Predictive Maintenance

Problem

A customer wanted to track the movement of assets within their 10,000 sq ft warehouses in 4 predefined areas. They also wanted to track productivity of assets, theft and access to real-time data for better decision making.

Solution

Each zone was covered with mesh network of fixed COIN devices which are then connected to the cloud via our Wi-Fi or Ethernet gateway and then all assets will be tagged with an additional set of FIND units, thereby enabling accurate real time location tracking of all assets via the cloud.

We need one set of fixed COINs, one set of FINDs for tracking. A FIND has to be placed on each asset to track it accurately and another set of fixed COINs in the meeting rooms etc to serve as the backbone network for asset tracking and triangulation. Also create geo-fence so as to trigger an alert when the asset moves out of the specific area. Gateways will be required depending on the number of COINs involved.

Benefits:

Reduced asset tracking time
Reduction in theft
Increased productivity

Additional use cases which can be offered for warehousing are: People tracking, predictive analysis and condition monitoring.

PROBLEM:

COVID-19 pandemic is a health and humanitarian crisis, and businesses have had a massive impact in terms of production and business continuity. While the crisis unfolds, Businesses will prepare for what is coming next and want to rapidly adjust to the ‘New Normal’.

A global leader in Quick Service Restaurants (QSR) was facing issues in restarting large-scale operations across multiple locations. The Management team needed help in monitoring locations of all employees at their offices, warehouses, outlets, etc. and ensure they maintain social distancing as per government norms. As part of employee well-being, they also wanted a solution to track employee contact history in case any of their employee was infected, so that their first-level contacts could be identified and isolated immediately. This would not only ensure employee safety but will also play a vital role in business continuity. Necessary actions could be taken only if they had access to such critical information real-time.

SOLUTION:

SenseGiz has served many large enterprises with asset & people tracking solutions. To address to the current COVID-19 pandemic, we built a world class solution on our existing platform to help prevent further business shutdowns and ensure employee health and safety.

We analysed the customer requirements and customized a solution based on that. With our solution, Social Distancing can be enforced in any factory/office environment and detailed Historical Contact Tracing can be done to minimize disruption and quickly isolate only the affected people and areas.

Social distancing enforced in factory/office environment

HOW IT WORKS:

Each employee is assigned a FIND device, which helps in unique identification. Employees have to wear the FIND as a tag or wrist band.
There are COINs and GATEWAYs installed across the facility at fixed points.
FIND will track every movement of the employee and relay this information to the nearest available COIN
FIND will also give an audio alert (buzzer/beep) to the users if they violate or come in close contact with other employees. The same information is sent to the Admin as well for further action
COINs form a mesh-network (proprietary) and transmit this data from FINDs from one node to another (COIN to COIN communication).
WiFi or Ethernet GATEWAYs located at strategic locations retrieve this data from the COINs and pushes it the cloud, using which, the admin can access dashboards with real-time information
Admin can assign a FIND, set social distancing threshold value, track location and violations with duration, as and when it happens since the Admin will have access to real-time information from the reports generated through our dashboard.
Admin can access real-time data via these Dashboards, and track employees if they are not following social distancing norms.
The Dashboard and reports can help the Admin identify the location where the violation /contact has occurred, which employees are involved, time duration, etc.
Admin can also set Geo-fencing for certain locations so that we have restricted entry only for certain employees and can also trace via historical data of employees to ensure infected employees/users and their contacts are quarantined and there no impact on the business.
Admin can do multiple tasks such as assigning work-shifts via the Dashboard, check battery status of individual FINDS, access reports along with LIVE monitoring

BENEFITS

Easy integration with no additional IT hardware.
QR code scanning for registration and reusability
Economical and Scalable
Location-based workflow management
Real-time people tracking
Improved workforce co-ordination
Real time alerts for all violations
Historical and current data reports through intelligent algorithms
Contact tracing for employees detected with COVID19 virus
Isolate only the affected employees and areas. Helps with business continuity
Data remains private to the customer and is not shared with any third party
Adherence to Government norms & quickly contain any outbreak

Video for SDCT solution

Problem

At an International airport, they wanted to monitor the temperature and Humidity of the waiting area at the departure zone and give real-time alerts for any change in temperature.

Solution

Our COIN devices were installed at every 50 to 60 feet across the area and we were monitoring the temperature and humidity of the zones. The data was captured in 2 ways;

Setting upper and lower threshold values–The admin can set the upper and lower threshold values for temperature and humidity to get alerted in case the threshold values are crossed
Stream data at regular intervals of time – Temperature and Humidity data can be streamed at regular intervals of time and all this data can be seen in real time on our dashboard

Condition Monitoring Airport
Benefits: Reduction in electricity consumption by 10%

Potential: There are 125 airports in India, where this solution can be deployed.

Perimeter Security solution for a Security Solutions company

We are offering Perimeter Security solution to several customers to detect illegal intrusion across agricultural lands and private properties.

Problem

The customer wanted to;
• Get real time data on trespassing and intrusion activity in an area where no person is allowed.
• The entire perimeter was to be covered against such activities and hence the solution was required to be very cost effective and efficient.
• No false alarms due to rains, winds etc.

Solution

We have deployed our COIN devices in such a way that,
• The entire is covered with our COIN devices which were placed at a distance of 40 feet from one another, forming a mesh network
• Sensors in the COIN will detect intrusion activity and send real time notifications to its users, which helps them take appropriate action.
• Due to its small size, the COIN is not visible to the intruders.
• The COIN devices can also be integrated with the existing security cameras.

