How to optimize raw material inventory using moneo

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industry 4.0

How to optimize raw material inventory using moneo

In order to protect the electronics of the sensors from shock, vibration and moisture, potting processes are an essential part of sensor production. For a smooth production process, but also for a constantly high product quality, the permanent availability of casting resin and casting hardener in the storage tank containers is absolutely necessary. The level monitoring application implemented at ifm prover gmbh thus contributes to a reliable logistics organization of temperature-critical media in the production process.

The initial situation: Level is monitored by the control system indicated by a stack light

ifm prover gmbh uses a two-component casting resin for potting terminal devices. Among other things, the internal control system monitors the current level of the drums. If the minimum level in one of the drums is not reached, a signal light on the line itself indicates that a drum change is necessary.

In the worst case, the visual signal will be perceived too late on site and the drum will be changed too late.

The refill materials coming directly from the warehouse must be tempered to processing temperature and so cannot be used immediately. Consequently, production can come to a standstill and equipment fail because it cannot be filled with casting resin at the appropriate time.

The goal of the project: Supplement the stack light with a modern real-time maintenance solution

In order to inform the personnel more reliably when a drum needs to be changed, software-supported level monitoring should be added to the existing alarm via signal lamp. The aim was to ensure uninterrupted supply of casting resin by means of automated, location-independent warning and alarm functions. The two-stage system, consisting of warning and alarm, makes it possible to have the new drum ready at the plant in good time and signal when a drum change is required.

The implementation: Level monitoring with moneo RTM

Due to the existing IT structure, moneo has been installed on a central server of ifm prover gmbh to activate the moneo RTM module. The level sensors for drum monitoring are connected to an IO-Link master that in turn is connected to the server – and thus also to moneo RTM – via an internal VLAN.

The result: More efficient use of resources and personnel

Level monitoring with moneo RTM has led to a significant optimization of the replacement process and to a more efficient use of resources and personnel. Thanks to the two-stage automatic notification, the procurement of the casting resin could be changed from a time-based to a condition-based provision. Thereby, storage costs can be reduced, maintenance work can be linked to the time when the drum is changed, thus reducing machine downtime to a minimum. The continuous availability of the cast resin has also ensured consistent sensor production quality.

Bottom line: Value-added services of level monitoring

  • Calculated values: Sensor values can be converted to process-relevant information with the help of data modeling
  • Cockpit functions: Comprehensive and individual visualization of all sensors in the process
  • Detailed information about levels by capturing sensor values
  • Integrated alarm management: Fast reaction to changing process parameters
  • Analysis: increase of levels according to the requirements by means of targeted evaluation of historical data
  • Identification of limit values that are exceeded or not reached

Read the full case study here to find out how this system can help your company to optimize raw material inventory.

Sponsored by IFM