Project/Activity – 01

Journey to Industry 4.0

(Dept. : Electronics Maintenance/Utilities)
Progress Report : Gen-II
Project Initialization : On 09.09.2021, at manufacturing excellence meeting , the project was
initialized for its 2nd generation development.
Proposal/Concept On discussion not yet finalized
Action Plan done
Budget Assessment done
Procurement/Vendor Assessment Yet not decided
Installation & commissioning ________________
Industries 4.0 – Digital Manufacturing

Material Gate In

PPC Data Point Material Scan using QR scanner

SQL table access SQL table access required
required
With ready to Material Issue to Winding Dept.
use table(T01) SQL table access required with
ERP Scope/ Kamaljeet ready to use table(T02)

Scope Matrix
Data Access at machine display/Entry

 On hold till ERP

development. OEE Calculation Lot Paper Project
 Discussion on
application & Press to enter Press to enter
future scope Concluded to installed pitch Proposal dropped due to not
pending. wise selected machines meeting desired ROI
(Max. 15 machines.)
IIOT : Machine OEE Calculation
 Proposal for Mpet Winding Machine-OEE Calculation
This architecture accessing data from Mpet Winding Machines to central data server will be as below,
Data Communication Over Ethernet
Data will Data will
interconnect interconnect
ed with Data ed with Data
controller controller

Application Server
Type of Information accessed

Machine layout from X to Y

Machine layout from X to Y
from Machines.
 Total Shift time
 Total Machine availability
 Total Machine Utilization
Cable Tray

Cable Tray
 Total Machine
Downtime(Alarm cond.)
 Total Machine Downtime
(without Alarm cond.)

Data Server
System deliverability:
 Shift % utilization
 Total Production
 Online Production
reporting
 Shift/ day/month wise best Mail Server
% utilization grading. Discussion Pending
 Shift/day/month wise least
% utilization Note: We request to concern, please appoint some one
 Each Machine Production/
% utilization charting who can ensure machines covers all pitch in single row
and share a list of them on arvindsof85@gmail.com
 IIOT : Testing Machine
Online data Recording
( Cap & IR Measurement)
 Proposal for Mpet Testing Machine- 100 % Online Monitoring
This architecture accessing data from Mpet Testing Machines no 12 to central data server will be as below,

Measured data to Measured data to

be: Cap & Tan Delta be: IR Value &
(1 K) Respective Voltage

Local Database with Reporting

Gateway will have
cost Rs. 9500
Cost May Reduce up to 6000
but working on it

Note: Application is under development mode so requesting all, please suggest if need any additional information/data, we are missing out there.
 Issue with Cloud Server : Security Beach found
As per Mr. Kamaljeet, there is a security beach found, results server got down 2 or more
time so requested to change IP, Socket, P ort , Password of all application being used in
process for IIOT so we need to update all applications.

Application Update Required

Note: Till then Data being stored in local CPU in Excel format.
 Project/Activity – 02
Machine Modification-Mpet Masking
(Dept. : Electronics Maintenance/Utilities)
 Mpet Masking Machine Modification – HMI development
Mpet masking machine hmi stops working & found HMI program obsoleted.
We developed new HMI application for the same. Now machine working nice without
effecting in production
 Project/Activity – 03
Digital Manufacturing : Oven Automation
(Dept. : Electronics Maintenance/Utilities)
Progress Report
Project Initialization : As per discussion/proposal submitted, we decided to digitized the baking
oven-05.
Proposal/Concept Discussed and finalized.
Action Plan Discussed and finalized.
Budget Assessment Discussed and finalized.
Procurement/Vendor Assessment Finalized.
Engineering 95% job done (HMI development in progress)
Installation & commissioning Cold run test has been completed.
 Backing Ovens –PLC based Automation
Additional Features :
1. Temperature sensor failure notification popup.
2. Heater failure notification popup.
3. Phase failure as well reversal notification popup.
4. Blower failure notification popup.
5. Belt broken failure notification popup.
 Backing Ovens –PLC based Automation
Additional Features :
Mode of Operation :
1. Oven is designed to operate in Baking Oven as well Curing Oven.
Curing mode: Auto logic will take care of stage heating (very similar to zig oven) as well timer logic
only to be in action, once desired temperature is achieved.
 Backing Ovens –PLC based Automation
Additional Features :
Mode of Operation :
Oven is designed to operate in Baking Oven as well Curing Oven.
2. Baking mode: Auto logic will take care of rack tray wise heating to minimized the process heating
time.
Notification if any of rack tray baking is been completed as well respective pop up to take baked
material out of oven. Time taken is also been recorded to avoid additional baking.
Buzzer action will be in operation for notification as baking cycle has been completed and logically
operated, must case to open oven gate in order to reset buzzer.
 Backing Ovens –PLC based Automation
Additional Features :
Mode of Operation :
 In any mode of operation, each zone temperature is available on monitoring as well can be access for
reports.
 It also have provision to operate manual override mode whenever PID gone failed/issue in
controlling.
 Temperature high threshold protection is also applicable in auto mode to avoid undesired shoot in
temp.
 Quering Ovens –PLC based Automation
Proposed Control Philosophy
Excel reporting across shift

