Migration into the future
"Smart Equipment Monitoring" from Dürr Systems AG on ADAMOS On-premise technology increases the availability of automotive paint shops and improves the workflow in maintenance and servicing.
The „Smart Equipment Monitoring" innovation project of Dürr Systems AG and Volkswagen Poznań Sp. z o.o. launched in April 2018 marks a further milestone in the digital@DÜRR strategy. In the Września plant, it involves the continuous acquisition, analysis, and evaluation of process data from automotive paint shops as well as the administration of master, event, alarm, and measurement data as a basis for predictive maintenance and sustainable plant and process optimization. Also on board the innovation project is ADAMOS GmbH – in particular with its ADAMOS On-premise technology.
A paint shop in the automotive industry is a highly complex, interactive entity covering tens of thousands of square meters and made up of countless systems, robots, components, and devices. Anyone guaranteeing 99.5% reliability for these interacting parts of the productive whole must have the plant and process under good control. At the same time there are few opportunities left for further improvement. This is precisely the challenge that Dürr Systems AG faced.
“A reason for everything”
On the way to the targeted optimum reliability, two questions were at the center of the innovation work for the developers in Bietigheim-Bissingen: firstly “how?” and secondly “why?”. The “how” is about the way to the goal and the effort that OEMs and plant operators have to make in order to achieve the impressive reliability rate. The “why”, on the other hand, examines the concrete causes of the 0.5% gap ignoring Murphy’s Law, because mistakes do not happen without reason or forewarning.
Achieving the digital optimum with „Smart Equipment Monitoring"
However, the (traditional) mechatronic possibilities of mechanical and plant engineering did not provide answers to the open questions. It was not until the intelligent use of new streaming analytics methods around three years ago that the trailblazing perspectives that manifest themselves so impressively today in the “EcoPRO Plant Analytics” project for the Września plant opened up. The migration of the existing software solution to the ADAMOS platform and thus the use of On-premise analytics functionalities in the project made a significant contribution to the future project.
An efficient look behind the data
„Smart Equipment Monitoring" makes it possible to continuously acquire, analyze, and evaluate data streams from the plant in the closed VW network. For this, the system intelligently links data from several thousand sensors, actuators, and control loops and converts it into “smart data”. Dynamic setpoint/actual value comparisons are the basis to that. „Smart Equipment Monitoring" can also detect anomalies in the process sequence based on unusual behavior patterns across specific signal groups and time ranges.
Finally a digital condition image is generated from the sum of the digital insights, which the diagnostic intelligence of “„Smart Equipment Monitoring" can use to reliably predict the key parameters:
When does a paint shop leave the specified window of the defined production conditions?
Where specifically should the source of error be sought?
This results in a number of improvements for operators and manufacturers of the plant:
- Integrated increase in process quality and overall equipment effectiveness
- Reduced effort to ensure availability for operators and OEMs
- Increased efficiency of on-site maintenance
- Optimization of service quality through intelligent remote support
- Reduction of basic operating complexity
- Optimization of the “first run rate” (percentage of vehicles produced with good quality after the first run through the plant without reworking)
- Incorporation of the insights into continuous process and plant optimization
"The next big Thing"
Predictive maintenance has become a convincing reality with „Smart Equipment Monitoring". Real-time adaptability would be the next level of “smart” use of new streaming analytics methods. This is still a long way off. However, the systems already offer the necessary sensory and control equipment today. In addition, Dürr Systems AG and the „Smart Equipment Monitoring" software will learn with each analysis, while the ADAMOS IIoT platform offers the necessary performance in the field of artificial intelligence and machine learning. What is missing, however, is the availability of appropriate measurement data for developing faster and above all 100% “trustworthy” algorithms. It is just a matter of time until Dürr Systems AG and ADAMOS can meet this challenge.
Dürr Systems setzt auf ADAMOS
The ADAMOS migration of "Smart Equipment Monitoring" at Volkswagen Poznań Sp. z o.o. for the plant in Września is the first ADAMOS On-premise testimonial worldwide. The project is a direct consequence of the involvement of Dürr AG as a founding member of the ADAMOS Alliance in September 2017.
The declared goal of this strategic investment is the harmonization of the Group’s IIoT technologies across all corporate divisions and Group companies. Further ADAMOS applications, including for balancing machines from Carl Schenck AG, are already being implemented.
As a strategic added value, the ADAMOS platform of Dürr AG offers the possibility to consistently implement all application scenarios in the areas of public cloud, private cloud, hybrid cloud, and edge computing on the basis of the comprehensive ADAMOS IIoT and platform portfolio.