Intelligent factory with digital twins
In addition to good R&D support, the production of good products also requires a strict, advanced, and efficient management of production organizations. In more than 20 regions in China, SANY has more than 30 companies, over 90 factories, and more than 8,000 pieces and 200 kinds of equipment, of which nearly more than 6,000 pieces are dumb equipment (i.e. the equipment that has not been connected through IoT technologies), involving 15 major production processes. The group was bearing more and more costs and pressure to manage such a wide range of production organizations, which can be seen in the following 2 aspects.
- In the traditional way, equipment is managed by privately deployed software like SCADA system. Each of these pieces of software finally turns into an information silo, which is difficult to manage and requires a cross-region and cross-business cloud platform.
- The connection is very difficult for it needs to connect a large number of different machines, and also 65% of them are dumb machines.
With ROOTCLOUD LEEMS, an innovative solution to identify equipment operating status by detecting electric current with AI technologies, the costs and difficulty of connecting common equipment are greatly reduced with such a high efficiency that more than 8,000 machines are connected in just about six months.
Through the real-time metrics of equipment assets, you can view the online or historical statistics of all the equipment in the group, and then classify equipment statuses such as online, working, standby, downtime, bottleneck, and redundancy, and derive decision-guiding data including online rate, power-on rate, working rate, utilization rate, bottleneck rate, redundancy rate, total power consumption, etc.
From 2019 to 2020, SANY Group’s compound output growth exceeded 55%, and especially, in the first half of 2019, sales grew by 60% year on year without SANY’s additional investment in equipment. The intelligent equipment management system plays a very critical role in helping SANY to accurately identify problems in production management. Lean management requires accurate data imported for analysis. With IoT data analysis, SANY obtains more and more insights into business; at the same time, SANY also finds out more than 500 units of superfluous equipment, saving tens of millions of dollars.
Sufficient, real-time, accurate data are very critical for lean management and intelligent manufacturing. In the past, manufacturing enterprises mainly relied on the management of scattered process data with low structuring and efficiency. In the era of industrial Internet, one of the biggest benefits is to network equipment in the physical world and get real-time data directly from the equipment. No matter how big a factory or a business group is, we can gain real-time insights into all aspects of its problems, and connect all the management processes and physical spaces, and control the operations on the site directly online. In the future, real-time data, coupled with artificial intelligence and other technologies, will revolutionize management in terms of accuracy and efficiency.