• Industry 4.0
  • Retrofitting
Industry 4.0 is considered to be a technological transformation focused on manufacturing and the integration of cyber-physical systems. Within implementation of the IIoT (Industrial Internet of Things) every device is connected to the Internet and exchanges vast amounts of data in real-time, facilitating the effective control of multiple production phases with MES (manufacturing executions systems).
In short, this means implementing new technologies such as sensors and connectivity to existing equipment. Retrofitting is considered to be a cost-saving solution allowing legacy systems to be retained and avoiding the necessity to purchase totally new equipment. The lean management approach says this has a positive impact on eliminating wastage and cutting costs.

Advantages

Maximizing effectiveness by cutting paperwork and manual tasks

Ensures high quality and prevents equipment from being lost or stolen

Reduces the risk of human error and accelerates the induction of new employees

Gives data for analysis and optimization

Mitigates stoppages and malfunctions by predictive maintenance (PdM)

Cuts expenses for new equipment by retrofitting

Comarch for Industry 4.0 in Factories

  1. ERP integration
  2. Thanks to the possibility of integration with any ERP on the market, Comarch’s solution enables control and management of the whole production process including supply chain, production, distribution, back office and sales. Implementing the Comarch system ends an era of printed lists with daily tasks for individual employees.

    ERP integration

  3. Tracking ability
  4. By adding detectable tags to manufactured items, the Comarch system can track items and register the order, time and condition of completed production stages. Data thus collected help with final quality checks, ensuring adherence to required lead times between stages. Additionally, Comarch’s solution permanently eliminates the problem of lost inventory.

    Tracking ability

  5. Task management
  6. When assembly lines are equipped with dedicated screens, employees are led through the manufacturing process and informed about the appropriate task order. With such instructions, they do not omit any steps or confuse elements. The system is not only the data gatherer but also the knowledge distributer, which is especially important in onboarding new employees.

    Task management

  7. Manufacturing execution systems
  8. Through incorporation with MES (manufacturing execution systems), the Comarch solution provides real-time data and feedback across the whole production cycle to prevent bottlenecks and wastage while maximizing uptime. It is crucial to provide flawless manufacturing processes based on up to date production performance analysis. That means no more “just in case” products or sudden shortages.

    Manufacturing execution systems

  9. Predictive maintenance
  10. Thanks to temperature, vibration and sound sensors fitted to machines, the Comarch system allows possible production hitches to be detected before they happen. Sensors warn of unexpected malfunctions during the overall process. With PdM (predictive maintenance), which provides real-time information about the condition of equipment, it is easier to arrange maintenance work according to necessity.

    Predictive maintenance

  11. Retrofitting
  12. Comarch solutions are designed with particular emphasis on existing plant. Retrofitting eliminates the need to purchase new equipment, enabling legacy system upgrades at a lower cost. Sensors with connectivity modules can even be added to the old machinery to give it the same functionality as a new device but generating less capital expense.

    Retrofitting

ERP integration

Thanks to the possibility of integration with any ERP on the market, Comarch’s solution enables control and management of the whole production process including supply chain, production, distribution, back office and sales. Implementing the Comarch system ends an era of printed lists with daily tasks for individual employees.

ERP integration

Tracking ability

By adding detectable tags to manufactured items, the Comarch system can track items and register the order, time and condition of completed production stages. Data thus collected help with final quality checks, ensuring adherence to required lead times between stages. Additionally, Comarch’s solution permanently eliminates the problem of lost inventory.

Tracking ability

Task management

When assembly lines are equipped with dedicated screens, employees are led through the manufacturing process and informed about the appropriate task order. With such instructions, they do not omit any steps or confuse elements. The system is not only the data gatherer but also the knowledge distributer, which is especially important in onboarding new employees.

Task management

Manufacturing execution systems

Through incorporation with MES (manufacturing execution systems), the Comarch solution provides real-time data and feedback across the whole production cycle to prevent bottlenecks and wastage while maximizing uptime. It is crucial to provide flawless manufacturing processes based on up to date production performance analysis. That means no more “just in case” products or sudden shortages.

Manufacturing execution systems

Predictive maintenance

Thanks to temperature, vibration and sound sensors fitted to machines, the Comarch system allows possible production hitches to be detected before they happen. Sensors warn of unexpected malfunctions during the overall process. With PdM (predictive maintenance), which provides real-time information about the condition of equipment, it is easier to arrange maintenance work according to necessity.

Predictive maintenance

Retrofitting

Comarch solutions are designed with particular emphasis on existing plant. Retrofitting eliminates the need to purchase new equipment, enabling legacy system upgrades at a lower cost. Sensors with connectivity modules can even be added to the old machinery to give it the same functionality as a new device but generating less capital expense.

Retrofitting

References

"Comarch knows our company, our processes and our quality thinking and can map all this in holistic software" – emphasizes Matthias Isel, Abnox CEO.

Abnox reference

How does it work?

Comarch for Industry 4.0 is a comprehensive system provided in SaaS (software as a service) or deployment model. It is composed of sensors with transmitters (e.g. Comarch Beacons) and receivers (Comarch IoT Hubs), connected to a cloud database (Comarch IoT Platform) integrated with the factory ERP system. Transmitters are installed on equipment such as production lines, forklifts, warehouses and components of the final product. Then, production floor data from sensors is collected by IoT Hubs, which are installed in crucial places to cover the whole plant area. After the IoT Hub transfers the data to the IoT Platform, the information becomes accessible online via a web browser and mobile application. Comarch IoT Platform is the heart of the smart factory, the place where all data are stored and analyzed. It allows easy control and management by defining rules and alerts. Comarch IoT Platform is the missing link between the production floor and ERP system.

Industry 4.0 infographic

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