C_{\mathrm{pk}}$ reports for tracking process stability and process capability in the manufacturing of each part/product by each of the 5 connected assets.
Tracking Reject Causes and Reject/Quality Rates
Recording of reject reasons on a smart phone or tablet for each rejected product-leading to reject analytics and recommended actions for process or operator improvement. Pareto Tracking of reject rates.
Tracking Cost of Quality
Computation of the cost of quality of 5 critical assets across different time periods and tracking its trend. Traceability of part/product produced by the 5 assets from two different points of view:
a) Journey Trace - that continuously records and traces the quality attributes, and measurements made on the part/product across the 5 assets; and
b) Production Trace - that records and traces the measurement of production/process parameters that are critical to maintaining quality.

Establishing Last Mile Connectivity
Establishing the last mile connectivity to major energy guzzlers in the plant using a non-intrusive sensor.
Automated Baselining
Automatic computation of "business as usual" profiles of energy consumption of a machine/process for every product type.
Production-Energy Optimization
Smart computation of energy consumption for every product (energy intensity) produced.
Comparison of Energy Usage
Comparison of the energy performances of identical machines to understand why one machine is behaving better than the others!
Smart computation of the expected savings & implementation of energy savings strategies to reduce energy consumption.

A Tier 2 SME tracks performance of CNC Machines in order to make incremental changes to improve performance within a shift.
An SME generates a report of root causes of line stoppages as a percentage of "available time" within a shift for performing analysis and improvement.

A boiler plant (utility) of an SME is monitored for KPIs & early warnings of anomalies in its operating performance that can lead to predictive maintenance.

An Auto Parts SME objectively records In-Process & End-of-Line QC measurements via Bluetooth enabled measuring devices.
An SME tracks Process Capability of their manufactured parts.

An SME Food Processor tracks, logs & is notified of Power Quality events to curb utility penalties.
A Paint Shop monitors & reduces weekly energy consumption of a Paint Line across different types of parts.
A Printing Plant implements energy savings strategies (e.g. Load Shedding) during specific shift periods.

Quad
0 - 3.5 A Operating core Cortex-A72 (ARM v8) 64-bit SoC @ 1.5GHz; Wi-Fi; Bluetooth; Gigabit Ethernet; 5V USB type-C Power Input; temperature: 0 - 50°C ambient.

I2C, SPI, RS232, RS485, UART, Relay Control, HMI, Analog (4-20mA, 0-5V, 0-10V), Digital Sensors, Industrial LAN, AV USB, Bluetooth, Wi-Fi.

PLC, SCADA, Historian, OPC $^{\circ}$, MTConnect, Maximo $^{\circ}$, Oracle $^{\circ}$ EAM, SQL $^{\circ}$ Server, SAP $^{\circ}$.

On-premise server model PHYSICAL SERVER (optional)
Octa-core Processor; 12 GB of RAM; 100 GB of HDD.
- OPERATING SYSTEM: Linux.
- DATABASE TECHNOLOGY: MySQL.
Cloud Service Mode: AWS, Azure Offered as a service (optional)

Suite 311, Workafella,
High Street, Mount Road,
Chennai, TN 600 018.
+91-44-2435-1778

98 Cuttermill Road, Suite 466,
Great Neck, NY 11021.
+1-613-368-4809