We are also exploring wired COINs for underground communication applications and wired COINs with wireless communication for on-ground applications.

Perimeter Surveillance

A government organization wanted real time data on trespassing and intrusion activity in an area where no person was allowed. The entire perimeter was to be covered against such activities and hence the solution was required to be very cost effective and efficient. The organization also demanded no false alarms due to rains, winds etc.

The perimeter was covered with our COINs. Sensors in the COIN would detect intrusion activity and send real time notification to its users, which helped them take appropriate action. Hence a perfect fit in such cases. Due to its small size, the COIN is not visible to the intruders.

Benefits

Hundreds of kilometers of area can be secured using COINs
Solution is economical
Physical surveillance reduced
80% Increase in People Safety
Detect multiple intrusions simultaneously even in the presence of background environmental noise
Can differentiate between animals and humans
Get real time alerts with location, if someone is trying to intrude the perimeter

Problem

A world-leader in welding rod manufacturing company working in 3 shifts wanted to monitor vibrations of machines, measure productivity especially in 3rd shift by monitoring On/Off time, further vibration of the machine due to change in the worker and also predict the failure in advance. This deployment was different from any other predictive maintenance use cases as we had to deep dive into the data.

Solution
To overcome this issue, we have deployed Pro version of COIN on the machines to gather accelerometer sensor data in all the 3 axis, viz. axial, horizontal and vertical direction. We run a complex algorithm on COIN where in data from COIN is analyzed and a final output is displayed on the dashboard. Currently we are streaming data every minute from accelerometer and gyroscope sensor. There is an option to set threshold values for each of the sensors and get alert only when it crosses.

With this deployment the customer gets lot of insights on the machine vibration, predict the failure well before it happens, and also the pattern in which machines are running.

Benefits of the system

a. Overall Machine Performance Parameter monitoring
b. Machine utilization report and alarm indication if idle for more than defined time slot
c. Real time data processing and online update collection at the central server
d. Automated Report, Customized Analytics and dashboard and notifications of Processed Data
e. Cost-effective Data transmission- 3G/LTE, multiple-sim aggregation
f. Measure the productivity by shift and operator wise

Expected RoI:
• Reduce losses due to unplanned shutdown
• Reduction in replacement cost of bearing, gearbox repairs, motors, etc.
• Estimate on ROI is 6 months

Problem Statement: A customer in 4-wheeler Sales & Service wanted to track the vehicles within a service centre, Calculate the time spent by each vehicle in a service bay, compare this time against the standard time and find bottlenecks, predict approximate delivery time of each vehicle and determine if the worker is within his workstation and how much time per day has he spent within his workstation.

Solution: To solve this problem, we have installed COINs on each bay and tagged each vehicle that enters into the service station with our FIND device. Each FIND with its unique ID is mapped to the registration number of the vehicle. Range of COIN and FIND are customized as per the area of each workstation and distance between two cars so as to filter out data from any adjoining FIND. By doing so, vehicles were tracked accurately within the service centres and at each bays/zones.

The service centre head was able to see the real time tracking of all vehicles within the facility on our dashboard and take actions accordingly to avoid congestion at zones and increase the efficiency of each zone. At any given point of time, the service head is also able to see how many vehicles are there in each zone, exact location of each vehicle, the average time taken by each vehicle in zone and take action in case the vehicle is delayed from the standard service time of each zone. The end customer is able to get the real time delivery status of his vehicle.
Also, using our solution the service head is able to calculate the time spent by the worker within his work station and determine his efficiency. At the end of the day, we are increasing the overall efficiency of the entire service centre.

Benefits: Increase in the number of vehicles serviced by 10% to 15%
Potential: We plan to cover 4,000+ service centres across India in the next 2 to 3 years.

Animation video of case study

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Test Items	Test Results	Test Conditions
Moisture resistance test	After test, no obvious change in appearance, and function was normal.	Temperature varied from 25°C±2K to 65°C±2 K Relative humidity at (93±3)%
High temperature test	After test, no obvious change in appearance, and function was normal	High temperature: 60°C Test duration: 96H
Low temperature Test	After test, no obvious change in appearance, and function was normal.	Low temperature:-10°C Test time: 96H
Heat cycle test	After test, no obvious change in appearance, and function was normal	Temperature rise 60°C 1H Operating 60°C 6H Temperature processing -10°C 2H Operation -10°C 6H Repeated 60H
Continuous vibration	After test, no obvious mechanical damage, and function was normal.	Condition A: Amplitude:0.25 mm or less Frequency: 5±1Hz~50±1Hz Test direction: X, Y, Z axis Test time: 10min/cycle, 5 cycles/direction Condition B: Acceleration:2.0 m/s2 or less Frequency: 5±1Hz~50±1Hz Test direction: X, Y, Z axis Test duration: 10min/cycle, 5 cycles/direction
Impact test	After test, no obvious mechanical damage, and function was normal.	Shock pulse: Half-sine Vertical: Acceleration: 5g Pulse duration: 30ms Shock direction: ±Z axis Shock Times: 3 times/direction Horizontal: Acceleration: 15g Pulse duration: 11ms Shock direction: ±X, ±Y axis Shock Times: 3 times/direction

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