top of page

Management and automated expertise in industrial production

01.png

Would you like to hear about a success story of a company that is living the digital transformation? 

Here's one of our partner companies, a global tobacco company. With its innovative spirit, the company is already in Era 4.0, achieving results such as increased efficiency and quality.

The automation of their processes has meant generating integrated communication to reach quality and productivity targets

02.png

Challenge

Improve process control to increase product standardization, reduce raw material losses and energy consumption.  

Context

This industry has implemented digital developments in its manufacturing processes. 


Let's understand the context: In manufacturing, it is necessary to mix ingredients according to a specific recipe; products such as food, drinks and even chemicals are created this way. 


This type of production has challenges such as variations at the start and end of each batch, process instabilities, among other factors that can affect the final quality of the product.


To manage this complexity, we have introduced “digital experts” at every stage of the process. These digital experts are known as cyber physical systems (CPS), which unite the digital world with the real world, autonomously collecting data for decision-making. 


Let's think in terms of a restaurant, where each member of staff plays a crucial role. The automation for the company had CPS acting, for example, as a “drying specialist” optimizing the use of gas, like a cook adjusting the temperature of an oven. Meanwhile, the “control specialist” takes care of the product's humidity, like a cleaning assistant takes care of the environment. Each digital specialist ensures that their “sector” works harmoniously with the others, right?

With these innovations, our client has saved

Frame 196.png
Frame 197.png

This is an increase in quality and efficiency in real numbers.

And the positive impacts don't stop there: 
 

Even if specialists achieve the best individual result, it is possible to improve the overall result by integrating these specialists. The maxim “together we are better” applies to digital too!
 

That's what we've done. We implemented a CPS that acts like a chef overseeing the quality of the final product. He ensures that each sector meets its targets and, what's more, this “central” CPS communicates promptly with the specialists, indicating adjustments needed to maintain specifications and minimize errors.

Diagrama.png

This process integration architecture has elevated our client to a Software Defined Facility company, because the entire factory is connected to intelligent systems that make autonomous decisions through cyber-physical systems, all with IEC 61499 technology. 

Benefits

We deliver to our partner technologies that make decisions based on real-time data, targeting the interests of the business, acting full-time, uninterrupted and according to the needs of the process.

Quality gain:

Frame 209.png

49% reduction in product variability. Less variability means quality, savings and safety.

Frame 206.png

Energy consumption reduction:

8% reduction in fuel gas consumption and 0.8% reduction in steam consumption.

Frame 212.png

Waste reduction:

5% reduction in the waste of raw materials, without wasting time on reprocessing.

Frame 208.png

Less Need for Operational Intervention:

17% reduction in the need for operational interventions. 

Frame 210.png

Development of the Operational Team:

Reduction in operational training time. What could have taken more than a year was resolved in a few weeks. 

Results

In the primary manufacturing department, we have 10 cyber-physical systems, working on 6 different processes.

The direct result is a

01.png
02.png
03.png
04.png

The team in this industry has gained excellence in decision-making, dealing with qualified data that allows management to be flexible and adaptable. 
 

The CPS has been supporting the manufacturing process for more than 4 years, delivering digital transformation in practice. 

Shall we arrange a demonstration of our portfolio?

bottom of page