Production measurement and quality capture running without an operator

The situation before

Production data was collected by operators writing it down and entering it at the end of a shift. Figures were therefore always one shift late.

When a quality deviation appeared, its cause was hard to trace because nothing recorded the machine conditions at the time. Inspection also rested entirely on operator eyesight, which degrades as a shift wears on.

What we built

We installed direct data acquisition from the sensors and machinery, plus automatic image capture at the inspection points, feeding a monitoring board on the production floor.

Above that runs a flow that checks whether readings stay inside the safe range and raises an alert the moment they leave it, while a batch is still running rather than after it has finished.