KCBS Expertise - iotone.com › files › pdf › vendor › KC_PDF... · production and condition...
Transcript of KCBS Expertise - iotone.com › files › pdf › vendor › KC_PDF... · production and condition...
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• KCBS Expertise
• KCBS Hardware Specifications
• Case Studies of our Successful Implementations
• KCBS Solutions Overview
• Our Value Proposition & ROI
• About KCBS
TOPICS
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Shop-floor Automation and Management
Industry 4.0 / Industrial IoT Solutions
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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MACHINE DATA ACQUISITION IS OUR EXPERTISE
We collect machine data thro’
sensors, Interfaces and generate
live dash boards, alerts and insights.
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Our Domain Expertise
• IoT Enabling Products for Field Performance Monitoring
• Energy Monitoring Application for all Industries
• Discrete Manufacturing, Machine Tools Industry
• Plastic and Injection and Blow Molding
• Metal Casting and Forging
• Painting, Electroplating and Galvanizing plants
• Cooling Towers
• Metal Fabrication and Welding
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Ethernet
Machine Runtime, Idle & Breakdown time Overall Equipment efficiency
Alerts for over speeding and mis-use Alerts for Coolant and Lubrication levels Production Qty, Rejection rates Actual Cutting time, Tool life alert Vibration and Energy Trends
ACS712
Current Vibration Sensor Sensor
KCBS Data Logger
Use Case: Moni tor CNC machines to improve Equipment e f f ic iency,
ef fect ive energy management and reduce machine breakdowns
Benefits Achieved:
• 20% Improvement in operator efficiency
• 30% reduction in failures
• 15% reduction in energy consumption
Client: Leading Automotive parts
manufacturer MNC in India
• KCBS CNC monitoring solution acquires
production and condition parameters using
standard libraries like FOCAS or KCBS data
logger.
• Live dashboards, Alerts and Reports helps to
improve the equipment efficiency.
• KCBS’ s proprietary Vibration sensors provides
real-time accurate vibration data that helps to
avoid machine breakdowns.
• Energy Monitoring helps to manage the energy
usage effectively Project Status: Running for 1+
years (installed base 50 CNC machines).
• Phase 2 being planned for additional 350
machines.
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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• KCBS cloud based compressor monitoring solution
helps to monitor critical parameters of the
compressors and manage them remotely
• Live dashboards and Reports helps to improve the
equipment efficiency
• Alerts on set parameters help to take preventive action
to avoid compressor break downs
• Energy Monitoring helps to manage the energy usage
effectively
• Project Status: Pilot implementation(10 machines)
Use Case: Manage Compressors remotely, monitor critical
parameters and create Alerts
Benefits (Target):• 20% Improvement in operator efficiency• 10% reduction in failures• 15% reduction in energy consumption
Client: Leading Screw Compressors OEM in India
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Use Case: Monitor
Electroplating machines to
improve efficiency, reduce
machine breakdowns and
manage consumables
Benefits (Target):• 20% Improvement in operator efficiency• 10% reduction in failures• 25% reduction in Consumable consumption
Client: Leading Electroplating
Company in India
• KCBS Electroplating Machine Monitoring Solution Acquires Production And Condition Parameters Level, ph, temp, current) kcbs Data Logger
• Live Dashboards, Alerts And Reports Helps To Improve The Equipment Efficiency
• Storage Tank Management Helps To Effectively Manage The Consumables In The Storage Tank
• Project Status: Pilot Implementation
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Use Case: Remote Machine Monitoring Of Captive/Ancillary
Units To Manage Production Efficiently
• KCBS Cloud I-IoT solution offers a machine monitoring solution that enables the Manufacturer to
manage the production and equipment efficiency of their Ancillary units effectively from Remote.
• The Mobile access to the application enables to view live dashboard and reports from anywhere.
• The solution offers to manage both Manufacturer’s shop-floors and their ancillary unit’s machines help
them to have visibility on overall production and effective usage of their equipment.