 System will also ensure, if there is any thermo couple failure as well heater failure.
 System will also ensure, if temp. is not being achieved with assign time delay as well will
generate alarm and log in report.
Stage-I 0-90 mins 65°C
Stage-II 90-150 mins 100°C
Stage-III 150-210 mins 120°C
Stage-IV 210-280 mins 180°C
 Overall Progress – 35 %

Project/Activity – 04
Digital Manufacturing : Online Monitoring
Recording and Analysis of Energy Data
(Dept. : Electronics Maintenance/Utilities)
Progress Report
Project Initialization : As per discussion/proposal submitted on 09.09.2021, we proposed for
online monitoring recording and analysis of energy data.
Proposal/Concept Proposed.
Action Plan finalized.
Budget Assessment finalized.
Procurement/Vendor Assessment __________________________
Engineering __________________________
Installation & commissioning __________________________
 ENERGY SAVING ACTIVITIES
Objective : Development of the IOT based energy management system
 Installing IOT:Based Energy Monitoring System
Activity Involved :
 We have estimated network architecture & BOM for the IOT solution and preparing a cost
effective solution for the same.
Energy meter for collecting energy data

Initial Installation cost

Energy Meter with RS485 Support 7700.00*
Current transformer 1800.00*
IOT Gateway (20 devices) 4500.00
PLC 16000.00
HMI 35500.00
------------------------------------------------------------------------ IOT Gateway
Total Price 65000.00

Note: * denotes to multiply if more no. of nodes energy meter

to be connected for monitoring .
In case of 1 phase ac measurement only 2300 is accepted in place of 7700.00.
 ENERGY SAVING ACTIVITIES
Objective : Development of the IOT based energy management system
 Installing IOT:Based Energy Monitoring System
Activity Involved :
 We have estimated network architecture & BOM for the IOT solution and preparing a cost
effective solution for the same.
Energy meter for collecting energy data

Temperature & Humidity sensor for collecting data

IOT Gateway
Note: by investing only 950 Rs. each we can also collect online
temp as well humidity data to any central display as well data
logging.
 Overall Progress – 45 %

Project/Activity – 05
Digital Manufacturing : Capacitor
Dimensional Sorting (Machine-10)
(Dept. : Electronics Maintenance/Utilities)
Progress Report
Project Initialization :
Proposal/Concept Proposed.
Action Plan finalized.
Budget Assessment finalized.
Procurement/Vendor Assessment Budgetary offer submitted
Engineering __________________________
Installation & commissioning __________________________
 Digital Manufacturing : Capacitor Dimensional Sorting
Technical cum Budgetary Comparative
 Blower Run &
Trip Indication
243 mm
50
R Y B
68.5 68.5
Blower Run & 28 42 42 42 70
Trip Indication

Belt Sensor 40
52 92
SP
52
Z1 Z2 92 40
30
52
Z3 Z4
52 92
Z5 Z6 645 mm
52
Z7 Z8 26.5
52 404 mm
26.5
st1 st2 st3 st4 st4
52
PB1 PB2 PB2 EMG BZ
52 42 42 42
M/s Deki Electronics Limited
76 (Made In India)