Wrapping up 2021 and Welcoming 2022

Wrapping up 2021 and Welcoming 2022

“This is a new year. A new beginning. And things will change.” ―Taylor Swift

The New Year is here and celebrations are pouring everywhere every minute. The dawn of each year carries a lot of positivity, good energy, and good vibes. With the same positivity and energy let us welcome 2022 with a bang and hope new year 2022 will be more eventful and brings normalcy in life and business. Bevywise had a busy 2021 in developing Industry 4.0 manufacturing solutions. A little recap on 2021 and how was our journey in becoming a Industry 4.0 solution provider. Let’s get rolling.

Recap 2021

Like 2020, the year 2021 was also dominated by COVID-19. Almost 2 years into a pandemic, people everywhere came unstuck to summon the energy for facing financial crisis. Well, in point of fact we’ve made it through year two of the pandemic and, considering everything, that’s no mean feat.  Leading through, the pandemic has been hard, exhausting, and sometimes terribly sad.

Moreover on the business side, we at Bevywise working hard to capitalize more effectively on the opportunities rising in the post covid19 recovery. This will not happen without a great team. Our customers have been the most impressive synergy which has helped us grow multi-fold. Thanks for showing your interest in our products and services. A special thanks to our partners, who believed and taken us to the next level with their huge commitment and active contribution.

A heartfelt thanks to our family and friends for their great support towards us that helped us to achieve great things.

2021 : A Year in Review

Though covid 19 is still at strike, 2021 has been a good and promising year for us.

Here’s a look at what we were up to in 2021.

One of the biggest achievement for us in 2021 is that we stepped in as Industry 4.0 solution provider. We have expanded our market with our new launch of Industry 4.0 solutions. With the global market demand ravaged by the covid 19 pandemic, digitization across industries is accelerating rapidly.  This factor uplifts the demand for integrating Industry 4.0 solutions in manufacturing operations. This made our self boldly step in as Industry 4.0 solution provider.

In June 2021, we made our initial version release of Factovize MES (Manufacturin Execution System) to help manufacturers in their production goals with the high level capability of collecting, visualizing & transmitting data across the manufacturing processes. The first implementation of MES is in progress for one of our customers in Bangalore. So far, Core MES is proving its capability on a positive note. And now we are working more on improving the features & functionalities on MES based on our customer requirements.

Also, In September 2021, as a part of Industry 4.0 solution, we have launched first version of WIP Manager, a fully digitized manufacturing WIP management tool. The high level development of this product is going on in a rapid phase and we are expecting to get our first customer for WIP manager soon.

The next big launch of the year 2021 is our completely managed hosted MQTT Broker, CrystalMQ. After months of hard work we released CrystalMQ in the month of October. Though using MQTT Broker on premise is not at all a bad choice, hosted solution is the best one for businesses who expects no-expertise needed approach in server management.

Along with such major releases, we had a good number of feature updates in IoT frameworks as well. This is just a short list of everything Bevywise was up to in 2021. 2021 marked Bevywise as the Industry 4.0 vendor as we made our footprint in Industry 4.0.

Hope for better 2022

After a dejecting year, intermittent between lockdowns and new outbreaks, we have to keep faith that life will ultimately get down to some semblance of normality. And now, as we turnover the page toward new year 2022, the truth is that it won’t be without its challenges & struggles, still, it’s necessary to stop and smell the coffee and truly examine all the things that server us. While 2020 was all about keeping our head above water and 2021 was about getting stable to the new norm, new year 2022 is about nourishing our roots and possibly coming up with a game plan for the successful journey.

We are ending this year with many successes and we will work hard to continue this with better services and greater commitments, to achieve new goals. We are now ready to write new success stories for the upcoming year.

Here’s wishing you all the joy of the season. Happy New Year!

Why is Integrated IOT Application the way to go ?

Why is Integrated IOT Application the way to go ?

Integrated IoT Application

Business today has a lot to be managed better.  Everything in an organization is related.  The power and other utilities consumption, employee availability and productivity, manufacturing process management and its utilization, predictive maintenance of the machines, Inward / Outward of materials, etc are today managed as Silos.  It does not make sense to digitize everything and still use them as siloed application. It is crucial to bring everything in to one application. The benefits of using it as one application from the management perspective are:

  • Have a better access control to various modules.
  • Deploy everything on one server and manage it better.
  • Employees need to remember a single identity.

