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- 2. About Us www.intellithink.in • We are a product company that offers comprehensive solutions in asset management, maintenance, monitoring and field service • Our solutions provide shop-floor the KPI’s and intelligence to increase asset productivity and efficiency through analytics and predictive maintenance • We believe we can assist our customers in their journey to Industry 4.0 and be their partner of choice. What We Do
- 3. Challenges in the Industry www.intellithink.in Real-time visibility and monitoring Increase Production efficiency Operations, up-time and Predictive Maintenance, Worker Safety
- 4. The Problem Statement (Why ?) www.intellithink.in • Gaps in manufacturing processes – lack of real-time visibility or data to make real-time data-driven decisions • Silo or manual systems to track production, quality, energy and machine monitoring with little or no interaction between the systems. • Data collected and analysed is reactive and takes them cycles to solve with connected issues. • Lots of manual intervention which is error prone and not productive • Lack of Digital road-map among manufacturing companies • Existing solutions are time consuming to implement and require customisations
- 5. The Intellithink Solution Simplify the IOT/AI Infrastructure Secure the Edges and Data Access Speed-up the Application Deployment
- 6. s The Intellithink Solution www.intellithink.in Intellithink Platform • Secure and infinitely scalable platform than can handle large amounts of data • Multi-tenancy support • End to end security and authentication • Machine learning capabilities • Rules processing • Alerts and notifications • API’s Applications • Unified view of the manufacturing floor that aggregates different industrial modules Productivity, Energy, QA, CBM all in one • Real-time and historical views • Robust and powerful reporting • Asset and Maintenance Management • Field Service Management
- 7. The Intellithink Solution www.intellithink.in Easy deployment in days/weeks with little or no IT impact and can be scaled infinitely. Cloud based means 24 * 7 support Single solution for the shop- floor/industry offering visibility and the KPI’s that are required for digital transformation Set up rules and alert based on any monitoring condition – trigger emails, SMS … PredictiveAnalytics – monitors live data for anomalies and warns users Industrial IOTDNA– platform and applications .. No long-term contracts and flexible for every market need
- 8. How it Works www.intellithink.in 2 31 Connect & Monitor Analyse and Improve Digitize and Transform • Connect devices to the Intellithink platform using Industry Protocols • Aggregate data and monitor the KPI’s that your business needs • Use collected data to gain insights into process improvements, machine up-time • Transition from Preventive to Predictive Maintenance • IOT blended into enterprise applications • Build new business models and revenue streams
- 9. Intellithink IOT Ecosystem OPC/Mod bus/MT Connect Intellithink IOT Platform • Data Ingestion and Aggregation • Rule Processing • Alerts & Notifications • Real time analytics • Application Programming Interface Customer ERP/Systems MQTT/HTTP Gateway – 4G/Ethernet Dell Edge www.intellithink.in Intellithink Applications • Manufacturing Intelligence • Service Management • Mobile Applications
- 10. Aggregate data from different shop-floor system into a scalable and secure platform for one unified shop-floor view. Connect disparate shop-floor systems Ease of Integration Easy to integrate and can be up and running in days or weeks. Our platform is cloud based with 24*7 support with little or no internal IT impact. Powerful Reporting and Alerts Superior and robust reporting features to cover all industrial use- cases i.e OEE, efficiency, energy, QA , process capability (cp and cpk) etc. Set up rules to alert on any machine conditions . Manufacturing Intelligence – Key Features www.intellithink.in
- 11. Monitor production flow in real-time to highlight lags to eliminate waste and redundancy and pursue improvements toOEE Productivity Conditional Monitoring Conditional based monitoring and alerts to eliminate machine down-time, increase throughput and machine reliability Predicitve Insights Develop intelligent and automated frameworksbased on IOT data which can identify process, QA issues before hand and can recommend corrective actions to drive efficiency.Advanced analytics on machine data to predict machine failure and move from reactive to predictive maintenance Manufacturing Intelligence – Key Features www.intellithink.in
- 12. Track rejections by machines, codes, shifts manually or automatically in real-time and analyze trends Quality Energy Monitor energy usage across assets, lines and plants in real-time for insights into energy optimization and co-relation of energy data tomachine health Maintenance Management Track Work orders, schedule tasks and digitize all asset maintenance information. Part planning for work orders and mobility tools for service engineers Manufacturing Intelligence – Key Features www.intellithink.in
- 13. § Monitor in real-time parts produced vs target § Capture OEE automatically and in real-time § Capture and track downtime (planned vs unplanned) § Analyse production data to eliminate waste and redundancy to improve OEE § Empower the shop-floor with real-time production data to make informed decisions that boost productivity Productivity www.intellithink.in
- 14. Condition Base Monitoring § Monitor critical asset parameters i.e vibration, temperature etc. in real-time § Set rules that trigger alerts on threshold conditions § View and analyze historical trends § Transition from preventive to predictive maintenance § Eliminate machine downtime, increase throughput and machine reliability using CBM www.intellithink.in
- 15. Energy Monitoring & Optimization § Monitor real-time energy costs and consumption at plant, line and asset level § Maximum Demand, Power Factor, Power Quality, Time of day analysis § Real-time anomaly detection and abnormal usage § Optimise your energy costs with unparalleled insights and what-if scenarios § Use energy as a parameter for CBM www.intellithink.in
