Smart Manufacturing
Condition Monitoring | Process Optimisation | Quality Control and Inspection
Data analytics and control features
Display live data from discrete sensors, machines, or production lines showing current values, trends, and alerts on key parameters.
Historise all data by default, for replay, analysis, or regulatory compliance.
Set predefined thresholds for sensor readings to trigger alerts when values go beyond safe limits.
Develop a scoring system to rate the health of each piece of equipment based on various parameters.
Analyse and visualise manufacturing data with out-of-the-box aggregation to determine the underlying causes of detected anomalies and failures.
Deploy standalone sensors or ingest existing data to score Availability, Performance and Quality.
View utilisation rates to track how often and to what extent equipment is being used.
Deploy standalone sensors, or ingest existing data to analyse Temperature, Vibration, Pressure, and Acoustic noise, to monitor wear, imbalances and other degradation of machine or process performance.
Measure and analyse power consumption, power factor, line voltages and harmonics characterise facility consumption, detect anomalous usage patterns, and identify power quality issues.
RPM and Speed Data to track the rotational speed of motors and other rotating equipment.
Additional features
Reporting
What does it achieve?
Enhanced Product Quality
Automated systems maintain consistent quality by detecting defects that may be overlooked in manual inspections.
Increased Throughput
Speeds up the inspection process, allowing for faster production without sacrificing quality.
Sustainability
Optimised processes reduce waste, lower energy consumption, and decrease the carbon footprint of manufacturing operations.
Reduced Downtime
By predicting failures before they occur, manufacturers can schedule maintenance during planned downtimes, minimising disruptions
Cost Savings
Reduces maintenance costs by focusing efforts on equipment that needs attention rather than following a fixed schedule
Data-Driven Improvements
Aggregated inspection data is analysed to identify patterns and root causes of defects, leading to continuous process improvements.
Optimised Maintenance Strategies
Allows for condition-based maintenance rather than time-based, extending equipment life and improving resource allocation.
Sensors
Vision Systems
High-speed cameras capture images of products on the production line. These systems are equipped with lighting and optics to enhance image quality.
Platform Integrations
Connect directly to machines or legacy systems using OPC-UA, MQTT, or use Edge Gateways to support Modbus, CAN, ODBC, BACnet and more.
Smart Sensors and Devices
Collect data from various parts of the manufacturing process, including machine performance, energy usage, and environmental conditions.
Utilise Machine Learning and AI
Deep Learning Models
Convolutional neural networks (CNNs) are trained on vast datasets of defect-free and defective products to accurately identify quality issues.
Real-Time Processing
AI algorithms process images and data in real-time, flagging defects immediately and allowing for corrective actions to be taken on the spot.
Data Processing
Collected data is pre-processed to remove noise and irrelevant information, making it suitable for analysis.
Predictive Algorithms
Machine learning models, such as regression analysis, neural networks and time-series forecasting, are used to predict potential failures.
Condition Monitoring
AI algorithms track equipment condition in real-time, identifying early signs of wear and tear.
Anomaly Detection
Use algorithms like Principal Component Analysis (PCA) or Autoencoders to detect abnormal behaviour in equipment.
Customer Case Study
In the complex world of industrial manufacturing, operational efficiency and process control are critical to success. When a leading manufacturing company faced challenges with their aging automation systems, they turned to CapitalAI for an innovative solution. This success story demonstrates how our advanced NexAI platform transformed their operations, setting a new benchmark in the industry.
Use Cases
Get in touch
Got questions? Want a demo?
Contact us to learn how CapitalAI can modernise your industry.