The Overview

Our client, a leading organisation in the manufacturing sector, sought to enhance the operational efficiency and reliability of their critical equipment. With facilities spanning key areas like the Assembly Line, Machining Line, Paint Shop, and Chassis Production, they required an advanced solution to address the limitations of traditional monitoring methods.

The Challenge:

Our client sought an advanced solution to ensure the optimal performance and health of their equipment and sensors located within their headquarters. Their facilities included key operational areas such as the Assembly Line (Transfer Line), Machining Line (Heat Treatment Plant), Paint Shop, and Chassis Production.

With critical assets dispersed across these areas, traditional monitoring methods proved inadequate. The client faced the challenge of detecting real-time issues while preventing potential failures. They required a centralized and integrated system that would:

Our solution:

To address these challenges, we proposed a cutting-edge Condition Monitoring System powered by a Digital Twin. This solution seamlessly integrates data from multiple sources, including IoT sensors, equipment, and live camera feeds, into a unified digital twin dashboard.

Key features of the solution included:

• Real-Time Data Integration: Live camera feeds and IoT sensor data were integrated to provide comprehensive, up-to-the-minute insights.
• Alerts and Alarms: A robust mechanism was developed to generate alerts and alarms for any detected anomalies, ensuring immediate attention to critical issues.
• Enhanced User Interface : The solution was tailored to integrate with the client’s large control room digital screen, providing an intuitive and immersive user experience.
• Continuous Monitoring: The digital twin enabled continuous monitoring of asset performance and condition, offering actionable insights to the team.

This innovative system empowers the client to monitor and manage equipment effectively, enhancing operational performance while reducing risks.

The Results

The implementation of the Condition Monitoring System using Digital Twin delivered transformative benefits:

• Proactive Issue Detection: By accessing live camera feeds through the Digital Twin and processing sensor data via AHI Middleware, the system provided a centralized platform to monitor the health of assets.
• Reduced Downtime : The predictive capabilities allowed the client to detect performance issues early, preventing costly equipment failures and reducing downtime.
• Enhanced Operational Efficiency : Real-time insights enabled quick decision-making, leading to streamlined processes and improved productivity.
• Optimized Asset Performance : Continuous monitoring and predictive maintenance extended the lifespan of critical equipment, ensuring maximum operational reliability.

Business Value Added

This innovative solution transformed the client’s operations, providing them with the tools to achieve greater efficiency, reliability, and risk management across their headquarters.