KCBS Expertise - iotone.com › files › pdf › vendor › KC_PDF... · production and condition parameters using standard libraries like FOCAS or KCBS data logger. •Live dashboards,

• KCBS Expertise

• KCBS Hardware Specifications

• Case Studies of our Successful Implementations

• KCBS Solutions Overview

• Our Value Proposition & ROI

• About KCBS

TOPICS

www.kcbsindia.com | [email protected] | +91-9444 35 38 16

Shop-floor Automation and Management

Industry 4.0 / Industrial IoT Solutions


MACHINE DATA ACQUISITION IS OUR EXPERTISE

We collect machine data thro’

sensors, Interfaces and generate

live dash boards, alerts and insights.


Our Domain Expertise

• IoT Enabling Products for Field Performance Monitoring

• Energy Monitoring Application for all Industries

• Discrete Manufacturing, Machine Tools Industry

• Plastic and Injection and Blow Molding

• Metal Casting and Forging

• Painting, Electroplating and Galvanizing plants

• Cooling Towers

• Metal Fabrication and Welding


Data Logger Hardware Specs


Ethernet

Machine Runtime, Idle & Breakdown time Overall Equipment efficiency

Alerts for over speeding and mis-use Alerts for Coolant and Lubrication levels Production Qty, Rejection rates Actual Cutting time, Tool life alert Vibration and Energy Trends

ACS712

Current Vibration Sensor Sensor

KCBS Data Logger

Use Case: Moni tor CNC machines to improve Equipment e f f ic iency,

ef fect ive energy management and reduce machine breakdowns

Benefits Achieved:

• 20% Improvement in operator efficiency

• 30% reduction in failures

• 15% reduction in energy consumption

Client: Leading Automotive parts

manufacturer MNC in India

• KCBS CNC monitoring solution acquires

production and condition parameters using

standard libraries like FOCAS or KCBS data

logger.

• Live dashboards, Alerts and Reports helps to

improve the equipment efficiency.

• KCBS’ s proprietary Vibration sensors provides

real-time accurate vibration data that helps to

avoid machine breakdowns.

• Energy Monitoring helps to manage the energy

usage effectively Project Status: Running for 1+

years (installed base 50 CNC machines).

• Phase 2 being planned for additional 350

machines.


• KCBS cloud based compressor monitoring solution

helps to monitor critical parameters of the

compressors and manage them remotely

• Live dashboards and Reports helps to improve the

equipment efficiency

• Alerts on set parameters help to take preventive action

to avoid compressor break downs

• Energy Monitoring helps to manage the energy usage

effectively

• Project Status: Pilot implementation(10 machines)

Use Case: Manage Compressors remotely, monitor critical

parameters and create Alerts

Benefits (Target):• 20% Improvement in operator efficiency• 10% reduction in failures• 15% reduction in energy consumption

Client: Leading Screw Compressors OEM in India


Use Case: Monitor

Electroplating machines to

improve efficiency, reduce

machine breakdowns and

manage consumables

Benefits (Target):• 20% Improvement in operator efficiency• 10% reduction in failures• 25% reduction in Consumable consumption

Client: Leading Electroplating

Company in India

• KCBS Electroplating Machine Monitoring Solution Acquires Production And Condition Parameters Level, ph, temp, current) kcbs Data Logger

• Live Dashboards, Alerts And Reports Helps To Improve The Equipment Efficiency

• Storage Tank Management Helps To Effectively Manage The Consumables In The Storage Tank

• Project Status: Pilot Implementation


Use Case: Remote Machine Monitoring Of Captive/Ancillary

Units To Manage Production Efficiently

• KCBS Cloud I-IoT solution offers a machine monitoring solution that enables the Manufacturer to

manage the production and equipment efficiency of their Ancillary units effectively from Remote.

• The Mobile access to the application enables to view live dashboard and reports from anywhere.

• The solution offers to manage both Manufacturer’s shop-floors and their ancillary unit’s machines help

them to have visibility on overall production and effective usage of their equipment.

