Production monitoring and capacity analysis based on real-time machine data
Accurate cost calculation thanks to precise data
Customer challenge
Collecting and processing data to map the production costs of the end product even more accurately was the task that family business Dely gave to Innomatic and Ikologik. To do this, various types of information were needed: not only about the raw materials used and the losses, but also about the operating times, downtime of the installations and energy consumption.
The solution
An important step in the process was to closely monitor the operating times of all machines in the factory. This allows their capacity and efficiency to be tracked accurately. As a result, the company knows exactly how many waffles can be produced in a given period of time. This is crucial information, as it works with a tight schedule that is fully aligned with planned transport by ship.
The Innomatic and Ikologik systems also map out any losses. They count how many waffles go into the oven and how many are packaged at the end of the process. In between, there are checkweighers that weigh the waffles. By carrying out this measurement at each stage – and not just at the beginning and end of the process – any deviations can be addressed in good time. This enables Dely to avoid having too many end products that do not meet its strict quality requirements.
Water, gas and electricity consumption is also measured continuously. If the consumption of the cooling system suddenly increases, it means that it is freezing up. Dely can then defrost the freezers preventively. This is maintenance that could otherwise have a major impact on production and planning, but which can be scheduled preventively thanks to the analysis of consumption data.
Perhaps somewhat surprisingly, Dely also uses the data for HR purposes. If there are (too) many alarms at a particular station, this is usually due to incorrect machine settings. The company therefore uses the alarm list to provide its employees with targeted training and further education, depending on the machine they operate.
One more thing: the Innomatic and Ikologik system was linked to Dely's existing production network with minimal adjustments to the existing infrastructure. This centralises all information to generate an end-to-end overview.
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