Industry 4.0 – Enabling Smart Factories

Our IIoT Center of excellence provides services at the intersection of Data Science and Manufacturing, redefining the micro economics of production floor. Our team is equipped to rapidly develop and deploy enterprise grade applications that organize, analyze, learn, predict, and operationalize your data. We leverage our Factory.360 platform to help you predict and pre-empt breakdowns, control asset health, improve OEE, reduce anomaly rates, etc. Our augmented reality platform virtualizes your factory floor helping you to increase value derived from your data.

Factory.360 platform

Ideas2IT’s Factory.360 platform provides a 360(degree) visibility of all your factory’s manufacturing floors in real time. Our platform digitizes plant operator’s intelligence using pattern recognition algorithms on inputs from disparate sources such as machines, controllers, sensors, SCADA, ERP, CRM, shopfloor, and unstructured data. The resulting mathematical models provide you actionable insights helping you to improve quality and reduce cost.

Our asset management system allows you to track all your assets across all plants and shopfloors. In integration with our ticketing system, it allows maintenance engineers to plan and track both scheduled and unscheduled work orders. Our configurable rules and workflow engine enable you to easily customize the platform to fit the needs of your factory.

Our platform for Augmented Reality presents data to technicians in an interactive format allowing maintenance heads to virtually train new maintenance personnel. Instead of leafing through pages of assembly manuals, engineers can utilize Augmently.360 to interactively assemble complex machines with higher efficiency. Factory.360 takes off the weight of day to day activities so that you can focus on your core business.



The Factory.360 framework

Acquisition

Consumes machine data, shop floor data (structured and unstructured), and enterprise data in raw form. Data from relational databases such as RDBMS, semi-structured data and binary data is collected in its original format and pooled into a data lake. This collection of data allows you to scale to data of any size, while saving time of defining data structures, schema, and transformations. Cleansing, de-duplication and aggregation of large amounts of data is performed so as to host a complete set of data sufficient for a 360-degree view of your factory.

Analysis

We have a highly scalable streaming and analytics platform with pre-built models. Our Data Analysis Platform leverages Workflow Engine, Rules Engine, Machine Learning, Deep Learning, and AI logics like KRR to deduce patterns based on historical data and external data from sensors. It implements analytics and visualization use cases such as plant-wise performance and factors contributing to machine failure. The platform also offers insights to decrease downtime, identify risks and optimize machine efficiency, allowing you to stop guessing and start predicting.

Action

Factory.360 provides multiple features such as Predictive Maintenance, Asset Maintenance, Augmented Reality, and Dashboards with real-time metrics and views that you need for a inside out view of your factory. It also provides audience-based perspectives and actionable insights for each persona – Operations Manager, Maintenance Manager, Plant Manager, GM. Maintenance Manager, CFO, etc. For example, a CIO can pull up a performance comparison across plants, a CFO can look at the macro factors impacting bottomline, while a line manager can get an equipment fixed before it fails, etc.

Asset Management

Tracks all your IT and Non IT assets in one place establishing a clean baseline and tight control over your assets. IT assets are automatically discovered using our discovery engine. fAsset.360 allows you to track warranty, define conditions for monitoring of assets, manage maintenance activities (routine and non routine), track depreciation and asset replacement, and gain a complete view of distribution of your assets across factories. In sync with our workflow engine and rules engine, our asset management platform lends itself to easy customization of workflow and fields leading to lower development cost and time.

Platform Highlights

Our Factory.360 platform is a comprehensive solution for the entire Industry 4.0 journey. These are some of the features guaranteed to usher your factory into the next decade of technical advancement.

Maintenance View

Our Predictive Maintenance solution is built on an IoT platform. Its components can integrate seamlessly to any third party component. It augments ML to Knowledge Representation formalisms to perform smart logistics and forecasting. Pre-built model kits have regression and survival models, and our asset library consolidates and reconciles multiple asset data sources for up-to-date information.

