Use Case

Smart Manufacturing: equipment-as-a-service

Real-time and historical data visibility

Smart Manufacturing: quipment-as-service

CUSTOMER OVERVIEW

  • Major European manufacturer for aluminum treatments for some of the world’s largest automotive companies
  • Offers mobile, modular micro-factories that can be relocated and reused on demand

CUSTOMER GOALS

  • Improve uptime across all deployed micro-factories
  • Reduce costs associated with maintenance and downtime
  • Improve interoperability and ease integration into customers’ manufacturing facilities
  • Gain competitive advantage through new and innovative customer services and support options

Challenges:

INEFFICIENCY

Management under pressure to increase productivity of existing treatment plants without increasing costs

UNRELIABILITY

Unexpected downtime and production delays for one client cause the customer delays in delivery of mobile micro-factories to the next client

COSTS

Customer is under increasing pressure to improve efficiencies and reduce production costs for their clients

LACK OF INTERNAL KNOWLEDGE

Needs to develop a Factory-as-a-Service model that enables accurate billing based on product output

Solutions:

1

relayr’s middleware platform was integrated with the customer’s existing Siemens S7 PLC to retrieve real-time and historical data of plant operations

2

An IoT gateway programmed with relayr’s device management software was installed within the micro-factories to collect, normalize, and perform anomaly detection at the fog layer, and securely transmit that data to the relayr middleware platform cloud deployment

3

relayr’s middleware was integrated into the customer’s billing platform and ticketing system, allowing usage- based billing and automated support ticket creation when error conditions are detected through relayr’s anomaly detection

4

relayr’s multi-tenant middleware platform was configured to provide real- time and historical data to a variety of users (single plant view for operator, multi- plant view for clients, and entire-estate view for customer)

Business outcomes:

Through relayr’s end-to-end Smart Manufacturing Solution, the customer was able to implement solutions that enabled:

 

  • Real-time and historical data visibility of micro-factory operations

 

  • Automated usage-based billing directly to the end client, enabling customer to move from a CapEx customer purchasing model to an As-a-Service model

 

  • Predictive Maintenance capabilities through anomaly detection and continual machine learning, reducing unexpected downtime

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