Smart Factory

Digitalizing Quality Control Data Problem Statement: Manual data recording in high-speed manufacturing is prone to “Human Error” and creates “Data Silos.” At ETON INDUSTRY, operators had to manually write down critical parameters (Weight, Thickness, Length) for every finished product, leading to delayed reporting and inaccurate traceability. The Challenge: The system needed to interface directly with the existing machine’s PLC to capture data exactly when the process finishes, without disrupting the operator’s workflow. It also required a robust “Target Counter” to alert operators when a specific order quantity was met. ...

Auto Transfer Laser Mark System Problem Statement: In a high-precision machining line, operators were manually transferring production data files from CNC machines to Laser Markers. This manual process, involving walking with USB drives or hand-keying serial numbers, created a bottleneck and introduced a high risk of “Human Error”—resulting in mislabeled parts and traceability issues. The Challenge: The core challenge was Cross-Platform Integration. We needed to bridge “Islands of Automation” that spoke different languages: ...

Digitalization of Batch Process in Rubber Industry Problem Statement: In traditional rubber mixing, reliance on standalone PLCs often limits the complexity of recipe management and data storage. The client needed to upgrade a Banbury Mixer 75L to handle complex step sequences based on Time and Temperature, while ensuring 100% data traceability for quality assurance (QA). The Challenge: The project required high-level interoperability. We had to centralize data from diverse legacy devices speaking different protocols (Ishida Scales, Delta Temperature Controllers, Ammeters) into a single control interface, all while maintaining millisecond-level stability for motor control. ...

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. ...

Rubber Compounding & Precision Weighing Control System Problem Statement: In the Master Batch (MB) and Carbon Master Batch (CMB) production lines of a leading automotive rubber manufacturer, manual chemical weighing processes were prone to human error. Deviations from the specific rubber formula resulted in quality issues, waste, and a lack of digital traceability. The Challenge: Precision Requirement: The system must interface directly with high-precision scales to ensure chemical weights fall within strict tolerance levels. Network Instability: Production cannot stop even if the factory network/server goes down. Inventory Control: Need real-time stock deduction and validation to prevent incorrect material usage (wrong lot/wrong type). Our Solution: Smart Weighing & Interlock System We developed a robust Windows Forms Application (C# .NET) that acts as the “Process Controller” for the mixing line. The system integrates IT and OT layers to enforce strict process control. ...

Adaptive Visual Inspection for Stamped Parts Problem Statement: In automotive part manufacturing, “Stamped Characters” (serial numbers/codes) are critical for traceability. However, the physical stamping process is inconsistent. Factors like die wear, hydraulic pressure changes, or slight positioning shifts cause the characters to look different over time. The Challenge: A traditional Vision System uses a static “Master Image.” When the production line’s stamping tool degrades slightly, the characters no longer match the static Master perfectly. This leads to a high rate of False Rejects (Good parts being rejected), causing frequent machine downtime and requiring constant code adjustments by engineers. ...

Smart Fleet Management for 1.2 Ton Forklift AGVs Problem Statement: A leading tire manufacturer faced bottlenecks in transporting heavy rubber rolls (1.2 tons) between the Iron MC machine and the Liner/Stock rails. The manual process was slow, prone to accidents, and difficult to track in real-time. The Challenge: Heavy Load: Handling 1.2-ton payloads requires precise and safe navigation. Complex Traffic: Multiple AGVs operating in shared aisles with human workers. Legacy Integration: Need to communicate with existing machines via varied protocols. Our Solution: Intelligent Traffic Control WP Solution architected a comprehensive Fleet Management System that acts as the “Air Traffic Control” for the factory floor. The system manages job queues, calculates optimal routes, and prevents traffic jams using a dynamic node-based algorithm. ...