Executive Summary
This case study showcases how a leading manufacturer successfully integrated Programmable Logic Controllers (PLCs) with ERPNext, their Enterprise Resource Planning (ERP) system, to implement predictive maintenance. This integration resulted in significant improvements in machine uptime, reduced maintenance costs, and optimized production planning.
Challenge
The manufacturer faced increasing downtime due to unexpected machine failures, leading to production delays and lost revenue. Traditional reactive maintenance, based on scheduled repairs, proved inefficient and costly. They needed a proactive approach to predict and prevent failures before they impacted production.
The Solution
The company partnered with Korecent to implement an integrated solution of PLC data acquisition and ERPNext analytics. Our team:
1. Installed sensors and gateways: We connected various sensors to critical machines, capturing real-time data on parameters like temperature, vibration, and energy consumption.
2. Configured PLC communication: We established seamless communication between PLCs and ERPNext, ensuring data accuracy and timely updates.
3. Developed custom dashboards: We built interactive dashboards within ERPNext, visualising operational data and highlighting potential anomalies indicative of impending failures.
4. Integrated predictive models: We implemented machine learning models trained on historical data to predict failure probabilities and recommend preventive maintenance actions.
Results
1. Reduced downtime by 25%: Predictive maintenance enabled early detection and intervention, preventing major breakdowns and minimizing production disruptions.
2. Cut maintenance costs by 15%: By focusing on targeted repairs, the company avoided unnecessary maintenance interventions and optimized resource allocation.
3. Improved production planning: Accurate failure predictions facilitated better scheduling of maintenance activities, minimizing impact on production schedules.
4. Enhanced transparency and decision-making: Real-time data and intuitive dashboards empowered staff to make informed decisions about machine health and maintenance planning.
Key Takeaways:
Integrating PLCs with ERPNext for predictive maintenance provides a powerful solution for manufacturers seeking to:
1. Optimize production uptime and efficiency.
2. Reduce maintenance costs and resource utilization.
3. Improve product quality and consistency.
4. Gain real-time insights into machine health and performance.
5. Make data-driven decisions for proactive maintenance planning.
Replicating Success:
Korecent offers expertise in integrating various hardware devices with ERPNext to enable predictive maintenance across industries. We can help you:
1. Identify critical machines and data points for monitoring.
2. Design and implement a customized data acquisition and analytics solution.
3. Develop and integrate predictive models tailored to your specific needs.
4. Train your staff on using the system for effective maintenance planning.
Call to Action:
Contact Korecent today to discuss how integrating PLCs with ERPNext can transform your maintenance practices and boost your manufacturing efficiency.
