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IoT COVID-19 solutions on Manufacturing

IoT Manufacturing

Business Challenge

Business challenge

As COVID-19 intensifies its grip on the world economy, the continued downward pressure on demand, production, and revenues pushes businesses to step up their typical contingency plans. Most of the of the manufacturing industries’—such as automotive, aerospace and defense, industrial, healthcare, and consumer goods—are feeling this pressure today.

About 80% of these manufacturers expect the pandemic to have a financial impact on their business, significantly higher than the 48% of cross-industry companies that are concerned about the pandemic, according to a Big Four consultant. Organizations across the world have put the safety of consumers and the workforce health at the forefront.

Additionally, the manufacturing industries grapple with hampered, on-ground operations with the reduced workforce and supply chain disruption. The reduced on-ground workforce has limited the operations and maintenance capabilities of the floor, thus affecting the overall functioning and efficiency.

IOT Proposition

Our proposition

With the new social distancing norms, the technological advances of Industry 4.0 are put to the ultimate test amid this pandemic. The existing technology solutions need to be repurposed to this hour, which is inevitable to the business contingency plans.

AR-assisted support for manufacturing operations by IoT WoRKS™, would enable efficient operations per the new norms. This solution increases the efficiency of on-ground operations with a reduced workforce, AR assistance for training, maintenance, and break-down support. It leverages and supports the line of sight of the on-ground workforce with AR-assisted help by remote expertise/technicians.

Real-time manufacturing insights (RMI) uses the Internet of Things to digitize and automate the manual processes on the floor, thus optimizing capacity utilization with a reduced workforce and disrupted raw material supply. A dashboard view of the floor operations—inventory levels, assembly line (with the critical parameters), and finished goods from across plants in different geographies—provides crucial decision support at several levels of the organization. Predictive maintenance, coupled with prescriptive insights, helps elude unplanned downtime and act promptly with the reduced workforce and resources.

Live social distancing monitoring (LSDM) solution combines radar sensors, AI models, and retrofittable, distributed architecture that can provide real-time locational insights on workforce movements, identify potential hotspots, generate alerts to optimize business operations proactively, monitor occupancy, and ensure disease-free premises.

IOT Impact

The impact

Our propositions enable enhanced workforce safety while optimizing operations with reduced resources, thus making the business flexible and agile for deployment in compliance with the new norms.

AR-assisted support for manufacturing operations drives a digitally enabled and safe workplace that could run with a flexible workforce. This, in turn, maintains and improves productivity as well as operational efficiency in these unprecedented times. The AR-assisted support reduces the time required to assemble complex machinery by 25% and with higher accuracy. This solution also enables productivity gains of an organization by 25%, due to the digital assistant alone.

Real-time manufacturing insights (RMI) enables a reduction in losses due to unplanned downtime—the single largest source of lost production time for most manufacturers, by about 30%. The continuous monitoring capabilities of the solution also reduce maintenance costs by about 30% and provide insight into the financial impact due to OEE losses. Increased visibility into asset health thereby improves productivity by about 10-15%.

Live social distancing monitoring (LSDM) solution enables businesses to automate social distancing, thus reimagining zero-contact premises, helping restore business continuity and operational profitability, and most important, ensures real-time monitoring and maintenance of people and workforce safety.

While the world economy gears up for a long-lasting impact of this pandemic, it is crucial to promptly tackle these challenges for a safer and stronger post-COVID world.

AR-assisted support for manufacturing operations

Remote operations with an optimized workforce

Features

Remote mentor

Remote mentor

Real-time expert guidance to a field technician on an asset site

Guided operations

Guided operations

Step-by-step instructions to resolve any technical issue at the asset location

Digitization of content

Digitization of content

Access to digital documentation and information

Access to a repository

Access to repository

A repository of training videos to enable the technician before visiting the site

Hands-free

Hands-free, zero-contact device

With intuitive navigation and voice-enabled application

Real-time sensor

Real-time sensor

IoT data visualization of OT asset parameters

Benefits

 
Enable minimal, critical workforce

Enable minimal, critical workforce

Deployment in compliance with social distancing norms

Enhanced safety

Enhanced safety

With real-time sensor data such as temperature, pressure, and rotation speed rendered on AR devices

High first-time success rate

High first-time success rate

With improved efficiency of service operations

Workforce optimization

Workforce optimization

With reduced field workforce requirements, and improved utilization

Reduction

Reduction

In service costs, workforce training costs, and unplanned downtime

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Real-time manufacturing insights

Real-time operational visibility, from shop-floor to top-floor

Features

Real-time monitoring

Real-time monitoring

Of plant efficiency with user-defined KPIs

Real-time alerts

Real-time alerts

To the pre-configured users via email or mobile

Predictive maintenance

Predictive maintenance

To preempt machine breakdown and line-availability issues

Cost analysis of OEE losses

Cost analysis of OEE losses

Availability loss, performance loss, and quality loss

Connectivity support

Connectivity support

With system integration of IT/OT systems

Monitor and manage

Monitor and manage

Machine connectivity across the floor, quickly troubleshoot issues

Benefits

 
Reduce unplanned downtime

Reduce unplanned downtime

By improved fault prediction, planning of remedial actions

Reduce scrap loss

Reduce scrap loss

By real-time alert in output quality drop

Increased visibility

Increased visibility

Into asset health throughout processes

Real-time visibility of finished goods inventory

Real-time visibility of finished goods inventory

To reduce inventory carrying costs

Predictive & Preventive Maintenance

Predictive and preventive maintenance

To reduce machine maintenance costs

Real-time actionable insights

Real-time actionable insights

To achieve higher productivity and better-quality goods

Live social distancing monitoring solution

Reimagine compliant, secure premises

Features

Dwell Times

Dwell times

Can be correlated with queues and wait times, enable live adjustments for smoother operations

Real-time Alerts

Real-time alerts

Triggered when queue, footfall cross threshold and, on detection of infection

Heatmaps and Interactive Cloud-based Dashboards

Heat maps, interactive cloud-based dashboards

Enable visibility of live and legacy insights

Advanced Insights

Advanced insights

Track footfall patterns, integrate with identified hotspots, contact tracing

Benefits

Redefine New Normal

Redefine ‘new normal’

Utilize insights to slow spread, minimize losses, reduce health-care spend

Automate Social-Distancing

Automate social distancing

Premise monitoring, automated alerts help automate social distancing

Optimize Operations

Optimize operations

Manage layout, footfall based on queues, dwell times for smooth operations

Ensure Safe Premises

Ensure safe premises

Maintain business continuity, profitability, safety of people, and workforce

Scale & Transform

Scale and transform

Retrofittable, distributed computing enables rapid implementation at scale

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