Co related Data Analysis

The world is filled with data and the data needs to be analyzed at width and depth.  Data Analysis cannot be done when businesses uses multiple applications and the data is stored in Silos, in spite of all the digital transformation. Closer correlation of data is crucial to create compelling decisions.

For example, when the machine / department productivity and the energy consumed per machine is mandatory to be managed in a single application which can help use do some detailed analysis like power consumed per part produced and the reverse against the variance of days and the batches.  This deeper analysis becomes more cumbersome when the data is stored in silos.

Cloud Servers are more reliable

We have been running our cloud servers on AWS, Google, Digital Ocean for the past 5 years and we have not even seeing any downtime or server crashes. Cloud hosting has come a long way that it has become more reliable, secure, flexible and much more affordable.  Running an integrated application based on the business requirement is going to be much easier going forward. Once set up we may just need to maintain the applications.  The applications again can be maintenance easily with tools like docker, mmonit, Kubernetes and more.

Affordable Implementation

Industry4.0 is synonymous with a lot of data being generated , processed and used in critical decision.  When you go for an on demand service, most service providers charge by the data used over time.  However when you have a private hosting, the data is unlimited. This will increase your data traffic and number of events you record without any increase in the data cost.  You may need to slightly increase the server configuration which will be very marginal against the data cost.

Create Customized Solutions

When you go by your own instances, you will have the complete flexibility to create your own reports and analysis. Out of our implementation of the IoT, we see that the requirement changes largely from one plant to another within the organization. So with a lot of custom build process and data, we need more specific solutions to deliver the best RoI for your business.

The MQTTRoute, top MQTT Broker has all the powerful extendability options to create & develop complex IoT Applications. The extendable python MQTT interfaces / hooks provide user interface customization, data aggregation & analysis, event data comparison with the processed data, Remote authentication & more. The python interfaces include Custom UI server, Custom data store, Custom storage, Custom scheduler & Custom Auth. You can play with the python hooks by downloading the FREE version of MQTT Broker to build faster applications.

Contact us for a FREE Consulting today on what is the best way to implement your IoT Solution.

Understanding MQTT Protocol Packet Format

Understanding MQTT Protocol Packet Format

MQTT protocol communicates by exchanging a series of predefined MQTT control packets. The MQTT packets consist of up to three parts in the following order as a 2-byte fixed header that appears in all MQTT packets, Variable Headers, and Payload that appear in some MQTT packets. This document describes how to format an MQTT Message or Packet.

MQTT client to MQTT protocol

MQTT Protocol Packet Types

Types of MQTT Protocol Control Packets are:

  • CONNECT – Fixed Header / Variable Header / Payload – MQTT Client requests a connection to a Broker.
  • CONNACK – Fixed Header – Acknowledge connection request.
  • PUBLISH – Fixed Header / Variable Header – Publish message.
  • SUBACK – Fixed Header / Variable Header / Payload – Subscribe acknowledgement.
  • UNSUBSCRIBE – Fixed Header / Variable Header / Payload – Unsubscribe from a topic.
  • UNSUBACK – Fixed Header / Variable Header / Payload – Unsubscribe acknowledgement.
  • DISCONNECT – Fixed Header – Disconnect notification.
  • PUBREL – Fixed Header / Variable Header – Publish release(QoS 2 publish received).
  • PUBACK – Fixed Header / Variable Header – Publish acknowledgement.
  • PUBREC – Fixed Header / Variable Header – Publish received(QoS 2 publish received).
  • PUBCOMP – Fixed Header / Variable Header – Publish complete.
  • SUBSCRIBE – Fixed Header / Variable Header / Payload – Subscribes to a topic.
  • PINGREQ – Fixed Header – PING request.

MQTT Packet Sizes

The fixed header field consists of the control field, and the variable header contains the packet length field. The minimum size of a packet length field is 1 byte, which is for messages less than 127 bytes.

The maximum packet size is 256 MB. The minimum packet size is only 2 bytes with a single control field and a single packet length field. Smaller packets less than 127 bytes have a 1-byte packet length field. The Packets greater than 127 and less than 16383 use 2 bytes, and so on. 7-bits are used with the 8th bit is the continuation bit.

