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57 case studies
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Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics
ThingWorx (PTC)
ABC faced two major issues when utilizing the data collected. One is the size, complexity, and disparity of the data collected would take lot of man-hour to process and evaluate. Two is real-time data cannot be put into use due to the nature of data science analysis.


Industries: Machinery
Functions: Information TechnologyProduction & Manufacturing Engineering
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementPredictive Maintenance
Software:
Services:
Delivers Business Differentiation to Vantron
Delivers Business Differentiation to Vantron
Delivers Business Differentiation to Vantron
ThingWorx (PTC)
Taking advantage of the fast growth of China and the growing demands in embedded computer systems, Vantron technology was established in 2002 by Silicon Valley professionals and headquartered in Chengdu, China. In addition to readyto-run low-power embedded systems, Vantron also provides assistance in application software development, tailoring its embedded systems based on customers’ requirements, and offering turn-key manufacturing services. With customers in industries such as healthcare, heavy equipment, vehicle tracking and telematics, looking for customized solutions, Vantron saw more and more customers looking for interconnectivity through the cloud so that they could access and interact with their equipment remotely


Industries: Computer & Personal ElectronicsMachinery
Functions: Information TechnologyProduct Development
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Hardware:
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University Duisburg Launches NectOne for IoT Research
University Duisburg Launches NectOne for IoT Research
University Duisburg Launches NectOne for IoT Research
ThingWorx (PTC)
In order for the IoT to become fully operationalized, system integration of devices and data with existing businesses systems and processes is vital. In reality, many manufacturing companies like NectOne® with individual systems often find it very difficult to build and use intelligent structures between their systems. Many of the data sources as well as connected systems may be external to the business. This systems integration work can be complex and difficult to manage, but is vital to achieving business objectives. The final goal is to deliver cloud base production control.


Industries: Fast Moving Consumer GoodsMachinery
Functions: Product DevelopmentProduction & Manufacturing Engineering
Capabilities: Data Acquisition & ManagementEnergy ManagementMass Customization
Software:
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Marine and Industrial Displays by Caterpillar
Marine and Industrial Displays by Caterpillar
Marine and Industrial Displays by Caterpillar
Bright Wolf
Caterpillar needed a flexible platform for a new generation of connected human-machine interfaces across a wide variety of industrial environments. Examples include marine, petroleum pumping, generators, custom hydraulics, mining, and rail applications.


Industries: Heavy VehicleMachinery
Functions: Information TechnologyOperations & Maintenance
Capabilities: Data Acquisition & ManagementOverall Equipment EffectivenessPredictive Maintenance
Hardware:
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Wearables for Connected Workers
Wearables for Connected Workers
Wearables for Connected Workers
Intel
Together, Honeywell and Intel have developed a IoT proof of concept (PoC) for the Connected Worker. The Connected Worker can take many forms - factory laborer, mine worker, first responder, firefighters and more. For each environment and worker role, a different selection of sensors may be appropriate to provide the most meaningful IoT-fueled dataset to represent that individual worker asset.As with most IoT solutions, it is critical to avoid being overwhelmed by a steady stream of meaningless data. Rather, it is essential to send select actionable intelligence to the cloud for visualization and customized alert notifications.The downside is that data from individual wearable devices - if viewed independently - can potentially cause false alarms and contribute to inefficiencies in a manpower as a result. Fusing sensor technology with big data processing (hub/gateway), analytics - all in the cloud - is the key to improving local intelligence as well as remote visualization of actionable intelligence.


Industries: Machinery
Functions: Environmental Health & SafetyHuman Resources
Capabilities: Data Acquisition & ManagementEnvironmental Health & SafetyRemote Access & Control
Hardware:
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versiondog on the Trial of Big Bang
versiondog on the Trial of Big Bang
versiondog on the Trial of Big Bang
Auvesy
Backing up and monitoring of Industrial control system programs for the Large Hadron Collider (LHC) at CERN near Geneva, the world´s largest particle accelerator, has been entrusted to the data management system versiondog. The European Organization for Nuclear Research uses the system to manage the data of around 500 components, making versiondog one of CERN's standard technologies.


Industries: Machinery
Functions: Operations & MaintenanceResearch & Development
Capabilities: Data Acquisition & ManagementData VisualizationPredictive Maintenance
Hardware:
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Version watchdog enables online/offline alignment
Version watchdog enables online/offline alignment
Version watchdog enables online/offline alignment
Auvesy
When complex systems are developed for a customer and commissioned with a particular delivery state, a data management system can make it easier to archive commissioned versions and track subsequent changes made by the customer.