Project Status: Running for 8 months with 2 captive& 2 comakers(25 plus CNC machines)
Benefits Achieved:• 20% Improvement in production efficiency• 10% reduction in downtime
Client: Leading Jewellery and Watch
Manufacturer in India
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Client: Leading FMCG Bottling
Plant in India
Benefits Achieved:• 20% Improvement in production efficiency• 10% reduction in downtime• 15% reduction in energy consumption
• KCBS Injection molding machine monitoring solution helps to reduce downtime and energy costs
• Live dashboards and Reports helps to improve the equipment efficiency
• Alerts on set parameters help to take preventive action to avoid break downs
• Energy Monitoring helps to manage the energy usage effectively and reduce energy costs
Project Status Running for 6 months(8 m/cs pilot 76 Total number of machines)
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Use Case: IoT Solution - Metal Foundry - Melting Process
Productivity/Efficiency
Benefits (Target):• 20% Improvement in production efficiency• 10% reduction in downtime• 15% reduction in energy consumption
Client: Leading Auto Industry Steel
Foundry Plant in India
• Digitization Of Manual Value AddedProcesses-input And Output Process OfMelting Furnace
• Sensor To Cloud Solution To Extract Data –
Efficiency Condition Parameters
• Dashboards/Kpi’s Including Mobile App
• Integration With ERP System
• Project Status Pilot Implementation
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Use Case: IoT Solution to manage cooling towers remotely
to improve operation efficiency and manage failures
Client: Leading Cooling Towers
company in India
Benefits (Target):
• 20% Improvement in operator efficiency
• 30% reduction in failures
• 15% reduction in energy consumption
• KCBS IoT solution for Cooling towers
collects critical parameters and sends them
to KCBS cloud for live monitoring and
alerting
• The cloud model helps to manage the
cooling towers remotely
• Energy data monitoring and analytics helps
to take appropriate action reduce energy
consumption
• Project Status: Pilot implementation
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Use Case: Iot Based Solution For Solenoid Actuators
To Reduce Abrupt Breakdowns
• KCBS Solenoid life monitoring solution helps to monitor the usage and send predictivemaintenance alerts
• KCBS IoT device installed with every Solenoid actuator sends actuators life data to KCBSmobile App on demand
• KCBS IoT device installed with every Solenoid actuator sends actuators life data to KCBS
mobile App on demand Project Status Running for 10 months -100 pcs
Benefits Achieved:
• 20% Improvement in production efficiency
• 10% reduction in downtime
Client: Leading Solenoid
manufacturers in India
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Iot Enabled Distribution Transformers
GPS Enabled Remote Monitoring And Alerts Thro’ SMS
• Client : Japanese conglomerate, Market leader in Power Systems, Social Infra
Equipments, Semiconductors and Office Mobile Devices,
• KCBS Scope : Development of Hardware, Firmware, AWS -IoT porting From PoC to
Field Beta Testing
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Iot Enabled Distribution Transformers
GPS Enabled Remote Monitoring And Alerts Thro’ SMS
Functionalities Supported
• Monitoring oil Temperature
• Monitoring oil Level
• Tamper Detection
• GSM-GPRS Data and Alarms thro ’ SMS
• Audio – Visual Alarms
• GPS position indication
• Battery based operations, Battery Back up for 1 hour (min)
• Three Phase LV Current and Voltage Measurement
• Amazon Web Services – IoT Implementation
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Ethernet / RS232 / RS485
Fanuc / Siemens / HaaS / Mitsubishi / Makino CNC Machines
Category 1
K-TypeACS712 ThermocoupleADXL345Current Accelerometer Temp Sensor
Sensor Vibration Sensor
Category 2
Conventional CNC Machines, Special Purpose Machines
Live Dash BoardsAnd Alerts
Office Mobile Devices
On-Premise CNC Machine Monitoring Solution
Float typeLevel Sensor
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Operator Dashboard
Operator dashboard can show the machines belong to the logged-in Employee with Employee ID, Login time, Date, Shift details are displayed
along with live production and OEE data
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Shop-floor Paperless Management
• Operator enters data before shift starts• Selects Employee ID• Select the FG part number of the product to
be produced for the shift• Number of products per cycle
Data Collection when shift starts