Project Status: Running for 8 months with 2 captive& 2 comakers(25 plus CNC machines)

Benefits Achieved:• 20% Improvement in production efficiency• 10% reduction in downtime

Client: Leading Jewellery and Watch

Manufacturer in India


Client: Leading FMCG Bottling

Plant in India

Benefits Achieved:• 20% Improvement in production efficiency• 10% reduction in downtime• 15% reduction in energy consumption

• KCBS Injection molding machine monitoring solution helps to reduce downtime and energy costs

• Live dashboards and Reports helps to improve the equipment efficiency

• Alerts on set parameters help to take preventive action to avoid break downs

• Energy Monitoring helps to manage the energy usage effectively and reduce energy costs

Project Status Running for 6 months(8 m/cs pilot 76 Total number of machines)


Use Case: IoT Solution - Metal Foundry - Melting Process

Productivity/Efficiency

Benefits (Target):• 20% Improvement in production efficiency• 10% reduction in downtime• 15% reduction in energy consumption

Client: Leading Auto Industry Steel

Foundry Plant in India

• Digitization Of Manual Value AddedProcesses-input And Output Process OfMelting Furnace

• Sensor To Cloud Solution To Extract Data –

Efficiency Condition Parameters

• Dashboards/Kpi’s Including Mobile App

• Integration With ERP System

• Project Status Pilot Implementation


Use Case: IoT Solution to manage cooling towers remotely

to improve operation efficiency and manage failures

Client: Leading Cooling Towers

company in India

Benefits (Target):

• 20% Improvement in operator efficiency

• 30% reduction in failures

• 15% reduction in energy consumption

• KCBS IoT solution for Cooling towers

collects critical parameters and sends them

to KCBS cloud for live monitoring and

alerting

• The cloud model helps to manage the

cooling towers remotely

• Energy data monitoring and analytics helps

to take appropriate action reduce energy

consumption

• Project Status: Pilot implementation


Use Case: Iot Based Solution For Solenoid Actuators

To Reduce Abrupt Breakdowns

• KCBS Solenoid life monitoring solution helps to monitor the usage and send predictivemaintenance alerts

• KCBS IoT device installed with every Solenoid actuator sends actuators life data to KCBSmobile App on demand

• KCBS IoT device installed with every Solenoid actuator sends actuators life data to KCBS

mobile App on demand Project Status Running for 10 months -100 pcs

Benefits Achieved:

• 20% Improvement in production efficiency

• 10% reduction in downtime

Client: Leading Solenoid

manufacturers in India


Iot Enabled Distribution Transformers

GPS Enabled Remote Monitoring And Alerts Thro’ SMS

• Client : Japanese conglomerate, Market leader in Power Systems, Social Infra

Equipments, Semiconductors and Office Mobile Devices,

• KCBS Scope : Development of Hardware, Firmware, AWS -IoT porting From PoC to

Field Beta Testing


Iot Enabled Distribution Transformers

GPS Enabled Remote Monitoring And Alerts Thro’ SMS

Functionalities Supported

• Monitoring oil Temperature

• Monitoring oil Level

• Tamper Detection

• GSM-GPRS Data and Alarms thro ’ SMS

• Audio – Visual Alarms

• GPS position indication

• Battery based operations, Battery Back up for 1 hour (min)

• Three Phase LV Current and Voltage Measurement

• Amazon Web Services – IoT Implementation


Ethernet / RS232 / RS485

Fanuc / Siemens / HaaS / Mitsubishi / Makino CNC Machines

Category 1

K-TypeACS712 ThermocoupleADXL345Current Accelerometer Temp Sensor

Sensor Vibration Sensor

Category 2

Conventional CNC Machines, Special Purpose Machines

Live Dash BoardsAnd Alerts

Office Mobile Devices

On-Premise CNC Machine Monitoring Solution

Float typeLevel Sensor


Operator Dashboard

Operator dashboard can show the machines belong to the logged-in Employee with Employee ID, Login time, Date, Shift details are displayed

along with live production and OEE data


CNC Live Dashboards


Mobile App – Dashboards And Reports


Shop-floor Paperless Management

• Operator enters data before shift starts• Selects Employee ID• Select the FG part number of the product to

be produced for the shift• Number of products per cycle

Data Collection when shift starts

• Machine goes to Idle status for more than 15 minutes, Operator will be alerted to book idle time

