Augmented Assist – GoDigital

Manufacturing utilize large number of machines at every stage of the production process. A failure in any of these machines or line of machines could cause shutdowns that cost thousands of dollars per hour in lost production and other cascading impacts. Keeping these valuable machine/equipment’s running depends upon the experience of the service technicians who has the responsibility to maintain, diagnose and fix problems. Most Industrial world is facing a widening gap in the availability of experienced and qualified workforce. There is burdening service knowledge gap created with well-educated and technology savvy, younger workers not showing interest in manufacturing and technical service positions and potential entrants not having real-world experience of their predecessors. Hence there is a need for digitalising the industrial maintenance and field service process to achieve the goal of delivering effective, efficient, and profitable service.

The Augmented Assist Solution enables manufacturers and machine / equipment builders to increase maintenance effectiveness and machine availability by:

  • Delivering more contextual and operationally relevant data overlaid onto a live image of a machine or object. This could mean giving plant and maintenance personnel the ability to abstract backend systems information for 3D product navigation, step-by-step work instructions, and remote visual guidance.
  • Reducing manual errors, whether the error is caused by too little information, too much information, or poor quality information, AR applications place the right information and instructions at the location of the work task.
  • Improved Training effectiveness and efficiency to create workforce multiplier. Training hours can be reduced as AR applications can include video instructions on repair/replacement tasks overlaid on the machines themselves. Workers can do more by themselves versus sending multiple workers to address the same problem.
  • Improves safety of a work task. For instance, AR applications can include not only written instructions for removing or replacing a part on a machine, but can also include visual instructions. This assistance avoids unnecessary and possibly unsafe interaction with the machine.

Connect to your machines

Machines/Lines are already equipped with sensors that monitors various parameters like flow, pressure, vibration, voltage, current, speed and many others. These are transmitted as data to the control systems like PLC/CNC where operating decisions are made. By connecting to these controllers or/and the sensors/intelligent devices you get access to the various readings of these sensors.

Collect & Aggregate Data

The data from sensor readings and control system states are sent to an edge gateway that aggregates data and perform some local analytics. The edge gateway also reduces the amount of information to be sent to the next level, which in turn reduces bandwidth consumption and overall latency. This data is sent to a system to analyse further and store the data.

Alert and attempt to solve the problem

Using collected and aggregated data, you can predict when a specific component might be nearing failure and monitor the condition of in-service equipment to determine when maintenance is required. When maintenance is required, it can send an alert to the service technician for remote or field diagnosis.

Use Contextualization Data

When the field technician arrives at the machine, using an AR application on the smartphone, tablet or smart glass, the sensor readings and other diagnostic information, part list, repair instructions and other information is superimposed on an image of the machine. This provides a better contextualize information for the machine and job functions, specifically for personnel performing intricate assembly, maintenance and repair jobs. As the field technician’s moves around the machine, real-time diagnostic information provided by sensors for the area that is viewed is visible on the screen. Based on this combination of the real-time data, analytics and knowledge base, the AR application provides likely diagnoses along with procedures to correct each one.

Leverage Experts to diagnose the problem on-site

Once the field technician arrives in the site, he or she using the AR application in smartphone, tablet can see machine readings and diagnostic information, parts lists, repair instructions and other information superimposed on an image of the machine/part of the line. With this in-context access to detailed information, the problem can be solved even using a less experienced and lower cost field technician. However, when necessary the field service technician can call on the help of the remote expert and the expert can view the problem through the eyes of the field technician and provide guidance to solve the problem.

Enhance with Advanced Analytics

When AR is combined with IoT solution, you can quickly move from basic descriptive analytics to advanced analytics that can predict events such as machine failure, or simulate future events called prescriptive analytics. For AR applications, advanced analytics information supercharges its value. For example, field services personnel using an AR application to replace a seal or filter, may see that recent operating data suggest a more robust filter to extend the machine’s lifetime under new operating conditions. This benefits the customer and the service organization, potentially eliminating an unplanned maintenance trip.

Benefits


  • Building Speed, Efficiency and Quality in operations & maintenance
  • Reduce language barriers
  • Train human operators quickly & efficiently
  • Identify the defected component quickly & reduce downtime
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