The customer's goal is to create a Shop floor management and connectivity solution with devices to be installed in component manufacturing plants, such as electric motors, automotive and industrial lights, electrical circuits, suspension systems, injectors, etc.
This Shop floor system applies supervision logics to the production lines. Moreover, it is responsible to verify consistency of products, congruency of components with current production and collect process and product data from lines.
It was developed by Hermes Reply and installed in several plants worldwide (Europe, North & South America, Asia).
The solution created can be divided, into three main constituents:
TECHNOLOGIES: .NET | SQL SERVER | OPC.UA | MQTT | WPF & MVVM | WCF | DOCKER | DEVOPS
The system controls the production line by communicating in real-time with the devices and collects product data (results, measures, quality data, components traceability) and process data (station status, alarms, warnings, variables), it also provides input commands to the line for process control, like consistency (check if a product is workable for specified station), congruency (check that components can be mounted on current product) and sending data (as an example, sending parameters to adequate stations according to the current product type).
The DSM has the main target, therefore, not only to collect and write data to shop floor, it acts as an intermediary layer between the line devices and the higher systems by sending results and values.
The DSM provides these set of capabilities through analysis and monitoring tools to be used by production managers, assembly line workers and quality managers.
The solution implemented has enabled, with a view to continuous improvement, a series of subsequent implementations going so far as to incorporate and manage many operations, such as the collection of product and process data, material management and congruencies, production analysis, performance reporting and collection of data of high-frequency machine cycles for the monitoring of trends.
From a technological point of view, this product was born as a simple traceability system evolving into an ecosystem for the Shop floor contexts. From a monolithic application approach, the customer with our support have moved to a micro-service architecture acquiring the ability to granularize the development of evolutions, installations and new modules.
Hermes supported the customer in this process of digitization and innovation and over the years has created a valuable collaboration.
Hermes Reply is the Reply group company specialized in architectural and technological solutions, Application Maintenance services for Automotive & Manufacturing industry and Management Consulting services. Hermes Reply accompany the customers throughout the digital transformation process in order to support the adoption of digital enablers and achieve short-term and long term results, combining in-depth knowledge of production processes, industry 4.0 technologies, delivery skills and strategic vision.