Smart factory transformation with IoT-based production monitoring system

Introduction

In the manufacturing industry, efficiency and precision are critical for success. One of Vietnam’s leading air conditioner manufacturers recognized the need to enhance its production monitoring capabilities to maintain quality and maximize output. With over $72 million invested in building a state-of-the-art factory, the company sought a robust IoT-based solution to oversee production lines and optimize performance.

Partnering with GITS, they successfully implemented a Machine & Production Monitoring System, enabling real-time data tracking, defect detection, and process optimization.

Customer overview

Our customer is a top-tier air conditioner manufacturer in Vietnam, operating a modern factory with a production capacity of up to one million units per year. Their goal was to gain real-time insights into their factory operations, including output levels, machine condition, and workforce performance, to make data-driven decisions and enhance efficiency.

By implementing an advanced monitoring system, they aimed to:

– Track production line performance in real-time.

– Identify inefficiencies and defects quickly.

– Improve decision-making for operational enhancements.

With these objectives in mind, they collaborated with GITS to develop an IoT-enabled, web-based monitoring system tailored to their needs.

Our Solution: smart IoT-driven production monitoring system

To meet the customer’s requirements, our team designed a comprehensive IoT system with two key components:

1. Real-time data collection and analysis from machines

The system collects and analyzes production data directly from machines on the assembly line. This process happens in real-time, ensuring that managers always have access to up-to-date information. All collected data is stored securely in a database, allowing for historical tracking and performance evaluation.

2. Web-based monitoring system for visualization & decision-making

The monitoring system is built using modern web technologies, providing a user-friendly dashboard that allows factory managers to visualize data through charts and reports. The interface presents critical production metrics in an easily digestible format. With these insights, managers can make informed decisions to optimize production processes, reduce downtime, and improve overall efficiency.

Development & implementation scope

Our team was responsible for the complete development cycle, including:

– Creating IA/SRS documents to define the system architecture.

– Designing the database and backend infrastructure for smooth operation.

– Programming and testing the system to ensure accuracy and reliability.

– Deploying the application and providing ongoing maintenance and support.

Technical overview & system architecture

The system is structured with a two-server architecture to ensure efficient data flow and high performance.

– The NGINX Server handles the front-end, developed using React.js, ensuring a smooth and interactive user experience.

– The Tomcat Server powers the backend, built with Spring Boot, which processes monitoring system logic and facilitates communication with the database.

– The system is integrated with multiple databases, including Oracle DB, MS SQL, and FireBirds, ensuring flexible data management and compatibility with existing factory infrastructure.

Real-time data processing allows for immediate updates from machines on the production line, enabling instant alerts and detailed performance analysis.

Project success & impact

The implementation of the Machine & Production Monitoring System has resulted in significant improvements:

– Factory managers now have real-time visibility into production performance, allowing them to make faster and more accurate decisions.

– The system automatically detects and flags machine malfunctions or inefficiencies, reducing downtime and increasing operational efficiency.

– Comprehensive data analytics enable management to optimize production lines, minimize waste, and improve product quality.

With these improvements, the manufacturer has streamlined operations, reduced production delays, and enhanced overall efficiency. This transformation sets a new standard for smart manufacturing in the industry.

Project details

– The development methodology used for this project was AGILE / SCRUM, ensuring flexibility and continuous improvement.

– The project was executed with a team size of five developers per month.

– Development started in April 2020 and is still ongoing to refine and enhance the system.

– The technology stack includes Java Spring Boot for backend development and React.js for the frontend interface.

Conclusion

By leveraging IoT technology and a web-based monitoring system, GITS helped a leading air conditioner manufacturer transform their production process. The system provides real-time monitoring, quick issue detection, and improved operational control, ensuring higher efficiency and better decision-making.

If your business is looking for a smart manufacturing solution to optimize factory operations and enhance efficiency, contact GITS today to explore customized solutions for your industry needs.