Factory Description
A study was conducted for an integrated Factory Management System for Eleven Stone polishing factories spread across multiple states in India and neighbouring countries operating under a business house based in Kerala, India.
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A typical individual factory has the following machinery and other equipment
- Two large and one smaller stone cutting machines,
- Three stone polishing machines,
- Large gantry head crane rung along the length of the factory for handing large stone slabs,
- Raw stone and finished goods storage area,
- Lorry loading and unloading area within the storage area,
- Large UPS for operation of the stone polishing machines,
- Cooling water handling system
- Electrical control panel for all the machines
- Emergency Generator
- 11kV to 440V LT transformer – Power Supply company property
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Functional Modules
A study was conducted to have an integrated monitoring system which consists of the following main functional modules.
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| Security Surveillance | |
| Video, audio and sensor-based Security surveillance – both inside and outside periphery of the factory. Facility to make announcements, listen to the sounds and sound hooter are also needed. To be linked to the lighting system to ward off and get a better-quality video of miscreants… |  |
| Power Supply Monitoring | |
| Continuous monitoring of quality of power and power consumption. This will also detect power surges, low voltages, variations in PF, percentage fluctuations, harmonics among other parameters … |  |
| Emergency Generator Monitoring | |
| Multiple operational parameters like temperature measurement at multiple points (as need be), Fuel level, Oil level, vibration level at multiple points, Power output, voltage levels and harmonics levels… |  |
| Electrical Panel and energy Distribution Monitoring | |
| Electrical panel busbar temperature monitoring at multiple points, panel temperature at multiple points, vibration levels and change in vibration intensity, power distribution and variation tracking … |  |
| Equipment Performance Monitoring | |
| Monitoring the performance of machines and its loading pattern. Corelating output with the current, vibration, temperature of the motor and at multiple points in the machine. Also cooling water flow and lubrication pressure. Video camera to supervise job progress … |  |
| Monitoring Goods Movement | |
| Monitoring inbound and out bound movements of goods, raw materials, and vehicles, vehicle identification along with driver, vehicle arrival and despatch timing. Proof of despatch … |  |
| Access Control | |
| Access control to specific locations, Intrusion detection, movement / tilting of specific items, tracking the period of stay, Use it for attendance monitoring… |  |
| Power Pack up monitoring | |
| UPS and battery back-up, input and output power supply voltage, current, Frequency and power monitoring. Battery terminal voltage and charging current monitoring to detect the health of battery… |  |
| Fire and Safety | |
| Fire, Smoke and high temperature sensors in appropriate locations. Unlike the normal fire detection sensing, this will be individual sensor detection and indication. Associated hooter and Fire swich will also have individual identity and operation. |  |
| Lighting Control | |
| Lighting control and switching of lights automatically as per rules like time of day, intrusion. Detect failed lights and alert for carrying out maintenance. Automatic testing of lighting circuits… |  |
| Two-way communication | |
| Two-way video and audio communication between the respective factory and authorised person in remote location. Facility to view the video feeds from cameras and also listen to sounds at multiple points in a factory… |  |
| Monitoring and Control | |
| Facility to view and control all parameters through an interface Locally and from a Remote Monitoring Station by an authorised person. Mobile access to the monitoring and control interface is available to predefined users with strict user authentication… |  |
Macro Functionality Details
Detailing of each of the functional modules given are ONLY indicative and each module can have scores of functionalities. To know more about the details please CONTACT US
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| Security Surveillance | |
| Use all types of cameras independent of the make Operate Pan, Tilt and Zoom functions from all the interfaces Local video recording of all video feeds Access historical data remotely Make automatic and manual announcements from the local monitoring station and also from remote interface Obtain all video-based alerts and execute actions as per rules defined by customer… |
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| Power Supply Monitoring | |
| Three phase energy metering Power availability monitoring Power factor monitoring Single phasing monitoring Peak power consumption Monitor the swell and sag in voltage Harmonic detection and alerts Electrical Overload warning … |
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| Emergency Generator Monitoring | |
| Monitor the time duration between the loss of power and start of DG set Measure the power delivered by the DG set and correlate with diesel consumption Measure the battery terminal voltage and compute the condition of the battery Measure temperature at multiple points like Oil temperature, Water temperature, engine body temperature as needed Monitor the vibration level of the engine and generator to detect deterioration… |
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| Electrical Panel and energy Distribution Monitoring | |
| Monitor busbar temperature Monitor temperature in critical power modules Monitor the vibration level Measure earth to Neutral voltage to understand the earthing effectiveness Monitor water seepage under the panel Monitor the power consumption of critical circuits and optimise consumption Electrical overload detection and warning |
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| Equipment Performance Monitoring | |
| Equipment power consumption and correlation with production condition Equipment vibration measurement and deterioration detection Machine idling condition detection and warning Machine temperature detection and correlation and condition-based alerts Oil pressure and other parameter monitoring Video monitoring of the operation of the machine for remote monitoring and control |
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| Monitoring Goods Movement | |
| Monitoring inbound and out bound movements of goods, raw materials, and vehicles Count of vehicles entering the factory Vehicle identification along with driver Vehicle arrival and departure timing Barcode / QR code reading Proof of despatch Data capture of the logistics … |
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| Access Control | |
| Access control to specific locations Face recognition Mobile based access code control Intrusion detection/unauthorised entry Shutter down or up detection Magnetic door closure Movement / tilting of specific items Tracking the period of stay Panic Button Use it for attendance monitoring… |
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| Power back up monitoring | |
| Monitor the power availability and quality of power into the UPS Monitor UPS input and output power supply voltage, and current Monitor output frequency Measure battery charging current Infer battery condition from battery terminal voltage under different charging and discharging conditions Based on changing current infer maintenance for battery… |
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| Fire and Safety | |
| Fire, Smoke sensors in appropriate locations Rate of rise temperature sensors in critical areas Unlike the normal fire detection sensing, this will be individual sensor detection and indication Fire switch and Fire alarm switch Automated hooter for individual locations corresponding the location of fire as need be Automatic telephonic alert to authorised person and fire and police stations as configured … |
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| Lighting Control | |
| Manage multiple lighting circuits Light switching according to time of day, Schedule, illumination level Swich On the lights in the areas where intrusion is detected Automatic testing of lighting circuits to detect failed lights and alert for carrying out maintenance Measure the power of lighting circuits to optimise power … |
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| Two-way communication | |
| Two-way video communication and two-way audio communication between the respective factory and authorised person in remote location. Facility to view the video feeds from cameras Listen to sounds at multiple points in a factory Make announcements – live or pre-recorded Mobile based access Multi factor authentication … |
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| Monitoring and Control | |
| Facility to view and control all parameters through an interface Locally and from a Remote Monitoring Station by an authorised person Mobile access to the monitoring and control interface is available to predefined users with strict user authentication Video wall accessible to both local and remote users and operate the individual camera – Pan / Tilt or Zoom operations Operate machines as per designed process Monitor the machine performance history and detect deviations View reports and access performance graphs Receive alerts as per rules defined and escalate as per the severity of the alert… |
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