Case 1: Solar Cell Manufacturing
Large-Scale Data Tracking, Integration & Accessibility
This client is one of the leading solar cell manufacturers in the world. With manufacturing spread through multiple facilities, and through a variety of machines. Our Facto-Tools were able to provide a solution to track, manage and organize this data, in addition to providing accessibility to high-level data, as well as granular data.
Old Processes & Issues They Faced
Manual performance tracking was cumbersome in a company stretched across multiple manufacturing plants. Our focus was bringing the systems together, and being able to both automate processes and track data throughout. In addition, we wanted to create a multitude of dashboards to have access to all of this data, in a clean, organized manner.
Facto-Tools We Implemented
Main Issues We Addressed.
01. Efficient Tracking: In their current process, performance tracking of individual machines from a single location was cumbersome. Parameters such as individual machine runtime, downtime, the reason for downtime etc. were not being captured efficiently.
02. Real-Time Monitoring: An MES application was designed & developed using Ignition for real-time production monitoring. Ignition was used as the SCADA to take care of all the above requirements and work in sync with the individual, real-time production processes.
03. Big-Data Management: With such a large operation, there were billions of data points and millions of datasets to organize & display – through our Facto-Tools, we were able to both capture this data and present it in clean, intuitive dashboards.
Primary Features of Our Solution.
A legacy system was already in place, but it was not efficient enough to meet the requirements. A lot of manual effort was needed to maintain constant output. Also, machine data was supposed to be captured in real-time to have correct production charts, but produced materials were too numerous to use bar codes.
Ignition was used as the SCADA to take care of all the above requirements and work in sync with the individual, real-time production processes. An MES application was designed and developed using Ignition for real-time production monitoring. All locations were integrated using a single server. The handshake with the ERP was done efficiently and the client was very impressed with the integration and performance of the system.
A Data-Driven Solution to Impact their Bottom Line.
Ignition was used as the SCADA to take care of all the above requirements and work in sync with the individual, real-time production processes. An MES application was designed & developed using Ignition for real-time production monitoring.
OpteBiz achieved a 2% reduction in downtime, 10% improvement in processing throughput, and helped the client achieve a paperless environment, which results in large cost savings.
Improvement in processing throughout the facilities.
Reduction in total Downtime.
The Optebiz Advantage.
Our expert team of consultants and proprietary tools enable your business to collect and analyze current and historical data. Our FactoTools break this data down, providing key insights of your business. Whether it’s on a small scale, or dealing with big-data on a multi-plant scale, we digest the data and present it through intuitive dashboards and reports built for you – giving you an in-depth oversight of your operations.
Our solutions are flexible – we can design web based or mobile solutions to fit your needs – giving you access anytime, anywhere.
A Trusted, Reliable Partner to Support Ops
Optebiz is an ISA-95 certified company for enterprise automation. We are also a preferred partner of Inductive Automation for consulting and implementation of Ignition based solutions across diverse manufacturing industries. With a comprehensive implementation and support experience of over 20 years, we build customized, reliable solutions for all of your MES tracking and reporting needs.
We’re here for you every step of the way. Contact us to get started!