If you’re assessing the feasibility of a machine monitoring system for your manufacturing unit, then you’re headed in the right direction. Remote monitoring is becoming a staple in manufacturing as the current shifts towards Industry 4.0. According to a McKinsey survey, digital upgrade of existing systems is now a top priority among machinery companies. The benefits it unlocks set them apart from the rest and open up business opportunities that were previously unavailable. So, how do you go about choosing the right remote machine monitoring system? In this article, we examine 8 key aspects and one case study on how it’s done right.
Factors to Consider When Choosing a Remote Machine Monitoring System
It’s a crucial decision requiring you to evaluate the following factors:
1. Assess the Monitoring Needs of Your Unit
Start by pinpointing the specific metrics crucial for your operations that are ready for a digital transformation. Are you trying to track the resources through the plant or measure the temperature of a cast product through the conveyer system? It could be different things, from fluid temperature to hydraulic pressure in the pumps. Assess your existing setup and come up with gaps where the implementation of remote monitoring can be most useful.
2. Consider System Compatibility With Existing Equipment
One of the most important aspects of choosing the right remote machine monitoring system is compatibility with your equipment. Even the most advanced solution in the market isn’t good enough if it doesn’t work with your equipment without major modifications. Compatibility reduces installation costs and avoids disrupting your operations. The monitoring solutions should support your equipment’s protocols and communication standards. Also, consider future upgrades and select a system adaptable to emerging systems so you’re not forced into costly replacements in the long run.
3. Look for Scalability With Your Business
Your business is bound to grow and expand, and hence, any remote monitoring system you choose should be able to scale without offering resistance. Modular designs are particularly beneficial as they let you add new features or devices without reconfiguring the entire system. The same goes for upgrades, as any new IoT device you introduce should fit perfectly with the system. Consider how the system handles increased data volumes and additional sensors. The monitoring system should also be able to offer services customizable to any unique needs that you have.
4. Evaluate Data Security Features
Data security is critical as the system exchanges information from devices to the monitoring platform. The system should have robust encryption to protect data both during transmission and in storage. The system should also include advanced authentication methods, such as multi-factor authentication, to prevent unauthorized access. The vendor should also provide regular security updates and patches to safeguard against vulnerabilities.
5. Check for User Friendliness of Solution
A surprising vulnerability to most upgrades comes from those who use completely new systems. Workers in the manufacturing sector are sometimes reluctant to adapt to digital technology as they are more comfortable with manual methods. Therefore, the monitoring solution must be user-friendly and feel like using any other intuitive application. Evaluate whether the system offers customizable dashboards and simple controls for accessing critical data. Also, consider the availability of training resources and customer support to help with onboarding and troubleshooting.
6. Make Cost Assessments
Cost is a significant factor in how most manufacturers choose a remote machine monitoring system. Start by comparing the initial investment required for each option, including hardware, software, and installation fees. Also, you must factor in ongoing costs such as maintenance, subscription fees, and additional updates or support charges. A good metric to assess vendors is transparent pricing with no hidden costs. Start with a cost and benefit analysis to weigh the expenses against the potential gains regarding efficiency, downtime, and productivity.
7. Review Vendor Reputation
Most vendors out there advertise the best of their services and make claims about how good their platforms and services are. It’s essential to look at the customer testimonials and reviews to understand whether their offerings are good. Look for feedback on the vendor’s customer service, support responsiveness, and overall satisfaction. Check if the vendor has a track record of delivering quality products and solutions in the case studies of real applications. Finally, consider their experience in the industry and any awards or certifications they’ve received.
8. Test System With A Trial Run
Once you’ve zeroed in on your vendor or vendors, start with a test run to observe their performance. Many vendors offer demo versions or trial periods, allowing you to evaluate the system’s performance in your environment. Use the test runs to assess how well the system integrates with your existing equipment, its ease of use, and its ability to deliver data effectively. Pay particular attention to any issues that arise and how quickly support responds, as this will be one of the weakest links going forward.
Case Study: Enhanced Productivity Performance and Machine Utilization With MachineCONNECT
The client is a machine builder in the manufacturing sector. As often happens in this industry, the client faced challenges with incomplete and inaccurate manual data on production parts, setup times, and manual delays. They also struggled to gauge performance against productivity targets effectively.
Solution:
Implementing machineCONNECT transformed their operations. The remote machine monitoring solution automated data collection on parts produced and cycle times. It also monitored setup times and analyzed machine performance to pinpoint productivity losses and unused capacity.
Outcome: By identifying and resolving bottlenecks, the client significantly improved productivity and gained higher machine utilization. The effect reduced the need for additional capital expenditures and saved money. The detailed insights into productivity losses also enabled targeted performance enhancements.
Conclusion
Selecting the right remote machine monitoring system can make all the difference in optimizing manufacturing processes. By following the steps discussed in the article, you have a general framework for how to analyze and choose the right remote machine monitoring system.
On that note, machineCONNECT’s remote monitoring has a proven track record in boosting manufacturing productivity and machine utilization. The system has helped numerous manufacturers to achieve more efficient operations and better performance outcomes.
To learn how your manufacturing setup can transform its operations, request a demo today!