Persona Perspectives

Instead of looking at any event in isolation, Factory.360 analyses holistically and gives insights specific to each role. Performs multi-segmented analysis on the collected pool of machine, enterprise and factory floor data to give a multifaceted department-specific view: Financial Analysis for the CFO, Machine Capacity Analysis for the Plant Manager, WIP Inventory Analysis for the Floor Manager, etc.

Augmented Reality

Augmently.360, our AR-prototyping platform, bridges the gap between the Digital and Physical world. It leverages the richness of 3D and transforms users’ interaction with product. It supports users in product assembly and maintenance within batch production lines, provides on the job training by leveraging key workflows and procedures from existing technical publications, and aids selling by allowing interactive exploring of features.

Other Features

Ideas2IT’s Factory.360 platform has a suite of software for smart manufacturing. From asset management to Machine Learning, every module of the platform integrates easily with existing back-ends (MES, ERP, etc) and is customizable for individual factories. You can forever change the way your factory works. Use our platform for exclusive passes to a new era of digital manufacturing!

Condition Monitoring

Condition Monitoring

We leverage sound and vibration analytics to decide when a machine is working outside normal conditions. Then, we parse through thousands of data points using Machine Learning to understand which conditions really affect the state of the machine.

Predictive Maintenance

Predictive Maintenance

Our IIoT framework builds out Machine Learning models based on volumes of data. We use open-source scalable ML models like Spark MLlib and commercial offerings like SPSS from IBM or Azure ML for Microsoft.

Incident Correlation

Incident Correlation

Multiple sources can create a flood of noisy alarms. Our IIoT solution intelligently clusters the IT alarms/alerts and correlates into high-level related incidents know as ‘situations’, which are much easier to manage than thousands of disparate alerts.

Incident Scoring

Incident Scoring

Manual prioritization is subjective and often devolves into FIFO. Our IIoT solution automatically prioritizes incidents (or situations, once the incidents are correlated) by analyzing severity, level of disruption, incident duration, and other parameters.

Root Cause Analysis

Root Cause Analysis

Use Machine Learning to automatically sort through massive volumes of log messages and identify messages that are truly relevant. We use powerful analysis algorithms that self-learn over time, providing fresh insights to find the root cause of the problem every time.

IIoT Security

As IoT and M2M technology increases, so does the risk of managing countless assets, thermostats, lightings, refrigeration units, etc. Factory.360 platform secures cyber physical systems with advanced solutions purpose built for Industrial and IoT devices. We partner with Industries to treat IoT Security as a journey and not an end goal.

Our platform focuses on securing applications at three levels:

  • 1 Device Level
  • 2 Communication Level
  • 3 Cloud or application level

To read more about some of the best practices that should be adopted for your IIoT applications, download our ebook.

Recent Blogs

At Ideas2IT, we learn every day. From product engineering to data science, from blockchain to chatbots, our experts discuss driving forces at the intersection of tech and business. We look at business through the lens of technology, and break down how cutting-edge tech will alter the way companies in various industries operate. These are some of our learnings from working with factories and helping them along the Industry 4.0 journey.

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Industry 4.0 Use Cases for Manufacturing

The first industrial revolution began in the late 18th century, with the mechanization of the textile industry. Nearly a century later, in the second half of the 20th century, the third industrial revolution appeared with the emergence of computers and the beginnings of automation, when robots and machines began to replace human workers on the assembly lines.

18 JANUARY 2018

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Condition-Based Maintenance Explained in Simple Terms

Condition-based maintenance (CBM) is about using the actual data gathered from the assets to decide what maintenance activity needs to be performed on the physical assets being monitored. In other words, it is a maintenance strategy that measures operational parameters in assets to determine a change in their condition, performing maintenance only when the need arises.

22 JUNE 2018

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The Future: Convergence of IoT, AI, and Blockchain

The next big change that seems to be sweeping the industry is the triad of Artificial Intelligence, Internet of Things, and blockchain. Individually, these technologies seem to have endless use cases and possibilities. However, put them together and the transformative effect seems to become multifold, forcing us to extend our imagination and reimagine the art of the possible.

09 FEBRUARY 2018

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