Industries: Fast Moving Consumer GoodsMachinery
Functions: LogisticsOperations & Maintenance
Capabilities: Data Acquisition & ManagementData VisualizationRemote Access & Control
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Logistics processes in safe hands
Logistics processes in safe hands
Logistics processes in safe hands
Auvesy
The latest logistics and automation technologies that help to safeguard work processes in large warehouses with complex, around-the-clock global distribution networks require regular changes and improvements to function optimally. At the same time, these modifications also increase the risk of errors or even production stoppages, which are unfavorable situations.


Industries: LogisticsMachinery
Functions: LogisticsOperations & Maintenance
Capabilities: Data Acquisition & ManagementData VisualizationInventory Management
Software:
Version Control for Systems and Machine Production
Version Control for Systems and Machine Production
Version Control for Systems and Machine Production
Auvesy
With the flood of data and numerous versions of software in the production environment of a firm, much time and effort is spent by workers searching, guessing or asking questions in order to solve issues.


Industries: Machinery
Functions: Information TechnologyOperations & Maintenance
Capabilities: Data Acquisition & ManagementData Visualization
Software:
Intelligent and Active Gas Detection System for Semiconductor Manufacturing
Intelligent and Active Gas Detection System for Semiconductor Manufacturing
Intelligent and Active Gas Detection System for Semiconductor Manufacturing
MOXA
As one of the world's largest semiconductor manufacturers, our customer needs to continually refine and expand their manufacturing capabilities to meet the constant, ever-growing demand for electronics products. Semiconductor fabrication requires minute nanometer-scale operations using dangerous chemicals and gases. To continue growing their manufacturing capabilities while maintaining high levels of precision, the manufacturer expanded operations with a new plant which was to incorporate new gas detection alarm technology.System Requirements• Real-time alerts of abnormal gas levels on the supervisory control and data acquisition (SCADA) system• Local alarms with local control logic to alert personnel of high gas levels• Mixed analog and digital I/O solution for broader device compatibility• High reliability


Industries: Computer & Personal ElectronicsMachinery
Functions: Operations & MaintenanceProduction & Manufacturing Engineering
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementEnvironmental Health & Safety
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Remotely Control Industrial Spray Pump Maximize Efficiency
Remotely Control Industrial Spray Pump Maximize Efficiency
Remotely Control Industrial Spray Pump Maximize Efficiency
CalAmp
Graco industrial sprayer customers needed real-time data to maximize utilization of assets and crews, to deter unauthorized use of equipment, to keep equipment in top condition, and to provide more accurate job estimates and billing statements.


Industries: Machinery
Functions: Quality Assurance
Capabilities: Billing & MonetizationData Acquisition & ManagementQuality Assurance & Control
Hardware:
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Providing Proactive Support with Intelligent Smart Services
Providing Proactive Support with Intelligent Smart Services
Providing Proactive Support with Intelligent Smart Services
PTC
“For us to maintain low costs and high customer satisfaction while providing improved response times, we need a better, faster way to resolve issues beyond dispatching onsite technicians,” explains Mark Hessinger, Executive Director of Worldwide Service at Gerber Scientific.Gerber faces a continuous need to train new personnel as they are brought into the service organization. A change in strategy for service allows Gerber to build a stronger technical support organization and a more efficient process to bring new field service engineers up to speed.“We have a lot of tenured employees in North America and Europe,” observes Hessinger. “In seven years, the loss of man years will accelerate, so we need to retain product knowledge before it becomes a greater issue and impacts our customers.”Hessinger and his team realized that they needed a solution to remotely connect to their products and identify, diagnose, and resolve issues. Ideally this would happen before their customers even become aware of a problem, reducing the dispatch of onsite technicians or improving first-time fix rates when onsite visits are required.By collecting data from their products deployed in production, the company could begin addressing the aging workforce issue by capturing and retaining information. Collecting information on consumables and parts could automate consumable resupply, optimize spare parts inventory, and enable Gerber to provide true preventive maintenance.“We do not have mean time between failure data because we don’t know how many hours our customers are actually using our products,” says Hessinger. “Some customers use our products a few hours a day, while others use them 24/7. Obtaining actual usage data will help us better plan our spare parts and the consumables required for run times.”Other capabilities identified to help build a business case for their initiative included minimizing product downtime, automating software patch distribution, offering value-added services, providing engineering with product usage data, and delivering remote training on product capabilities for distributors and new technicians.


