Customized Real-Time Monitoring Solution for Cold-Forming Machines

Introduction

Our esteemed client is a leading player in the manufacturing sector, specializing in Railway Construction Equipment. Their Product Development Centre (PDC) with a commitment to innovation and excellence, constantly strives to enhance the quality and performance of its machinery.

The Problem Outline

The Product Development Centre (PDC) faces challenges in real-time monitoring of crucial parameters for outdoor railway construction equipment. This lack of visibility into factors like temperature, oil level, vibration, RPM, running time, idle time, predictive maintenance, load factor, accurate working location, fuel consumption, and more hinders data-based decision-making. The absence of instant insights into performance trends, fault identification, and necessary improvements leads to time-consuming processes, impacting productivity and customer satisfaction. There’s a pressing need to enhance overall machine quality and lifecycle through actionable data.

The Solution Summary

To address these challenges, we proposed a customized IoT solution for the railway construction equipment industry — Heavy Equipment Asset Management. This solution involved monitoring crucial parameters (temperature, oil level, vibration, RPM, running hours, electrical parameters, and fuel consumption) using the Trinetra application. This data-driven approach offered timely insights, enabling informed decision-making. Beyond data collection, our solution, developed in collaboration with domain experts, took a holistic approach to address pain points and deliver tangible value.

For example, in the remote monitoring solution for a concrete batching plant, the Trinetra application, equipped with wireless technology, improved asset visibility, leading to time and cost savings, ultimately enhancing productivity.

Railway construction equipment that can be monitored:

• Excavators: Hydraulic Excavators, Crawler Excavators & Wheeled Excavators
• Bulldozers: Crawler Bulldozers
• Backhoes: Backhoe Loaders
• Cranes: Mobile Cranes & Tower Cranes
• Tamping Machines: Ballast Regulator & Tamping Machine
• Concrete Batching Plants: Mobile Concrete Batching Plants & Stationary Concrete Batching Plants
• Pavers: Asphalt Pavers & Concrete Pavers
• Graders: Motor Graders
• Track Maintenance Machines: Rail Grinders & Rail Lifters
• Railway Inspection Cars: Track Inspection Cars
• Tunnel Boring Machines (TBMs): Main Beam TBMs & Shield TBMs
• Railroad Tie Replacers: Tie Removers & Tie Installers
• Rail Welding Machines: Flash Butt Welding Machines & Gas Pressure Welding Machines
• Rail Drills: Portable Rail Drills & Vertical Rail Drills
• Track Renewal Trains: Ballast Cleaning Machines & Track Laying Machines
• Railway Maintenance Vehicles: Rail Inspection Vehicles & Rail Cleaning Vehicles
• Railway Signal Systems: Signaling Equipment &Train Control Systems
• Railway Safety Equipment: Trackside Warning Systems & Level Crossing Systems

Our IoT solution can be implemented across these machines to monitor and optimize their performance, providing valuable insights for efficient operation and maintenance.

Results

• Performance Improvement: Noticeable enhancement in overall asset performance.
• Customer Satisfaction: Substantial reduction in equipment functionality complaints.
• Brand Value Enhancement: Improved asset performance and proactive maintenance elevate brand value.
• Operational Efficiency: Swift analysis of asset performance streamlines decision-making and operational processes.
• Time and Cost Savings: Reports generated within minutes, leading to significant time savings. Monitoring results in cost savings.
• Proactive Maintenance: Real-time monitoring identifies potential faults, facilitating proactive maintenance.
• Improved Visibility: Enhanced visibility over asset status contributes to improved operational efficiency.
• Data-Driven Insights: Trinetra application provides valuable data-driven insights for informed decision-making.
• Overall Productivity Gain: Holistic monitoring and maintenance approach contribute to a sustained increase in overall productivity.

This collectively underscores the successful impact of the IoT solution on PDC’s operations, affirming its value in the competitive industry of construction machines manufacturing.