- 16. Quality § Track rejections on the shop-floor by codes and shifts § Video data ingestion, analytics and closed loop control § Video ingestion modules on edge capture frames from Basler/RTSP for real-time analysis § Streamline inspection procedures, improve decision making, and reduce costs driven by quality defects. www.intellithink.in
- 17. Asset Management & Maintenance § A comprehensive asset database that tracks sites, maintenance history, BOM, service and parts planning § Workorder management and advanced scheduling § Service Templates mapped to work-order types § Mobility tools for technicians for WO fulfilment and part requisition § Plan service based on calendar time, usage or machine conditions § Integrate and digitize plant maintenance www.intellithink.in
- 18. Alerts, Notifications & Reports § Create rules that send alerts or create Work- orders, based on thresholds and anomalies that indicate service issues § Empower workers on the shop-floor with the right alerts and escalations for action to be taken on the shop-floor § More than 25 ready-made reports and dashboards that give provide insights § Export and schedule reports to be emailed automatically to you www.intellithink.in
- 19. Powerful Analytics & Insights § Track down-time and identify factors that are causing the maximum down-time § Map OEE to shifts and jobs to analyse trends § Understand the impact of part/job setup changeover § Build and train ML models on the edge or cloud § Identify bottlenecks, find the root cause of problems, drive plant efficiency and improve at a faster rate. www.intellithink.in
- 20. KEY BENEFITS IMPROVE Use IOT data to identify process and QA issues, improve efficiencies, reduce waste and increase profits EMPOWER Empower workers to leverage real-time KPI’s and metrics to make data driven decisions on the shop-floor PREDICT Anticipate what failures may occur and what maintenance needs to be performed on the shop floor, before they occur to prevent unplanned downtime www.intellithink.in
- 21. Case Studies Client and Problem: A large industrial estate's Effluent treatment plant was dealing with high maintenance costs and was looking at implementing condition based monitoring to lower maintenance costs and keeping machine up-time high Solution: • Energy, temperature and vibration monitoring was implemented across critical equipment at the ETP, using industry grade sensors and energy meters. • Data received from sensors on the field was aggregated to an industrial grade M2M router, which then pushed the data to the Intellithink platform. . • Rules were created on the platform to alert for anomalies on the data that was received. The data received was processed and analysed, then graphically visualized in the platform. Benefits: • Lower downtime • Condition based monitoring leading to better predictive maintenance • Real-time energy monitoring www.intellithink.in
- 22. Case Studies Client and Problem: A leading manufacturer of automotive and architectural glass. The company wanted to monitor the performance of their glass lamination lines in real-time. They also wanted to understand and analyse machine alarms which impacted production. Solution: • Intellithink installed industrial grade M2M routers that captured data from the lamination machines PLC's via OPC. • Data from the machines was transmitted data every 30 seconds to the Intellithink platform over MQTT protocol. The acquired data was persisted in the platform. • Rules were setup in the platform for notifications on machine alarms, to appropriate personnel. • Dashboards in the platform provided the customer, production and target quantities in real-time at a machine and line level. Data was analysed to map machine stoppages to productivity. Benefits: • Real-time visibility into machine and line - output vs target – OEE • Impacts of machine alarms on productivity – trends on machine health and enhance productivity • Real time escalations to increase efficiency in the shop floor www.intellithink.in
- 23. Case Studies Client and Problem: A 35 year old manufacturer based out of Chennai, India that manufactures industrial rolling components and bearing accessories. They wanted to track OEE automatically in real-time and automatically using IOT. The goal was to improve the efficiency of the assembly line. Solution: • The shop-floor had a combination of different machines, some had PLC’s which had job information, whereas others had to fitted with sensors that could calculate job start and stop times. Energy meters were also connected to calculate energy consumption and capture idle time. • Data collected from the machines was transmitted to the secure Intellithink platform via MQTT which persisted the data. • The Productivity module of Intellithink’s Manufacturing intelligence product, provided the customer with OEE, uptime, downtime calculations at a line and asset level. The functionality came out of the box with very little customisations. It provided the customer with in-depth machine utilisation at a shift level Benefits: • Real-time visibility to operations and KPI’s • Increased operational effectiveness • Better production and shift planning www.intellithink.in
- 24. Case Studies Client and Problem: • A leader in renewable energy principally involved in the fabrication and construction of wind farms • The team currently uses a heuristic model based framework for enabling predictive maintenance • The team wanted to move towards a fully automated and analytical framework for establishing predictive maintenance across all its wind farms Solution: • Identified the relationship between parameters and turbine faults • Established a comprehensive escalation matrix for issue severity identification Benefits: • The team observes decreased downtime due to appropriate predictive maintenance of wind turbines and does not need to constantly monitor the framework • The team is able to free up time from manual maintenance of the predictive maintenance framework • IntelliThink has developed an intelligent and automated framework which identifies turbines at risk of fault, creates relevant work orders and recommends appropriate corrective actions www.intellithink.in