Industries: Fast Moving Consumer GoodsMachinery
Functions: Human ResourcesOperations & Maintenance
Capabilities: Data Acquisition & ManagementPredictive MaintenanceRemote Access & Control
Hardware:
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Avoid Unplanned Downtime with Predictive Analytics
Avoid Unplanned Downtime with Predictive Analytics
Avoid Unplanned Downtime with Predictive Analytics
SAP
Objectives• Create an innovative IT environment that supports the move toward a solution-provider business model• Enhance existing business processes and leverage the power of Big Data and predictive maintenance to become more proactive, customer oriented, and competitive• Leverage the SAP HANA® platform to transform and simplify the entire SAP® solution landscape


Industries: Machinery
Functions: Information TechnologyProduction & Manufacturing Engineering
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Software:
Services:
IIC Smart Manufacturing Connectivity for Brown-field Sensors
IIC Smart Manufacturing Connectivity for Brown-field Sensors
IIC Smart Manufacturing Connectivity for Brown-field Sensors
TE Connectivity
The discrete manufacturing domain is characterized by a strictly hierarchical structure of the automation systems, commonly referred to as the automation pyramid. Data acquired by a sensor typically flows through an IO-module into a Programmable Logic Controller (PLC) which manages the local real-time control system. As all process data are concentrated in the PLC, re-programming the PLC and thus, implementing interfaces to access these data appear to be the natural choice to transfer them to the IT system. However, for brownfield installations this choice has proven impracticable for the following two reasons:In brownfield facilities, PLC usually operate within a once-specified environment and are rarely re-programmed. That is why the active staff is often not familiar with the code and lacks of the competence to modify the existing implementation in a reasonable amount of time.Furthermore, for cost reasons, any PLC was selected to exactly match the requirements of the environment within which it was intended to operate. That is why it cannot be assumed that a PLC will be able to support additional tasks such as communicating data through additional interfaces.


Industries: Machinery
Functions: Operations & MaintenanceProduction & Manufacturing Engineering
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementRemote Access & Control
Hardware:
Software:
Services:
Logistics Visibility Services
Logistics Visibility Services
Logistics Visibility Services
NEC
Fuji Xerox faced several challenges. Delivery inquiries from distributors had to be manually associated with order information and container B/L documents. Response to delivery inquiries was slow and delivery date estimates inaccurate because Fuji Xerox had to contact each transportation carrier for shipment status updates before warehousing dates could be estimated. Manual handling of an average of 1,800 inquiries a month created an excessive workload for staff. Distributors had begun securing extra stock in a system known as just-in-case inventory to prevent inventory shortages at hub warehouses in each region, leading to chronic over-inventory


Industries: LogisticsMachinery
Functions: LogisticsOperations & Maintenance
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Hardware:
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ABB Increases Productivity and Reduces Operational Costs
ABB Increases Productivity and Reduces Operational Costs
ABB Increases Productivity and Reduces Operational Costs
Cisco Jasper
ABB relies on Control Center to monitor connections to its customers' industrial robots for potential problems. As soon as conditions change, ABB engineers want to know about it so that they can act on it. Engineers wanted a solution so that they can anticipate problems by constantly analyzing the information that they receive from the devices. They have developed a set of predictive KPIs, which they share with their customers to help them decide if their equipment requires maintenance.


Industries: Machinery
Functions: Information TechnologyOperations & Maintenance
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementPredictive Maintenance
Software:
Services:
Reshaping the Shipping Industry
Reshaping the Shipping Industry
Reshaping the Shipping Industry
ionSign Oy
Loading of containers on to the deck of a container ship lacks correct data of container weight. This causes less than optimum load balance, risk of containers breaking loose and dropping to the sea, even capsizing. Further, the full capacity of the vessel can't be utilized with unreliable load weight data.


Industries: MachineryShipping
Functions: Operations & MaintenanceProduct Development
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementPredictive Maintenance
Hardware:
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Services:
Obbligato for SaaS in Thailand
Obbligato for SaaS in Thailand
Obbligato for SaaS in Thailand
NEC
A large amount of engineering work involving frequent specification changes not only resulted in a nightmare for staff but also caused a considerable amount of material wastage due to miscommunication and last minute change notices. Need a system that is not too complicated to manage, and is easy to learn and use for typical employees because there a shortage of specialist IT staff and the company employs many short-term contract employees. Need an application that is not too expensive to implement, easy to use and powerful enough to handle a large volume of work.


