Improved Quality

Detect and prevent quality problems by finding and addressing equipment issues sooner.

Improved visibility

Make more informed decisions with a real-time picture of operational status.

Improved utilization

Maximize asset performance and up time with the visibility required for central monitoring and management.

Connected Factory Solution

The Internet of Things (IoT) is changing manufacturing by connecting equipment, eliminating silos, exploiting data and taking automation to a whole new level. Considering the multitude of equipment, protocols and technologies in today’s manufacturing environments, the solutions lie at the Convergence of OT and IT to create a truly smart, Connected Factory. Factories and plants that are connected to the Internet are more efficient, productive and smarter than their non-connected counterparts. In a marketplace where companies increasingly need to do whatever they can to survive, those that don’t take advantage of connectivity are lagging behind. The new system reduced maintenance costs and downtime, as well as the capability to collect more data.

The Connected Factory is able to effectively manage and consolidate inputs across a range of interacting devices and physical systems. On a factory-level, this Machine-to-Machine (M2M) communication works, with processes and data being fed into and managed from a central platform. Information from previously separate parts of the supply chain are being used to inform decisions on the factory floor, and vice versa. Advanced analytics tools that integrate with the collective digital infrastructure of Connected Factories are playing an increasingly vital role in manufacturing. M2M systems are able to deliver complex data sets which can be quickly used to drive innovations in efficiency and quality whilst minimizing waste.

Manufacturing companies are constantly looking for ways to improve efficiencies and product quality in this competitive environment. Synergi-FX is collaborating with major service providers to present a modern platform to collaboratively manage and improve your manufacturing processes. Synergi-FX connected smart factory will help manufacturing companies to better predict and resolve maintenance requirements, correlate quality issues to machine and environmental factors, reduce downtime, and improve quality. Leveraging a modern cloud platform, IOT connectivity, Big data analytics, predictive Intelligence, and Cloud supply chain tools, Synergi-FX will help companies to modernize their production and supply chain processes to competitively meet current and future requirements.

  • Digitization of objectives

    Digitization is about transforming manufacturing operations using the latest technology and it often starts with connecting factory floor equipment. The cost of components that support connectivity has fallen dramatically. Consumables like RFID tags now cost very little to include in products. Sensors are becoming more affordable, increasing the amount of new equipment sold with sensor capabilities built in, while older equipment can be retrofitted, or IoT-enabled, at lower price points. At the same time, it is now possible to collect and analyze massive quantities of sensor and device-generated data.

  • Experiment with simulated data

    Explore your options in a low-risk environment by connected equipment simulations. Simulation gives you the freedom to explore how digital changes could offer value, such as better visibility, without affecting operations. By exploring simulated interfaces and dashboards, you can get a sense of how equipment all over the world can be viewed holistically, including both an overall view of performance and detailed insight into the status of individual machines. Even if connecting operations around the globe is a much later step, seeing the results of a simulation firsthand can help you refine your objectives and get a better sense of what’s possible.

  • Connect equipment without disruption

    Connecting a set of equipment enables you to experiment on a small scale and at your own pace all without disrupting operations. It creates a foundation you can build on and scale out across your organization when you’re ready. See simulated data, and then hook up your own equipment and see real-time data and insights from your own operations. Connecting equipment can be relatively simple at a basic level, it involves:

    • Determining the communication protocol your equipment uses.
    • Hooking up the equipment to a gateway device that consolidates data across machines.
    • Connecting the gateway to the cloud to provide visibility into status and key performance metrics.

    From there, you’re ready to start exploring real-time data from your equipment. The right kind of solution also enables you to connect equipment without taking it offline, and to connect individual pieces of equipment at your own pace, with no need to connect everything at once.

  • Visualize manufacturing performance

    Insights is easy to extract via intuitive, visual dashboards, and is readily available to the people that can act on them, such as shop floor technicians and plant supervisors. With a robust technology solution, you can quickly identify the data points to collect for KPI calculations and root cause analysis. In some cases, you may find you are collecting data that isn’t needed, or isn’t providing insight, and adjust accordingly. Cloud-based solutions make it easy to fine-tune the information you collect. Data from connected equipment is also the foundation for uncovering trends and patterns. A digital approach to operational visibility offers tremendous potential value. A recent Automation World survey found that nearly three-quarters of respondents use plant-floor data at the corporate level, but a spreadsheet was cited as the most common reporting tool. With a connected factory solution, operational intelligence is available automatically and immediately, enabling better, faster decisions at the plant and at the corporate level.

  • Make operational changes based on data

    Connected equipment is useful when it drives changes, anomalies can be quickly detected and fixed. Maintenance schedules can be optimized to minimize disruption. There’s no limit to the kinds of data-driven improvements that become possible. With the ability to monitor performance via a live dashboard, you know immediately when failure conditions occur, and can quickly dispatch a repair technician to address the issue.

    Another benefit of visibility is the ability to identify under-performers and out-performers, and make corresponding improvements. With the ability to see performance side-by-side, you can more easily identify these outliers and investigate what’s behind them. Issues can be uncovered like machines not being run or maintained optimally, or you may find utilization differences related to different operators. You may also discover best practices that you want to roll out more broadly. When you can compare performance across equipment and over time, these kinds of variations become more apparent, and easier to act on.

  • Scale and enable new scenarios

    Scale from a single assembly line to an aggregated view across your operations. Add new equipment and capabilities at your own pace. Use your solution as a starting point for expanding to scenarios like Predictive maintenance. With a single consolidated view of your operations, you stand to gain better, faster insight into performance, and the ability to compare performance across the organization. Beyond scaling to more equipment and factories, you can also choose to expand the capabilities and scope of your digitization efforts.

    Visibility into current performance and historical data are a powerful foundation for other digital changes, such as predictive maintenance programs and an optimized energy management approach. By applying predictive analytics to performance data, it becomes possible to not only identify when maintenance is imminently needed, but to accurately predict maintenance needs well ahead of time. You may choose to integrate performance data into other business applications, such as a field service system. In this case, if an anomaly is detected, a service alert could automatically be triggered, and a technician automatically scheduled to look at the equipment with the potential problem. Digital transformation can take many forms and mean many things for your operation. As you enable new scenarios and scale, the key is to continue experimentation using a phased approach, and to continue fine-tuning as your needs and environment evolve.