iFactory Simplifies Digital Transformation for a Zipper Brand

Abstract

Based on meaningful insights into machine utilization, production performance and quality, and energy consumption, the zipper factory is now more able to make better production expansion strategies in Indonesia. 

Region: Indonesia

Interview with Hanggar Cahya Kusuma, CEO of Eforel

Introduction 

Being aware of the latest trends and technologies in data-driven smart manufacturing is key to remaining competitive, reducing costs, improving efficiency, and optimizing production, a large Japanese zipper brand with many factories around the world tasked Eforel to implement a smart factory solution in one of its factories in Indonesia. 

In Phase 1 of the project, Eforel implemented Advantech’s iFactory/OEE Overall Equipment Effectiveness Solution, which provides automatic data acquisition, real-time monitoring, and cross-system integration features. During the six-month trial of the OEE solution on one production line, the factory was able to automatically collect production data to analyze production performance and quality with real-time machine monitoring, helping them take immediate action whenever a machine error occurred. In Phase 2 of the project, the zipper brand decided to implement the complete iFactory Smart Manufacturing Suite on all production lines, including iFactory/OEE, iFactory/EHS Environmental Health and Safety Solution, and iFactory/EAN Event, Alarm, and Notification Solution.

Data collection: the cornerstone of smart manufacturing

To gain insights into the factory’s day-to-day operations, PLC units from 100 machines were connected to Advantech’s ESRP-SCA-UNO2484 Edge SRP/Visualizer, which has built-in WebAccess/SCADA for production data collection and conversion. The ECU-1051TL RISC-based industrial communication gateway was adopted to collect power consumption data for production machines and production-related procedures such as plating and water usage. 

The setup allowed data to be collected and converted to the MQTT protocol using the ESRP-SCA-UNO2484 and ECU-1051TL, and this data was passed to the iFactory Smart Manufacturing Suite, which was linked to the customer’s manufacturing execution system (MES). To support the integration of iFactory and the MES, Eforel helped the customer set up a database with a GraphQL interface for APIs. Eforel CEO Mr. Hanggar Cahya Kusuma said that the biggest challenge in this project was the acquisition and integration of all production related data, which involved not only iFactory and the MES but also many facilities, such as several types of PLCs as well as electricity, water, and gas supplies. Advantech’s hardware platforms unified the collected data with the built-in WebAccess/SCADA, while its flexible and expandable WISE-PaaS platform simplified the system integration process. Also, Advantech’s rich technical resources and timely support not only helped solve issues during project implementation, but it also helped fulfill the customer’s additional demands. 

Optimizing production performance and reducing costs with iFactory

After the project was completed, iFactory/OEE was able to provide real-time production numbers and defect counts, as well as data on machine status, thus improving machine visibility, production performance, and inspection quality. With iFactory/EAN, the customer was able to quickly identify and address critical events such as machine downtime and abnormal power consumption. Also, iFactory/EHS constantly monitors their power consumption. It offers an overview of past and current energy consumption data and KPI settings, allowing the customer to review energy usage while also providing a systematic approach for identifying abnormal problem areas and prime targets for energy reduction. This ensured that the customer could accurately evaluate energy costs and optimize energy efficiency. 

Mr. Kusuma concluded, “iFactory helps managers efficiently optimize production resource allocation based on real-time production-related data including production performance, machine utilization, and energy consumption.” Moreover, the customer can now calculate how much energy is required to produce one thousand pieces, making it possible to more accurately calculate production costs compared to their previous approach. Based on meaningful insights into machine utilization, production performance and quality, and energy consumption, the zipper factory is now more able to make better production expansion strategies in Indonesia. 

Benefits

• Efficiently optimize production resource allocation.
• More accurately calculate production costs compared.
• Make better production expansion strategies.

Why Advantech

Advantech’s iFactory helps managers efficiently optimize production resource allocation based on real-time production data including production performance, machine utilization, and energy consumption.