Smart Manufacturing Suitefor Plastic, Print & Packaging Industry

Plastics and print/packaging plant owners are often challenged to keep costs under control and maximize productivity in a

highly demanding and cost competitive market. This calls for:

The Solution

Introduction

Lack of right information to the right people at the right place and right time leaves plant managers and personnel struggling to

meet these challenges. Expansive plants and multiple distributed plant locations only compound the challenges. A centralized

on-line real time Decision Support System that would empower personnel with the crisp information on the device of their

choice i.e. laptop, mobile phones or tablets would help meet these challenges. Such a system will involve:

1. Continuous monitoring of plant assets for real time information on:

a. Production

b. Productivity

c. Availability

d. Losses

e. O.E.E.

2. Continuous tracking of critical process parameters that help:

a. Identify and address deviations quickly

b. Track equipment health / condition to instill and manage predictive / condition based maintenance

3. Real-time reporting of KPI's like specific resource consumption, O.E.E., batch change time, production etc. that help keep track of operational effectiveness and performance

4. Alerts intimating plant users about critical plant conditions before they get out of hand

Ÿ Continuous and aggressive management of operations and maintenance practices to maximize Overall Equipment Effectiveness (O.E.E.)

Ÿ Quick response to deviations from Standard Operating Conditions to minimize revenue loss and ensure effective use of skilled man-power

Ÿ Optimization of specific resource consumption (air, water, electricity, fuel etc.) to reduce operating costs

Ÿ Maximize equipment life while minimizing Total Cost of Ownership (T.C.O.) Critical aspects like cycle time of job, thermal and electrical energy consumption, solvent consumption etc. are a complex

function of material type, size of job, number of colours to be printed, speed of operation, ambient temperature, seasonal

variation etc., making it even more challenging to manage.

Benefits for End Users

Benefits for OEMs

Ÿ Remotely monitor performance of multiple equipment at multiple sites

Ÿ Use role based analytics for crisp and actionable information - empower key stake-holders in operations, maintenance, top management etc. for quick redressal of issues.

Ÿ Continuously track KPIs like OEE, MTBF (Mean Time Between Failures) and MTTR (Mean Time to Repair) and specific fuel consumption to maximise efficiency and minimise total cost of ownership

Ÿ Maximize availability through tracking of service compliance and service effectiveness in terms of critical parameters

Ÿ Perform quick root cause analysis through tracking frequently occurring faults and key associated parameters

Ÿ Integrate easily with existing PLCs and controllers

Ÿ Remotely monitor installed base of equipment in the field to provide proactive service

Ÿ Customized dashboards & reports over PC, Laptop & smart devices

Ÿ Important alerts/ notifications via email & SMS

Ÿ Region wise/model wise/dealer wise classification of information

Ÿ Condition based maintenance – track maintenance due of remotely based on equipment run hours

Ÿ Manage service man-power deputation and spares logistics

Ÿ Achieve first visit resolution - minimize service costs and maximize service revenue

Ÿ Benchmark equipment performance and evaluate performance against benchmark

Ÿ Remotely evaluate performance of new designs and design changes in the field

Ÿ Remotely evaluate capacity utilization, loading patterns and identify cross and up-selling opportunities

Ÿ Track frequently occurring faults - improve equipment availability

Ÿ Track critical parameters and perform root cause analysis of frequently occurring faults

Ÿ Integrate easily with existing PLCs and sensors

Ÿ Delight your customers – help them enhance equipment life and minimize Total Cost of Ownership (TCO)

Data Acquisition: EcoAxis deploys hardware data-loggers and software connectors for collection of field information from

machine PLCs, sensors like temperature and pressure sensors, smart instruments like energy meters etc. and streams the

data thus collated over the web using either in-built GPRS modems or Ethernet LAN, to a cloud server.

Data Management: The cloud server provides for a big data ware-house for collating & managing field information in a

structured format.

KPIs & Advance Analytics: The cloud server also provides dashboards, notifications & alerts for important information

through email or SMS using state of the art BI tools.

Production Overview

Maintenance4%

Job Changeover13%

In Se�ng 13%

Machine TRIP4%

Other4%

Produc�on67%

Washing4%

Machine Run SummaryMachine Run SummaryOEE & OEE Trend

Downtime Analysis

A.T.E. ENTERPRISES PRIVATE LIMITED

T-126, T Block, MIDC, Bhosari, Pune 411 026T | +91 20 3088 1100 E | contact@ecoaxisindia.comW | www.ecoaxisindia.com / www.ateindia.com

(Business Unit: ) EcoAxis

Waste watereffluent disposal

monitoring

Continuous Measurement &

Verification (CMV)

Analytics for renewable

energy

Discrete equipment monitoring

Facility monitoring

Utilities monitoring

Plant process monitoring

Understand your most critical challenges

Setup systems to collate the most pertinent data

Data acquisition & historization

Build advanced analytics

Generate insights for better decisions

Cloud based platform

EcoAxis Solution

Manual Entry

Trending Tabular

Data

Export

to Excel

Export

to Pdf

ax si EYE - Historian

EcoAxis Hardware

OPC Client

Process 1

Process 2

Process 3

Process n

Basic Functionality

Additional Information

Any device, Anytime, Anywhere

Alerts & NotificationsAnalytics

GURUax si NOTIFYax si

Your Scope Our Solution

Process 4

Data Acquisition Data Management Advanced Analytics