Smart Factory Fridays
Webinar series
EPISODE 2: THE CHALLENGE OF PRODUCING FOR A BETTER TOMORROW
Learn how the tools that support digital transformation can also support initiatives related to sustainability goals, especially in times when the energy crisis is making it imperative to look at energy consumption in relation to production efficiency.
Discover how Danfoss and Blackbird are addressing these challenges.
What you'll learn:
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How real-time data overview and analytics can help you derive new insights into resource and energy use of your production, and how that can be used to reduce waste
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Tips regarding energy efficiency journey from Martin from Danfoss
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The benefits of Digital Performance boards
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Insight-reaction process based on real-time data
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What are the system interlinks between electric consumption, production data, and predictive maintenance
Q & A Session
What areas will Danfoss be looking into in terms of sustainability in the future?
How is Danfoss driving process change in the company?
Before we started the digitalization journey there were contrasting opinions on decisions to be made. The ones that raise the voice highest in the conference room, for instance, were the ones having the right to do so. But with data, we could then focus on facts, and by having the facts in real-time is easier to discuss and arrive at a conclusion. By having access to real-time data, we could act on it. It was easy to utilize data from Blackbird as a base for discussion.
How does Danfoss's future factory look like 5 years from now?
Danfoss is looking into renovating part of the plants to be totally optimized in regard to electricity consumption, we are looking into having solar panels on the roof so everything that we do is with green energy. We are looking into purchasing more local technology and machinery, and we plan to require our vendors that the machinery we purchase is able to switch off the power when not in use by itself.
If you have a fixed process time (Peter), can the operators get an indication that they can visualize on the board?
If you have a fixed process on the line, for instance, if you have a batch or process that has a fixed target time, yes you can see if you are ahead of behind in terms of that target.
Are you (Martin) using camera as well? And if so, how do you deal with GDPR?
Danfoss uses Factbird View, but our scope is not watching or listening over operations, every camera is placed in a way to look only at the process. We also have printed announcements in the areas where cameras are located so people know that the area is being filmed.
We are using video material only when the machine has a breakdown and we need to fix the machine and understand the cause of the crash.
Learn why manufacturers use Blackbird
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Danfoss
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Sintex A/S
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McBride
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Swedish Match
40% increase in production performance in less than a year by getting reliable data
Danfoss is an industry-leading global manufacturer of hydraulic, climate, and power solutions and has been one of Europe’s most notable industrial manufacturers for nearly a century.
By using Blackbird and having access to real-time data collection, they could see when the machine was stopping or when there was a pause or break in the plant shift, and that became an eye-opener. Several hours is equal to a lot of money wasted in production, so by adding the cameras and sensors, they could see the relevant data so we could locate the problem in the production line and fix it much faster.
Sintex increases OEE by 5% and uptime on a line by 92%
Before implementing Blackbird, Sintex was still relying on their operators to manually collect production data that their managers would compile into Excel spreadsheets for analysis - A process that is human-error prone, inefficient, and far too familiar to those of us in the manufacturing industry. They rolled out the Blackbird solution slowly, at first, installing it on 10 of their machines. They needed a solution that could take live data directly from their equipment's PLC and display it in real-time. Blackbird's IoT functionality and flexible connectivity options made it the perfect solution. They have since expanded Blackbird to 30 of their machines.
McBride's road to a Smart Factory
McBride’s operators were able to get quick overviews of which lines were on target and which ones were not, allowing them to pinpoint each line's problem areas. Additionally, their managers created a daily management screen to visualize data and create daily reports on the ten most common codes to address. Powered with data, both the managers and operators were able to understand their capabilities and gain full transparency over their production lines.
By fully embracing the Blackbird system, the production team at McBride now have the data they need to make continuous improvements. Having already experienced a 4% boost in their OEE, McBride is expecting to improve by an additional 20% within the next calendar year.
Swedish Match digitalized their processes
Initially, all their data was written down on paper and stored in binders. This method meant that operators were required to remember to perform their quality control duties, which – due to the potential for human error – was significantly compromising the quality of their production.
To help solve this, Swedish Match decided to implement digitalization, and as a result, saw immediate improvements to their quality control process by using Blackbird’s Control Recipe feature.
Blackbird’s proprietary software prompts operators to perform necessary control duties, with pop-ups, scheduled tasks, and operator specific duties that can be tracked in real time.