Industries: Machinery
Functions: Information TechnologyProduction & Manufacturing Engineering
Capabilities: Data Acquisition & ManagementInventory ManagementOverall Equipment Effectiveness
Hardware:
Software:
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Customized Price Plans
Customized Price Plans
Customized Price Plans
ZIN Technologies
Bosch security systems have quite a good number of resellers through which they sell security devices. For all of their security devices they have pre-installed SIMs/CDMA's in them. For each customer to have its own login and competitive prices for each operator was a big challenge. They offer the same services for each customer and therefore every customer spends the same amount of money for each device.


Industries: Machinery
Functions: Product DevelopmentSales & Marketing
Capabilities: Billing & MonetizationData Acquisition & Management
Software:
Services:
IIC Condition Monitoring & Predictive Maintenance Testbed
IIC Condition Monitoring & Predictive Maintenance Testbed
IIC Condition Monitoring & Predictive Maintenance Testbed
National Instruments
The current state of condition monitoring requires manual measurements that are compounded with aging equipment and the retirement of knowledgeable personnel.


Industries: MachinerySmart Grid
Functions: Facility MaintenanceOperations & Maintenance
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementPredictive Maintenance
Hardware:
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Services:
Wireless Vibratory Data Acquisition System for Maintenance
Wireless Vibratory Data Acquisition System for Maintenance
Wireless Vibratory Data Acquisition System for Maintenance
HiKoB
In the framework of its predictive maintenance offering, ONEPROD part of the ACOEM group provides monitoring solutions that allow to avoid unexpected breakdowns in industrial production tools. Traditionally ONEPROD was using wired data acquisition systems. However they were costly and hard to install in harsh environments or explosive zones, like in the oil & gas and mining industry. To cover the distance to connect and power the monitoring equipment considerable lengths of cable are required especially in industrial spaces with difficult access. Developing a wireless data acquisition system became a key success factor in the ONEPROD strategy in order to avoid any cabling issue and to improve the safety of the staff in charge of portable measures.


Industries: Machinery
Functions: Facility MaintenanceOperations & Maintenance
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementData Visualization
Hardware:
Software:
Services:
Schneider Automation PLCs
Schneider Automation PLCs
Schneider Automation PLCs
RTI
Schneider Automation wanted a solution to its PLCs on the factory floor so that they can meet cost target for manufacturing systems. The challenges were that the solution needed to connect smaller PLCs and embedded devices that have limited storages or processing capacities.


Industries: Machinery
Functions: Information TechnologyOperations & Maintenance
Capabilities: Data Acquisition & ManagementData VisualizationOverall Equipment Effectiveness
Hardware:
Software:
Services:
Connection Listing
Connection Listing
Connection Listing
ZIN Technologies
Bosch security systems offer solutions with pre-installed connections in it, which is tested once before it’s made available for sale. Now when they have sold the solution they had to made sure its working and there is no loss in connectivity. Bosch security due to its nature of business has to keep track of where the said device is installed so they can troubleshoot in case of any issues. Now to keep track of more than 10,000 devices is a hard thing if you do not have any reference against devices. Bosch needed a solution where they can add information against each connection about its specific location and could see at a single glance if it's working or not.


Industries: Computer & Personal ElectronicsMachinery
Functions: Product Development
Capabilities: Data Acquisition & ManagementData Visualization
Software:
Services:
Stepping up Production While Keeping Costs Down with Smarter Maintenance
Stepping up Production While Keeping Costs Down with Smarter Maintenance
Stepping up Production While Keeping Costs Down with Smarter Maintenance
IBM
To achieve its goal of doubling production capacity while keeping tight control of costs, major shoe manufacturer PT Chang Shin Indonesia set out to unlock greater efficiencies in its operations.


Industries: Fast Moving Consumer GoodsMachinery
Functions: Operations & Maintenance
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementPredictive Maintenance
Software:
Services:
Increased Range and Flexibility for Custodia Systems Customers
Increased Range and Flexibility for Custodia Systems Customers
Increased Range and Flexibility for Custodia Systems Customers
Vodafone
Custodia Systems is a security consultancy based in the UK. It was founded in 2005 by Peter Thompson, a former Goldman Sachs technology and engineering lead, with start up capital of £4,000 (approximately €4,800). It is now the global distributor of Appello tracking devices and its products currently protect £150 million (€180 million) of construction machinery in the UK.The Appello device is a small, portable unit (no bigger than a smartphone) with a battery life of up to two years. It has no external wiring and cannot be located by scanning devices used by professional thieves like GPS (Global Positioning System) units.The device is hidden, for example among the engineering of a piece of plant machinery and sends out a regular signal to mark its present location. Worldwide, Custodia Systems claims 80% of stolen equipment is recovered and back with its owners within eight hours.To ensure consumer confidence and provide a competitive advantage, Custodia Systems needed a fail-safe communications infrastructure that needed to be international, reliable and as accurate as possible. In addition, to support the launch of the AppelloGEO – a new product that can be used globally – Custodia Systems needed a global platform and fixed price international tariffs.


