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Outperform competitors with Real-Time Operational Intelligence (RtOI)

  • to prevent accidents and save time. It helps companies identify issues with their machines before they arise so that smarter preventive maintenance can be done. This reduces the risk of accidents happening, which saves time for the company, customers, and employees;
  • to provide information on the current state of the plant and equipment, how it is performing and what might be needed for maintenance. This information can be used to identify potential problems and take corrective action before a problem becomes a disaster.
  1. Collecting data from sensors and other sources (i.e. people, machines and systems).
  2. Analysing this data and generating insights.
  3. Providing stakeholders with direct access to information they need.
  4. Generating alerts when conditions are not as expected.
  5. Notifying operators of these alerts.
  6. Analysing the situation and creating a plan of action for dealing with the problem.
  • implementing actionable quality control insights;
  • triggering notifications based on production quantity, timing & events;
  • defining, capturing, and analysing test results easily and quickly;
  • allowing production prediction & control in real time.
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  1. The first obstacle that manufacturers have to overcome is the resistance to IT/OT convergence. There is still a strong resistance to organizational change. The IT and OT departments of companies remain highly siloed, with different people, different objectives, and different policies. They work in a completely independent, competitive, and conflicting way. Traditionally, IT (Information Technology) was used primarily for financial calculations and commercial transactions. On the other hand, operational technology (OT) was a pre-configured, proprietary vendor system designed to only work on a specific piece of equipment. While the difference in technology has gradually become organizational, the use of IT in OT is now becoming increasingly intense.
  2. The absence of a digital backbone. Many operational structures lack an interconnection structure consisting of tangible and intangible assets that supports the plug & play of technological assets, allowing for an immediate benefit from the exchange of data between different levels.
  3. A lack of or inefficiency in the Manufacturing Execution System (MES). Digitized production shop-floor management is only possible with a specific platform that allows data exchange across the various management areas: planning, scheduling, monitoring, process and product traceability, real-time data analytics, proactive maintenance, etc.
  4. A lack of training and knowledge about enabling technologies. Most companies invest in technology without adequately training the human resources involved in its use, at all levels.
  5. Process analysis and the ensuing development strategy are lacking. Too frequently, companies struggle to understand how to design a transformation process to evolve from the current condition to the desired state.
  6. Data and cyber security. As technology advances, cybercrime is in the pursuit of methods to breach the current technology, including finding loopholes and misconfigurations to exploit the technology in use. Communication and cybersecurity cannot be considered as separate processes in Industry 4.0. Manufacturers of all sizes must understand Industry 4.0’s capabilities and risks in order to take full advantage of its potential.
  • SM.1 The seamless integration with the RtOI Platform prevented any downtime from interfering with just-in-time production.
  • SM.2 The access to accurate productivity information allowed Client to increase productivity with better machine and operator scheduling.
  • SM.3 Having access to real-time data and alerts lets Client address issues as they happen and provide on-time delivery more consistently.
  • SM.4 Improved raw material management with the platform allowed Client to reduce the cost incurred by waste materials and improve OEE with fewer stoppages.
  • SM.5 Improved data visibility and effective communication tools from Client allowed departments to cooperate more effectively.

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Giuliano Liguori

Giuliano Liguori is a technologist, an influencer in the digital transformation and artificial intelligence space.