Data Collection Systems

The Industrial Internet of Things

IIOT BENEFITS

  • Multi-Site Operations
  • Manufacturing Performance
    • Real Time Visibility
    • Equipment Metrics – Availability, Productivity, Quality
    • Operational Intelligence
    • Data driven insights
  • Service
    • Remote monitoring
    • Alarm management
    • Predictive maintenance

IIOT BUILDING BLOCKS

  • Devices
    • Inserters, Printers, Cameras, Sensors, Actuators
  • Edge Gateway
    • Site Server PC, SQL DB, Software Services
  • Cloud Platform
    • MS Azure, IOT Hub

IOT DEVICES REPRESENT HARDWARE

  • Inserters, Printers, Standalone Mail Tables, Web Controllers, etc.
  • Devices maintain their state – Status, Software Version, Config Parameters
  • Responds to Command – Device to Cloud, Cloud to Device
  • Send Telemetry Data Messages – Mail Piece Records, Printer Records, Events
  • Devices can run on small low memory embedded controller or Full Server (Windows or Linux)
  • Tracking devices for 3rd party Equipment

OBJECTIVES

Collect Operational Data (Mail Piece, Job, Operator Shift, Downtime )

Report Equipment State and Job Progress

Manage Device and Software Deployments

Secure Open Communications Protocol (TLS, MQTT)

OPEN STANDARD ARCHITECTURE

System uses the same secure documented and universal interface that the customer’s client or third-party can utilize.

  • MQTT
  • HTTP
  • TCP
  • API

*No Special proprietary protocols to be licensed.

ELEMENTS

Live Monitoring

Job Management

Post Analysis Insights

EDGE DEVICE CATEGORIES

  • Piece Sensors – Machine Output Detectors (Cutter, Stacker, etc.)
  • 3rd Party Equipment (Ethernet, Serial) – Cameras, Scanners, Magnetic Stripe Readers, etc.
  • Raptor – Mail-tables, Presses, etc.
  • PerfectTrack – Inserters, Mail-tables, Card-Attacher, etc.
 
SENSOR INTELLIGENCE
3RD PARTY DEVICE (ETHERNET / SERIAL)
RAPTOR
PERFECT TRACK

SENSOR INTELLIGENCE

  • Piece Present
  • Piece Rate
  • Count
  • Derived Status and Downtime
  • Manual Job ID Assignment
  • Manual Operator Assignment

3RD PARTY DEVICE (ETHERNET / SERIAL)

  • All Sensor Intelligence
  • Piece IDs
    • Job Status
      • Progress
      • Duplicate Detection
      • Missed Pieces
  • Manual Job Assignment
  • Manual Operator Assignments

RAPTOR

  • All Sensor Intelligence
  • All 3rd Party Intelligence
  • Printer Status ( Ink Levels, Printer Performance, Fault Codes)
  • Automatic Job Identification
  • Automatic Operator Identification

PERFECT TRACK

  • All Sensor Intelligence
  • All 3rd Party Intelligence
  • Machine Performance ( Camera misreads, Mismatches, Doubles, Misfeeds, Jams, Alarms, etc. )
  • Automatic Job Identification
  • Automatic Operator Identification

OEE DASHBOARD METRICS

  • Availability – Time equipment is available and scheduled.
  • Productivity – Number of pieces produced compared to maximum.
  • Quality – Percentage of good pieces produced.
  • Overall – Product of availability, productivity, and quality.

OEE – SIX BIG LOSSES IDENTIFY AREAS TO IMPROVE

  • Breakdowns
  • Setup / Adjustments
  • Idling / Minor stoppages
  • Speed
  • Defects and rework
  • Startup losses