• Operator books idle-time under Break-down reasons

Operator Idle Time Booking


Tool-life Management

Tool life Monitoring and SMS Alerts

• Tool list with Life Count and Current Count

• Send SMS Alerts to Tool room for life crossing 90%

• Update tool data from Barcode/ QR code

• History reports of Tools


Preventive Maintenance

Configuration Schedule

Analyze with Alarm historyand enhance checklist

Maintenance Execution

Analyze and Enhance checklist


Shop-floor Quality Management

Operator scans the part after production

• Operator inspects the part after the production

• Classify into good, rework needed and rejected

• Operator Rework reason or Reject reason on

Operator dashboard based on the quality

Operator inspects and enter quality data

• Optional Barcode or QR code scanning for

part count

• Operator scans for each product after the

production

• Part count from scanner will override the

part count from machine that gives better

accuracy


Energy Management – Live Dashboard

Power Factor Avg 0.999000013

Power Factor Red 0.999000013

Power Factor Yellow 0

Power Factor Blue 0

Frequency 50.08371353

Voltage Line to Line 162.1385651

Voltage Line to Nuetral 81.05152893

Voltage Red Yellow 243.0788269

Voltage Yellow Blue 0

Voltage Blue Red 243.3368683

Ampere Avg 0.148502842

Ampere Red 0.44550854

Ampere Yellow 0

Ampere Blue 0

Watt_Total 108.3701172

Watt Red 108.3701172

Watt Yellow 0

Watt Blue 0

Watt_Hour 29.90679169


ERP Integration

ERP integration for Work Order Management

• KCBS has flexible options to integrate with existing ERP applications

• APIs or direct DB access, KCBS can read and write data to pull work orders to be processed for the particular machine, day and shift and sends data back to ERP

Planning integration

• Shift planning to process work orders for each machine and

manage operators for each Bay/Zone/Cell to execute

orders can be pulled from the existing ERP system and

integrated with KCBS.

• KCBS paperless shop-floor automation with ERP integration

gives a seamless complete solution.


Reports Thro’ Daily E-mails


Power BI – Analytics : Insights 1


Power BI – Analytics : Insights 2


We Help To Improve Machine Utilization, Quality And Reduce

Operational Cost


Customer Benefits And Roi

Maximize production by monitoring and

improving OEE

-10%

+20%

-10%Reduction in machine downtime by

predictive maintenance

Reduction in energy costs by monitoring

And reducing power consumption per part



Bin Management Solution for Assembly warehouses


Smart Solution for Warehousing

OUR VISION OUR MISSION OUR MOTTO

Our vision is to be the highest level of IOT

solutions and service provider to satisfy our

clients’ expectations and to provide an environment to

prove the excellence

To help our clients achieve their business objectives by providing innovative, best-

in-class consulting, IOT solutions and services. To

direct all our efforts in achieving the excellence in

current IOT industry.

Our business should benefit the people and

society. We devote our talent and technology to create superior products

and services that

contribute to the economy of our nation

About Us


OUR PROJECT FLOW

KCBS evolves client-specific strategic initiatives with a dual aim to achieve cost

savings, and to improve on quality of services offered

PLAN &CREATE!

BUILD ASKILLED TEAM

MAKE QUALITYPRODUCTS

PUBLISHWORLDWIDE!

1 2 3 4

The Foundation of any

successful business

starts with a rock solid

plan of action

We had a good and

effective team, who are

having confidence to

handle any kind issues

in the project

We are committed to

provide quality

products and services

to our customers which

will enhance their

productivity

We delivers a wide-

range of value added

services adopting a

unique approach of

integrating people,

processes and

technology

Our Project Flow


Documents

KCBS Expertise - iotone.com › files › pdf › vendor › KC_PDF... · production and condition parameters using standard libraries like FOCAS or KCBS data logger. •Live dashboards,