A leading food manufacturer has over 1000 metres of conveyor belts split into 52 individual sections at one of their sites. These conveyor belts are used to transport product from one part of the large factory to another and some of the conveyor belts are located overhead or in locations that are not frequented by personnel. Operators relied on ”following” the product whenever a line started up which meant leaving other manning stations unattended to carry out the task. Each conveyor belt had its own individual drive motor, belt, tension, rollers and assembly of which any would fail on occasion. This resulted in product pile up, waste, downtime and reduced efficiency. The client required an affordable solution which the operators could easily interface with.
Traditional CCTV would not work for this application as the number of cameras required would be significantly large. In addition there was a need for automated real time alerts for any adverse event that occurred. Smartenise initially developed a replica model of the conveyors and connected sensors onto the model. Using the model, a virtual twin was created and various scenarios mimicked. These included successful Line Startup, Line Startup with one of the conveyors not starting, Line Running and one of the conveyors suddenly stopped. These simulations were used to create a virtual twin visualisation of the line on the Smartenise platform. A Proof of Value was realised, with the client able to see the solution at work before deployment. Upon completion, an led beacon and audible alarm were integrated into the system for the operators without the need for long cables running everywhere