• Machine goes to Idle status for more than 15 minutes, Operator will be alerted to book idle time
• Operator books idle-time under Break-down reasons
Operator Idle Time Booking
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Tool-life Management
Tool life Monitoring and SMS Alerts
• Tool list with Life Count and Current Count
• Send SMS Alerts to Tool room for life crossing 90%
• Update tool data from Barcode/ QR code
• History reports of Tools
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Preventive Maintenance
Configuration Schedule
Analyze with Alarm historyand enhance checklist
Maintenance Execution
Analyze and Enhance checklist
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Shop-floor Quality Management
Operator scans the part after production
• Operator inspects the part after the production
• Classify into good, rework needed and rejected
• Operator Rework reason or Reject reason on
Operator dashboard based on the quality
Operator inspects and enter quality data
• Optional Barcode or QR code scanning for
part count
• Operator scans for each product after the
production
• Part count from scanner will override the
part count from machine that gives better
accuracy
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Energy Management – Live Dashboard
Power Factor Avg 0.999000013
Power Factor Red 0.999000013
Power Factor Yellow 0
Power Factor Blue 0
Frequency 50.08371353
Voltage Line to Line 162.1385651
Voltage Line to Nuetral 81.05152893
Voltage Red Yellow 243.0788269
Voltage Yellow Blue 0
Voltage Blue Red 243.3368683
Ampere Avg 0.148502842
Ampere Red 0.44550854
Ampere Yellow 0
Ampere Blue 0
Watt_Total 108.3701172
Watt Red 108.3701172
Watt Yellow 0
Watt Blue 0
Watt_Hour 29.90679169
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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ERP Integration
ERP integration for Work Order Management
• KCBS has flexible options to integrate with existing ERP applications
• APIs or direct DB access, KCBS can read and write data to pull work orders to be processed for the particular machine, day and shift and sends data back to ERP
Planning integration
• Shift planning to process work orders for each machine and
manage operators for each Bay/Zone/Cell to execute
orders can be pulled from the existing ERP system and
integrated with KCBS.
• KCBS paperless shop-floor automation with ERP integration
gives a seamless complete solution.
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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We Help To Improve Machine Utilization, Quality And Reduce
Operational Cost
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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Customer Benefits And Roi
Maximize production by monitoring and
improving OEE
-10%
+20%
-10%Reduction in machine downtime by
predictive maintenance
Reduction in energy costs by monitoring
And reducing power consumption per part
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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www.kcbsindia.com | [email protected] | +91-9444 35 38 16
Bin Management Solution for Assembly warehouses
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OUR VISION OUR MISSION OUR MOTTO
Our vision is to be the highest level of IOT
solutions and service provider to satisfy our
clients’ expectations and to provide an environment to
prove the excellence
To help our clients achieve their business objectives by providing innovative, best-
in-class consulting, IOT solutions and services. To
direct all our efforts in achieving the excellence in
current IOT industry.
Our business should benefit the people and
society. We devote our talent and technology to create superior products
and services that
contribute to the economy of our nation
About Us
www.kcbsindia.com | [email protected] | +91-9444 35 38 16
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OUR PROJECT FLOW
KCBS evolves client-specific strategic initiatives with a dual aim to achieve cost
savings, and to improve on quality of services offered
PLAN &CREATE!
BUILD ASKILLED TEAM
MAKE QUALITYPRODUCTS
PUBLISHWORLDWIDE!
1 2 3 4
The Foundation of any
successful business
starts with a rock solid
plan of action
We had a good and
effective team, who are
having confidence to
handle any kind issues
in the project
We are committed to
provide quality
products and services
to our customers which
will enhance their
productivity
We delivers a wide-
range of value added
services adopting a
unique approach of
integrating people,
processes and
technology
Our Project Flow
www.kcbsindia.com | [email protected] | +91-9444 35 38 16