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Blending the Right Reasons with GainSeeker Suite® to make a Sensible Investment
技术
- 功能应用 - 远程监控系统
- 分析与建模 - 实时分析
适用行业
- 消费品
- 包装
适用功能
- 质量保证
- 流程制造
用例
- 预测性维护
- 过程控制与优化
服务
- 软件设计与工程服务
- 系统集成
挑战
The quality manager for a consumer goods packaging company faced a critical issue due to recent automation of the ingredient mixing process. While automation increased first pass yield, line efficiency, and throughput, it eliminated the meticulous records previously kept by inspectors. This posed a challenge in ensuring quality data to support federal regulations, especially for long-term stability of the consumer product. The quality team envisioned software that would automatically collect data from the PLCs controlling the flow meters, providing accurate inspection documentation to satisfy federal regulators in the event of a product recall.
关于客户
Hertzler Systems has been providing seamless, accurate data acquisition solutions for over 30 years. They serve a diverse customer base in service, transactional, and manufacturing environments, including notable companies like Consolidated Biscuit Company, Darden Restaurants, Pactiv Inc., McCormick & Company, and Hormel Foods. Their customers invest in Hertzler's software and services to easily acquire data in any process, analyze it in real-time, and instantly notify process owners of process variations. These capabilities help clients reduce costs, cycle time, errors, and defects, while increasing profitability and customer service. Hertzler Systems' core competencies lie in delivering these data-driven solutions.
解决方案
Hertzler Systems provided the GainSeeker Suite, which turned detailed PLC data into actionable intelligence for each fill cycle. This software automatically collected data from the PLCs controlling the three flow meters that fed ingredients into the mix. The real-time data collection allowed key stakeholders to receive immediate alarms if there were changes in the ingredient mix, giving engineers time to proactively prevent problems. The solution also provided accurate inspection documentation that was easily identifiable and retrievable, satisfying federal regulators in the event of a product recall. This automated system ensured that the quality manager had the necessary data to maintain compliance and improve operational efficiency.
运营影响
数量效益
相关案例.
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Case Study
Improving Vending Machine Profitability with the Internet of Things (IoT)
The vending industry is undergoing a sea change, taking advantage of new technologies to go beyond just delivering snacks to creating a new retail location. Intelligent vending machines can be found in many public locations as well as company facilities, selling different types of goods and services, including even computer accessories, gold bars, tickets, and office supplies. With increasing sophistication, they may also provide time- and location-based data pertaining to sales, inventory, and customer preferences. But at the end of the day, vending machine operators know greater profitability is driven by higher sales and lower operating costs.
Case Study
IoT Data Analytics Case Study - Packaging Films Manufacturer
The company manufactures packaging films on made to order or configure to order basis. Every order has a different set of requirements from the product characteristics perspective and hence requires machine’s settings to be adjusted accordingly. If the film quality does not meet the required standards, the degraded quality impacts customer delivery causes customer dissatisfaction and results in lower margins. The biggest challenge was to identify the real root cause and devise a remedy for that.
Case Study
Zenon the Ideal Basis for An Ergonomic HMI
KHS develops and produces machines and equipment for filling and packaging in the drinks industry. Because drinks manufacturing, filling and packaging consist of a number of highly complex processes, the user-friendly and intuitive operation of equipment is increasingly gaining in significance. In order to design these processes as simple as possible for the user, KHS decided to introduce a uniform, transparent and standardized solution to the company. The HMI interface should meet the requirement for people with different qualifications and enable them to work on a standard platform.
Case Study
Series Production with Lot-size-1 Flexibility
Nobilia manufactures customized fitted kitchens with a lot size of 1. They require maximum transparency of tracking design data and individual processing steps so that they can locate a particular piece of kitchen furniture in the sequence of processes.
