IoT

Smart AGV Queue & Fleet Management via Tablet The Requirement: A Tier 1 automotive parts manufacturer required a comprehensive fleet management system for their Autonomous Guided Vehicles (AGVs) on the production floor. The core operational needs were divided into two main flows: Finish Good (FG) Handling: Operators finish assembling products and use a physical remote to call an AGV to transport the FG to the warehouse. Material Preparation: When raw materials are depleted, operators trigger an AGV via remote to bring empty boxes to the stock room. The stock preparation team needs a way to know exactly what parts to prepare, how many, and which station requested them before the AGV arrives. The Challenge: The complexity lies in “Queue Management.” With limited AGVs and multiple production lines triggering remotes simultaneously, a robust Queue Dispatcher was required. Additionally, operators at the stock room are working against the clock. The Tablet UI needed to be highly intuitive, prioritizing the destination (Target Station) visibility, and required foolproof mechanisms, such as preventing operators from loading more than the AGV’s maximum capacity (15 boxes). ...

Visualizing Invisible Energy Costs Problem Statement: In large-scale manufacturing, electricity bills are a major operating cost, yet they often remain a “Black Box.” Factory managers struggle with manual meter readings, lack of real-time visibility into power consumption trends, and inability to correlate energy spikes with specific production processes. The Challenge: The client needed a centralized system to collect data from multiple Digital Multimeters distributed across the factory. The system had to handle high-frequency data (Voltage, Current, Power, THD), process it for cost analysis, and present it on a responsive web dashboard accessible from anywhere. ...

Real-time Crepper Motor Monitoring System Problem Statement: In a large-scale rubber processing plant, the “Crepper Machines” are the heart of production. The client, Sri Trang Agro-Industry PCL, needed to monitor the electrical current (Amps) of 3 critical motors in real-time. Previously, operators had to manually check readings from local panel meters, making it impossible to analyze historical trends or detect anomalies (like motor overload) instantly. The Challenge: Legacy Connectivity: The existing meters were standard Digital Meters (Primus TCM-94N-AB) communicating via Modbus RTU over RS-485, requiring a reliable bridge to the IT network. Data Integrity: The system needed to handle potential connection drops and ensure data continuity for accurate reporting. User Accessibility: The dashboard had to be accessible via a web browser on the local network without complex software installation on client machines. Our Solution: Hybrid IoT Gateway WP Solution architected a Web-based Monitoring System that bridges the gap between the factory floor and the control room. We utilized Node-RED as a robust middleware to poll data from the meters and Vue.js for a high-performance frontend dashboard. ...