MQTT Packet size

Control Field

The 8-bit control field is the principal byte of the 2-byte fixed header. It is divided into two 4 bit fields and contains all protocol commands and responses. The first four most important bits are the command or message type field, while the remaining 4 bits are used as control flags.

control field structure

Control Flags

While there are 16 possible flags, a limited is used. The Publish message makes the most use of these flags. The duplicate flag is used when a message is republished with QoS or 1 or 2. QoS flags are used when publishing to indicate a QoS level of -0,1,2. The Retain Message flag is also used when publishing a message.

Remaining Length

The Remaining Length is the number of bytes left in the current packet, including variable header and payload data. The Remaining length does exclude the bytes used to encode the Remaining Length.

The Remaining Length is encoded using a variable-length encoding scheme that uses one byte for values up to 127. The least seven important bits of each byte encodes the data, and the most important bit is used to indicate there are following bytes in the representation. Thus, each byte encodes 128 values and one “continuation bit”. The greatest number of bytes in the remaining length field is four.

Size of the remaining length field

Variable Header

Some types of MQTT control packets have a variable header component. Variable-length header fields are not always present in MQTT messages. Some MQTT message types or commands require this field to carry additional control information. It remains between the Fixed Header and the Payload. The Variable Header will vary depending on the packet type.

Example: MQTT Connect Message Structure

As an example, let’s take a look at the details of the CONNECT message packet in the Bevywise MQTTRoute / MQTTBroker.

After establishing a connection between the MQTT client and the broker, the first packet must be a CONNECT packet. The CONNECT packet only needs to be sent once over the network connection. The second CONNECT packet sent by the MQTT client is ignored and disconnected.

Fixed Header

Fixed header

Variable Header

The variable header must have four parts. They are the protocol name bytes, protocol level, connect flags, and keepalive.

Protocol name bytes

MQTTRoute will disable false protocol name.

Protocol name bytes

Protocol level

The protocol level for MQTTRoute is 4, other values lead to disconnection.

Protocol level

Connect flags

This field indicates the presence or absence of data in the payload.

Connect flags

Keep Alive

The MQTT client should send control packets that do not exceed the value of the defined Keep Alive. The Keep Alive value depends on the duration of the control packet of one transmission by the client.

Keep alive

MQTT Protocol Payload

The payload contains the MQTT client credentials (username, password, etc.). The client ID must be unique for each client. The broker responds with a unique client ID for each client. If you send a client ID in an empty field, the client will be rejected. The following fields must be filled in the following order: Client ID, Will Topic, Will message, username, password.

The above fields must be in string format. Any packet that does not send a CONNECT packet after a reasonable amount of time will be rejected by the broker. After successful above validation, the broker will respond in 2 format

  • Check if the client already exists. If so, the broker will respond with the disconnection.
  • The MQTT Broker will send a CONNACK packet with zero value.

After successful CONNACK, the broker will do a keepalive monitoring regularly.

To know more about the MQTT messages or packets structure, do visit the MQTT Developers page.

To know about the format of the MQTT-SN packets, visit the MQTT-SN Developers page.

Download the free version of the MQTTRoute now to validate all the features.

You can upgrade to the premium version of MQTTRoute for the full-fledged functionalities after your free trial period.

Killer Tips & Tricks to win the Industry 4.0 Race

Killer Tips & Tricks to win the Industry 4.0 Race

Industry 4.0 is gaining momentum all over the industrial world. With the endless possibilities of innovation & technology, every production manufacturers are keen in adopting automation to succeed the race. However, most of them are giving consideration to the cost for adopting new technology i.e IoT Industry 4.0 against the capital gains. Others are hell-bent regardless of whether they ought to bide their time until the battle reveals the clear-cut evidence of the gains before starting out into this untold sector. Even now, others are hurt by the extravagant promises of overly intricate and costly technologies. At the end, all of them are working to crack what actually can be done to boost their productivity. Whether a small scale, or large scale industries, they need an exact strategic plan that helps them keep their business run successfully. To put it simply they need an effective way to tackle the challenges & lead the race. How ready are you to tackle the challenges & win the race?? keeping that in mind, here we provide the killer tips & tricks for every manufacturers to handle their production problems & boost productivity with IoT Industry 4.0.

