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Manufacturing strives to become a predictable process, but is often plagued by unexpected problems. And time and money can quickly add up in trying to find and fix the cause. With many plants and machines working together, the interactions within a process can be complex and difficult to assess. A viable solution is to use a whole system monitoring approach that eliminates guesswork, identifies the real problem, and maximizes data collection. Taking the bold approach of monitoring the entire system gives engineers a clearer picture that fills in coverage gaps and reveals hidden issues. There are 3 steps to implement this approach and significantly improve existing surveillance efforts.
Dig Deeper – Include equipment in inaccessible places
Do you have places that are difficult to access but could benefit from surveillance? Some detection solutions must have a power source or require routine maintenance to function (battery changes). This makes inaccessible places with little infrastructure difficult to monitor and maintain. The solution is to find a sensor that thrives in these places. Energy harvesting collectors only need the smallest amount of energy to recover. This energy can be found even in remote places with little infrastructure. For example, hard-to-reach locations may include prohibited tunnels, roofs and chimneys, as well as equipment installed very far away. Therefore, these are the exact places that could benefit greatly from monitoring but where you don’t want to worry about changing the batteries. In addition, the energy recovery sensors feed continuously and are always on. Encompassing all equipment is a critical step in implementing whole system monitoring and it is now possible.
Extend the Reach – Monitor more components in parallel
You probably already have a surveillance system in place, but most detection solutions come with fixed capabilities. At this point, you may be just scratching the surface. Rather than replacing existing systems, upgrading capabilities is another step in achieving overall system monitoring. Again, self-powered energy harvesting collectors are designed to complement existing systems and fill in the gaps. Energy harvesting sensors can monitor more components at a time as they are not limited like battery powered sensors which “do less†in order to have a longer life. Simple plug and play options extend the number of machines and the performance characteristics monitored. As a result, engineers are given a rich data set that creates a complete picture and can be used immediately.
Receive alerts – Monitor your entire system in real time
Finally, machines and equipment need maintenance to keep them running smoothly. Monitoring the entire system gives engineers the advantage of seeing equipment as requiring predictive and / or preventative maintenance. Engineers can identify which machines are performing well with regular, scheduled maintenance and which machines are performing well until something goes wrong. And before that “something” goes wrong, the dashboard scan will alert and notify engineers of any inconsistencies that could lead to mechanical production failures.
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COD systems offer self-powered energy harvesting sensors that are great for inaccessible places, monitor multiple components at once, and notify you if something goes wrong. Monitoring the entire COD system is a cost-effective solution and simplifies problem diagnosis with a rich and robust data set. To get started with affordable COD monitoring tools, visit dcosystems.co.uk, send an email to: info@dcosystems.co.uk or call: 01285 359059.
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