Accelerating the Industrial Internet of Things
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Altizon Systems Case Studies FMCG Case Study – CPG Line Monitoring
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FMCG Case Study – CPG Line Monitoring

Altizon Systems
FMCG Case Study – CPG Line Monitoring
Consumer Goods
Retail
Production - Manufacturing
Equipment Efficiency Optimization
Factory Operations Visibility & Intelligence

The leading CPG company operates several warehouses, mostly closer to the last distribution point (Large retailers). Products in various categories are packaged in specific delivery or display cartons at these facilities. As most CPG businesses consist of high volume with low margins, optimizing every operation and effective utilization of resources add up to profit margins. The key problem at these warehouses is the lack of visibility into reasons for machine breakdowns or idle time, thereby delay in delivery. The sunrise meetings lead to post-mortem of delivery issues like delay or quality. The customer wanted to implement real-time line monitoring and alert system to gain control over downtime issues and implement improvement measures.

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As packaging lines carry variety of old and new machines, many aren’t designed to share data. The solution demanded retrofitting of hardware and custom dashboards to visualize multiple lines and machines. Altizon, along with the hardware partner, designed an integrated IoT solution. It deployed high quality wireless object detection sensors on case sealers, wrapping machines, and box printers to capture real-time operating pulse. The 24/7 real-time machine data at

Datonis Edge helped analyze equipment failure & generate alerts. The aggregated data was processed at Datonis IoT cloud to analyze production line throughput and offer tailored visualization and BI reports. The business intelligence reports with machine idle time, breakdown reason codes, and overall productivity/OEE data helped management in better planning and addressing issues.

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  • Real-time visibility into packaging line’s performance (downtime sources, suboptimal processes, slow teams, aging equipment)
  • Up to 8% performance gain through optimization initiatives driven by actionable insights
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IOT
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Mature (technology has been on the market for > 5 years)
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Real-time visibility into packaging line’s performance (downtime sources, suboptimal processes, slow teams, aging equipment)

Up to 8% performance gain through optimization initiatives driven by actionable insights

Retrofitting the Hardware: For the older machines which could not send data, a simple wireless and battery-operated sensor mechanism was implemented. In other cases, data was tapped from existing SCADA, DCS systems. Therefore, the solution required no hardware changes to existing packing line system.

Faster Deployment: Overall deployment time is in minutes and not in days. Because of Datonis IoT platform’s wide range of connectivity protocols and ‘Thing’ templates, overall deployment time was in minutes and not in days. With platform features, data aggregation, processing, and reporting started immediately, and the solution came in operation instantly.

Hardware
Hardware that enables dual directional communication for data collection and control message delivery. Examples include cellular, Ethernet, and Wi-Fi.
Sensors transform energy into electrical data; they are the eyes and ears of IoT. Actuators transform electrical data into energy; they are the muscle of IoT.
IoT power supplies include traditional, thin-film and printed batteries, energy harvesting modules, flexible photovoltaic panels and thermoelectric sources.
Products used by end users that contain IoT technologies. Examples include enabled equipment, wearables, hand-held scanners, and tracking devices.
Software
Horizontal applications are standardized (e.g., asset tracking). Vertical applications are tailored to specific needs (e.g., delivery fleet management).
APIs are the market enabler for IoT. They allow users to manage devices, enable data transfer between software, and provide access capabilities.
IoT analytics includes real-time or edge computing and batch analysis. Analytics can be behavioral, descriptive, predictive, or prescriptive.
Visualization solutions use dashboards, alerts, events, maps, and other tools to present easily comprehensible data to end users.
Data management solutions capture, index and store data in traditional database, cloud platforms, and fog systems for future use.
Services
IoT data management consultancies help to make sense of big data, decide which data to maintain and for how long, and troubleshoot IT issues.
IoT hardware consultancies provide services such as solution specification, product design, connectivity setup, and partner identification.
IoT software consultancies support the development of data analytics, visualization solutions, and platforms, as well as integration into embedded systems.
Training programs range from executive workshops to technical programs intended to upgrade workforces with IoT expertise.
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