In today’s global economy, manufacturing industries cannot gamble becoming ineffective and incompetent. The production reality in today’s increasingly competitive world claims competence and quality with endless and bettered processes. It is carping to lessen the production costs, strengthen production line and machine use and adaptability to improve not only product quality but services as well. Any production company with its successful growing business, may be quite satisfied with their results. But, how much they really know about the operational efficiency of their factory. How can they improve their production capacity without any data?. Hence, in order to achieve first-rate production efficiency, production monitoring is decisive. But, the traditional approach of machine monitoring & machine monitoring system lacks its ability because it is expensive to apply, lots of hurdles in data sharing, imperfect integration with other systems, and provides more security threats as well. To overcome these challenges and to achieve successful transition to Industry 4.0, manufacturing industries should adopt the latest technologies that can incorporate obsolete systems with recent systems. Here comes the MQTT protocol which has its own critical features in solving all the industrial challenges. Let us see how we can link the different levels of shop floor in a manufacturing industry & automate them with MQTT-based messaging framework.

Key Issues in Traditional Production Management

Data Silos: Present day Industries often have machinery from a broad range of suppliers that generate data in unique formats which gives rise to data silos. This becomes the barrier for wide survey & decision-making across the whole industrial operations.

Lacking visibility: Deep visibility into the individual assets’s performance is lacking in the traditional SCADA systems and it is restricted to the shop floor. Assets can’t be managed anywhere, anytime because the machines / equipment data can be viewed & accessed only inside the plant.

Network Latency : The connection between the industrial equipment & the production management should be highly available. When the connection fails unexpectedly in low bandwidth scenarios, it will cause severe damage to the equipment.

Security Threats : Industrial tracking & visibility is necessary for industrial manufacturing. Some Industries are monitoring data by connecting every user’s mobile phones to the modbus interface on the individual monitoring console. This mandated the professional to be near every production control dashboard to view the status. Besides that, security issues will prevent them from connecting the modbus protocol directly to the internet.

Connecting the Industry with MQTT

The MQTT messaging protocol is well suited to address the above mentioned issues and it acts as a reliable messaging systems within a Industry. This is because MQTT has an attribute, Last Will & Testament which permits any application to trigger a message when there is an unexpected disconnection between devices & server. For example, considering a scenario for manufacturing use cases, when a manufacturing equipment fails, then the entire production line will be instructed immediately to take action in order to prevent equipment damage. And also, MQTT has very low overhead in its protocol which makes it compatible to transmit data over low-bandwidth networks. This enables monitoring of manufacturing equipment, SCADA networks, sensor devices, and scenarios involving low bandwidth, such as radio and cellular networks.

When it comes to data silos, one common server/platform which can break down the data silos that exist at different levels of automation is necessary. This can be reliably done by MQTT Broker which uses MQTT protocol for communicating reliably between devices thus avoiding unwanted data silos. And also, security threats arise when the equipment is directly connected to the internet. Hence, the solution should be connecting the production line with multiple equipments in one server & making it available in a more secured way. In that case, MQTTRoute comes with a device level auth and TLS/SSL to make secure connection between the gateway and MQTT broker. And also, the Modbus MQTT Gateway that comes as part of the Bevywise IOT Solution collects all data from production line and send it to the Central MQTT Broker. In addition, the Mobile app can be connected to the MQTTRoute and the data generated can be monitored using the collected data.

Over the past few months, we were building products / solutions for Manufacturing Industry above our MQTT Broker. Our focus was to enable manufacturing Industries to connect their machinery in a reliable and scalable manner using MQTT. One such ready to deploy solution is Pace DPR, the production / machine monitoring system. This IIoT application will automate the complete data collection, analysis and decision making process of manufacturing industry.

Why MQTT is used in production management system?

MQTT is a global standard for connecting devices in the internet and is becoming more & more popular within smart manufacturing and Industry 4.0.
The reason why production management projects can rely on MQTT as a messaging protocol is that its publish/subscribe framework. We all know that, MQTT clients will send data to a central MQTT server/broker from there the data will be transferred to the clients who subscribe. Consider the scenario in which the MQTT clients can be a manufacturing machines, a peculiar sensors, SCADA systems, or MES, etc. MQTT supports bi-directional messaging & it allows for measured data to be transferred from machinery to the cloud. And also, if integrated, ERP/other systems such as SCADA can create a command to be sent across the shop floor. The central MQTT broker/server will track all the client connections (equipments/sensors/other systems) and the subscribed topics for each of the clients. Hence, MQTT can be more reliably used in the manufacturing industry for exchanging data between the machinery & the entire production line.

Thus, the reliability and scalability of MQTT made us to build a production management system over MQTT Broker.

A little on Pace DPR : MQTT Platform for smart manufacturing

Bevywise MQTTRoute is a profoundly extendable, adaptable, and versatile MQTT Broker utilized for gathering information from IoT edge devices in which it is easy to transfer data to and from associated machines / equipments in a dependable and quick way. Hence we have built Daily production monitor, Pace DPR over MQTTRoute for manufacturing industry as part of one of MES initiatives.

This production monitoring solution built using MQTT will ease the production managers to analyze and improve OEE & can help them make a necessary change in their manufacturing process that leads to the big improvements on the production floor. By providing data on KPIs that tied up with the real-time status of your shop floor, which makes this machine monitoring system an extremely useful tool for improving productivity. Performing analysis with the shift based cumulative reports & hourly production reports, will uncover areas to improve OEE by connecting dots & eliminating the gap between machine performance & its efficiency. This boosts the preventive maintenance of assets by tracking & monitoring machines at individual level which allows operators to see when & where the flaws in the production line occurs. The real-time data on OEE & production is just a number unless it is turned into an excellent insight & action. This will help you turn the obtained data into actionable insights and make necessary decision on improving manufacturing productivity.

During the development of this IIoT application, we came to know that MQTTRoute is doing its core part right and that’s why we are able to build such a best production / machine monitoring system that can address all the challenges, a manufacturing company meets.

Conclusion

Many manufacturing companies are beginning to deploy production monitoring solutions in their shop floor to achieve greater efficiency and flexibility. Several factors favour use of MQTT as the standard protocol for modernizing the messaging framework of an Industry. Due to the performance scaling capabilities of MQTTRoute, Pace DPR as a production management system is well suited to provide an accurate picture of overall production operation in manufacturing Industry.

Moreover, our recent update on MQTTRoute that transforms MQTT Broker into an IoT application framework will help you build a complete industry 4.0 application faster with much ease.

Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.

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