Industries: ConstructionMachinery
Functions: Operations & MaintenanceProduct Development
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementRemote Access & Control
Hardware:
Software:
Services:
Reducing Energy Costs Across Pella’s Manufacturing Plants
Reducing Energy Costs Across Pella’s Manufacturing Plants
Reducing Energy Costs Across Pella’s Manufacturing Plants
C3 IoT
Pella’s commitment to continually improve its processes for its team members and the environment has led the company to seek innovative technologies that advance overall productivity and the quality of its manufacturing operations.


Industries: Machinery
Functions: Operations & MaintenanceProduction & Manufacturing Engineering
Capabilities: Data Acquisition & ManagementEnergy ManagementOverall Equipment Effectiveness
Software:
Services:
The Connected Enterprise Optimizes Facilities and Supplier Networks
The Connected Enterprise Optimizes Facilities and Supplier Networks
The Connected Enterprise Optimizes Facilities and Supplier Networks
Rockwell Automation
Rockwell wanted to implement flexible and agile global MES for diverse product portfolio and a variety of manufacturing processes and replace individual ERP systems and custom application with a standardized system that spans all plants.


Industries: Machinery
Functions: Operations & MaintenanceProduction & Manufacturing Engineering
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Software:
Services:
奥迪-生产力提升20%
奥迪-生产力提升20%
奥迪-生产力提升20%
FORCAM
作为汽车行业内一家开创性的汽车制造商,奥迪享有极高的知名度。 奥迪的冲压件厂位于德国因戈尔施塔特和内卡苏尔姆,均配备有 FORCAM 的先进车间管理技术,在部署该技术后的第一年就提高了 20% 的生产力。在汽车行业内,小众产品目前正变得日益重要。过去几年来,汽车行业已经发生了相当大的变化。毋庸置疑,要想保持竞争力,就必须对客户的特定要求作出及时反应,这一点极为重要。在我们的社会变得日益个性化的同时,奥迪提供的系列车型也有所增加。


Industries: AutomotiveMachinery
Functions: Operations & MaintenanceProduction & Manufacturing Engineering
Capabilities: Data Acquisition & ManagementData VisualizationOverall Equipment Effectiveness
Software:
Services:
Boost in Online Orders and Aftermarket Revenues for Atlas Copco
Boost in Online Orders and Aftermarket Revenues for Atlas Copco
Boost in Online Orders and Aftermarket Revenues for Atlas Copco
Digabit
Printed parts manuals become less and less relevant and useful with time. The static information offered by printed documentation was no longer good enough for a major global player like ACC.ACC needed a solution that would deliver updated versions of documents to their network immediately. The company wanted a dynamic system, which would not only display current inventory levels, but also provide customers with information regarding how products should be used.Atlas Copco Construction’s Needs •Offer customers real-time part and information updates •Provide customers a comprehensive parts lookup and search platform •Administer an eCommerce platform with shopping cart and ERP integration •Produce a multilingual site for parts ordering


Industries: MachineryMining
Functions: Production & Manufacturing EngineeringSales & Marketing
Capabilities: Data Acquisition & ManagementInventory ManagementOverall Equipment Effectiveness
Software:
Services:
Consolidating the IT landscape
Consolidating the IT landscape
Consolidating the IT landscape
Bosch Software Innovations (Bosch)
The IT architecture had grown over 15 years and the EDI communication was spread across several EDI server. This involved high efforts which were to be reduced with the introduction of an EAI standard software:- Connection of about 100 partners and 400 customers, exchange of highly heterogeneous message formats, i.e. record structures, EDIFACT, customer specific formats, XML and binary files- Connection to FTP, E-Mail, mailboxes (IBM, Eurolog, Telecom) and MQ-Series- Reduction of maintenance and evaluation efforts, easy tracing of data flows, increase in performance, introduction of central error handling


Industries: Heavy VehicleMachinery
Functions: Facility MaintenanceLogistics
Capabilities: Data Acquisition & ManagementInventory ManagementOverall Equipment Effectiveness
Software: