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IIoT – Industry 4.0

Are you one of those manufacturers who usually get stuck with managing the industrial assets, machine operations, replenishment of goods, re-ordering, procurement, and other operations? Do you require help to addresses these issues with simple technology solutions to help you operate, innovate and grow? If yes, then it is always better to choose an ERP for industrial automation. From automotive manufacturers to telecommunication, medical devices to high-tech manufacturers, every business owner is looking for an intelligent ERP solution that can be integrated with IoT devices and make day-to-day work easier.

Since decades, manufacturing companies endeavour to stay competitive while retaining their customers. Evolving technology and changing customer demand can reflect the production cycle and the entire business. For those organizations who want to outpace the market and stay a top, Industrial IoT (IIOT) is the apt solution. We deliver rich discrete smarter and scalable IIOT systems and helps you to streamline your Production processes and Quality processes. You can also gain a greater insight into your operations so that you can act fast and make decisions based on real-time information, and help you drive profitable growth 

Leveraging the extensive data generated and accumulated within a company is essential for enhancing both productivity and quality. By designing systems that record overall production performance in real-time, organizations can gain valuable insights into their assets operational status. Data collected from various sensors allows for a comprehensive visualization of machine performance and quantification of product quality. Connecting sensors, devices, and machines to a network enables organizations to analyse the vast amounts of information processed in real-time, transforming raw data into actionable intelligence. Monitoring systems gather production data from multiple sources along the production line, providing managers and staff with critical information to improve efficiencies. This data-driven approach empowers teams to make better and faster decisions, ultimately increasing overall production volume and operational speed. Continuous performance analysis using asset data and real-time monitoring is vital for driving ongoing improvements. By focusing on control, enhancement, and transformation, companies can elevate their production efficiency, leading to significant impacts on productivity. Additionally, operators are empowered to meet production goals through real-time visualization of machine status via dashboards, which facilitates continuous asset inspection, real-time data collection, and onsite process monitoring. Daily insights and reporting on assets foster effective management and control over product quality and processes, ensuring consistency while maintaining specifications and improving operational efficiency. This holistic approach not only streamlines production but also cultivates a culture of continuous improvement that is crucial in today’s competitive landscape.

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Control
Control your operations by highlighting the issues
in real-time and alert your people to respond to the
right issue at the right time in right way
Improve
Graphical Analysis & Charts to identify the root
causes, leading continuous improvement & fruitful
decision making.
Transform
Aligning people, process & technology to create a
transformative change and ensuring efficiency in
their processes and maximising productivity.
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In IIOT, the primary focus is asset management – where we Monitor, Analyse and Optimize your assets that helps to achieve

Optimized Production Processes

Optimized Production Processes

Optimized Production Processes

With production optimization, an industry is in a better position to understand and manage its production processes and bottlenecks. Manufacturers optimize the industry assets for productivity and delivery times. As a result, production efficiency increase, and you can think about expansion plans for the future. Production optimization also monitors a range of performance through indicators, while encouraging employees to be responsible for eliminating wasteful practices.

Process optimization in manufacturing plays a crucial role in enhancing the efficiency of industrial assets, leading to improved product quality and ultimately boosting profitability. By analysing real-time data, organizations can identify inefficiencies in their processes, allowing for quicker root cause analysis and faster resolution of asset-related issues. The use of digital twins is particularly beneficial, as they enable manufacturers to detect inefficiencies and investigate bottlenecks without interrupting production. This capability not only facilitates timely issue resolution through virtual simulations but also significantly reduces downtime, thereby enhancing overall productivity. Addressing bottlenecks with real-time data ensures that equipment capacity is fully utilized throughout the production schedule, maximizing output. Daily performance tracking is essential to maintain optimal production levels, while standardizing processes minimizes variability, resulting in a more efficient workflow. By implementing these strategies, manufacturers can maintain a competitive edge in a constantly evolving market. By utilizing real-time data, process monitoring and actionable insights we can optimize the operational efficiency via –

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Tracking downtime effectively
Monitoring production and enabling real-time control
Providing alerts and notifications
Displaying KPIs through comprehensive analysis dashboards
Monitoring machine conditions in real-time

Down Time Tracking
Automatically collects data from equipment in real-time.
• Operator user interface allows to augment this data,
track downtime and get machine feedback.
• Through down time tracking, you can take preventive
maintenance measures in place, helping you to come
more proactive than reactive.
• Allow you to prioritize the relevant maintenance issues
or even additional purchases using the real-time data.
• Help you see which pieces of equipment are effective and
which are always failing – or fail enough to make a big
impact on your productivity.
Production monitoring & Real-Time Control
Track machine performance, production output and
quality of your entire operation.
• Operators can easily identify bottlenecks using historic
and real-time data.
• Can connect to any equipment on the floor for collecting
and visualizing the data.
• Estimate and manage the condition of the machine assent
from any distant locations.
• Automatically collect the data from the machines without
any manual interference
Alerts & Notifications
When actions need to be taken, alerts are sent to
the right person at the right time.
• Optional messages are provided to keep you
updated on the operation performance.
• All active alerts and notifications are available to
the right person in the Notification Centre.
KPI Displays & Analytics Dashboard
Screens communicate essential and relevant data to keep your
teams on target and reduce delays.
• Data is reviewed at short, regular intervals (often hourly or per
shift) to identify issues and implement immediate corrective
actions.
• Unite data sources and provide at-a-glance visual feedback with
interactive charts and graphs.
• Allow user to easily explore the data and uncover actionable
insights
Real-Time Machine Condition
• Helps to improve a factory's overall equipment effectiveness
(OEE) and productivity.
• System continuously analyses data, triggering alerts during
abnormalities.
• Collect data on a machine's condition in real time and transfer it
to software for analysis.
• This data can be used to predict potential issues, improve
machine performance, and reduce downtime.
• Create an accurate data foundation & transforming that data into
actionable information

Predictive and Preventive Maintenance

Implementing a predictive maintenance strategy provides organizations with many strategic advantages. This approach is not just a passing trend; it stands as a proven method to prevent costly breakdowns and optimize the performance of valuable assets. Embracing predictive maintenance is a wise investment that can help businesses stay competitive in today’s technology-driven world and pave the way for a more efficient and sustainable future. Transitioning from reactive maintenance to predictive maintenance requires a change in mindset, processes, and technology adoption, and expert support can be valuable in making this transition successful.

The integration of real-time machine sensor data for predicting machine health and safety represents a significant advancement in industrial maintenance practices. This innovative approach allows maintenance technicians to remotely monitor the condition of each individual piece of machinery, ensuring that any changes in machine health are immediately communicated through alerts. Such timely notifications enable technicians to swiftly assess situations and implement corrective actions, when necessary, effectively preventing unplanned downtime caused by machine failures. By leveraging the combined capabilities of artificial intelligence (AI) and human-enhanced machine learning (HI), organizations can achieve optimal availability, performance, and production levels across their operations. This comprehensive monitoring solution spans the entire plant, providing an overall strategy for managing any equipment while also minimizing unnecessary costs associated with over-maintaining machines that are still in good working order. Adopting condition-based maintenance techniques not only enhances reliability but also offers high rewards with low risk. Additionally, through data analysis, businesses can optimize their maintenance schedules, leading to a deeper understanding of asset health and performance data that correlate with potential machine failures. This proactive approach improves inventory efficiency by preventing parts from running to failure or being replaced prematurely. Ultimately, the ability to identify problems before they lead to downtime allows for maintenance to be scheduled based on the actual health of the machinery, ensuring smoother operations and enhanced productivity.

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Minimize Downtime, Maximise Production
Monitor, report, & analyse production loss from unplanned
downtime, poor quality, and performance issues.
• Automatically captures downtime events.
• Records downtime cause and other data.
• Analyse data and events.
• Integrate with process data and improve productivity
Reduce Maintenance Cost
Can manage your maintenance strategy and planning
more efficiently.
• Measuring KPI’s for maintenance
• Analyse machine and sensor data to avoid unplanned
downtime
• View and export real-time data and charts to help
diagnose and resolve problems
Alarms & Notifications
When actions need to be taken, alarms are sent
to the right person at the right time.
• Optional messages are provided to keep you
updated on the operation performance.
• Identify the most recurred downtime happened
with the histories of each machine and data
summary is shared to the concerned authority.
Increase Asset Life
• Regularly monitoring equipment health and
addressing minor issues before they become
major can extend the useful life of assets
Optimize Maintenance Activity
Instead of routine or scheduled maintenance,
maintenance is carried out only when required,
leading to efficient use of resources
Spare Parts Management
Knowing in advance what parts might fail allows
for better inventory management.
• Reducing the need for overstocking and ensuring
parts are available when needed.

Leveraging data effectively allows organizations to proactively address potential issues before they escalate into significant problems. By analysing trends and patterns in asset performance, companies can extend the lifespan of their equipment, ensuring that machinery operates at optimal levels for longer periods. This proactive approach also facilitates scheduled maintenance activities, which can be planned based on actual usage and predictive analytics rather than reactive measures. As a result, maintenance teams can avoid unexpected downtime and allocate resources more efficiently. Furthermore, efficient spare parts management becomes possible, as data insights enable businesses to maintain optimal inventory levels, reducing costs associated with overstocking or emergency purchases. Overall, harnessing data not only enhances operational efficiency but also contributes to better resource management and improved overall productivity.

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