Throw off the Old Production metrics

The huge mistake that every production managers / production manufacturers doing today is believing in the raw data from old metrics. The drawback of the old methodologies is that the inaccuracy of the production data & it generates measurement errors. Struggling to gauge the volume of potential services, and lags between investments are the two drawbacks in measuring inputs when the traditional method is actually utilized in production. It is paramount to unpack the measures of productivity to understand the proximate and factors affecting productivity growth. In layman terms, “if an equipment is partially utilized or not utilized today, then the equipment is completely ignored from the productivity calculation”. This results in the incorrect measurement displaying the calculated productivity higher than the actual ones. Measuring the productivity data right is the first step to improvement. Manufacturing Productivity is a measure of how great the asset works compared to its fullest potential. OEE metric which is a direct combination of Availability, Performance & Quality which directly indicates the gap between the actual and ideal performance of your industrial operation. It reports the overall utilization of facilities, time and material for manufacturing operations. This ultimately helps the business work on the improvement of equipment effectiveness and thereby its manufacturing productivity.

Tip*

Manufacturing Productivity measurements are overlooked and calculated with skewed data. Measuring it right is with OEE – A combination of Availability, Productivity & Quality is the first step to improvement. Improving OEE will improve your overall efficiency & revenue.

IoT Industry 4.0 tip-1

Win the Downtime battle

One of the fundamental issues which manufacturers deals every day is the cost of downtime. Manufacturers wage to keep machines running figures eminently in Industry. Bringing down the cost analogous to these basic elements of manufacturing are among the most demanding challenges a manufacturer must address. A recent survey showed that the cost of a machine breakdown is more than just the maintenance labour and materials to make the repair. Roughly every industry loses at least 5% of its productivity by dint of downtime, and many loss as much as 20%. The awful part is that many of the industries are impotent to calculate the actual cost of downtime precisely. When the machines are idle, everyone’s attention will get averted from growing the business, whether it’s responding to new opportunities or innovating new products and services. Keeping an eye on how, when, where the downtime occurs will help you prevent & manage the excessive loss. A speedy move towards minimizing downtime is possible only when it is tracked precisely & cautiously. Hence, utilizing complete monitoring software that provides real-time view of shop floor will significantly provide the data on downtime events.

Tip*

IoT based predictive maintenance will proactively identify machine failures & push fixes. This reduces the equipment downtime by 50%.

IoT Industry 4.0 tip -2

Revamp Industrial Data Management

The conventional way of acquiring data that involves log sheets in which operators manually write down the production data will not lay out any improvement in the productivity. This is because the production data obtained can be inaccurate and the operator will frequently miss the downtime events. Then, How can they improve productivity without an accurate data? This finally results in operational waste, lost sales, productivity loss, disengaged employees & dissatisfied customers which cost manufacturing industry, $9.7M per year. An automated production monitoring system that collects data from each machine individually will report the production unit heads / operators real-time. This helps operators & production managers communicate with each other internally with an exact data to make faster decisions. Finally leading to win IoT Industry 4.0.

Tip*

Better data management can improve operational productivity level 50%. Act fast with an automated data collection & monitoring.

Keep Product Quality High

According to industry experts, the most critical issue that any manufacturing environment is facing through the production process is the cost of poor quality because of its direct effect on reducing the manufacturing process efficiency and that most of the causes are hidden and not directly noticeable. This finally results in chargebacks, lost sales, product returns, rework costs, and freight costs. The true cost of poor quality includes the tally of the costs from repair, rework, scrap, service calls, warranty claims and write-off from outdated finished goods can range between 5 and 30% of a manufacturing company’s total revenues, with the range for most companies falling between 10 and 20%. With the Quality management / monitoring system in hand this can be eventually avoided. The sensor fitted with the production machines will monitor machine health parameters & equipment calibration that checks whether parameters are approaching threshold & monitor variance in equipment behaviour. This alerts the quality manager if any issues are detected & finally improving the product quality. This results in gaining customer loyalty, business repetition, acquiring customer referrals, & improved market position.

Tip*

Catch the flaws before the product reaches the market. An Effective IoT based quality management will make a direct contribution to profits.

An Effective Production Monitoring System

Any production company to successfully execute the above mentioned tips requires a first-rate production monitoring system to know about the operational efficiency of their factory really. Hence, in order to achieve first-rate production efficiency, production monitoring is decisive. Moreover, when done with the right tools, production monitoring has the potential to transform an entire manufacturing industry. The perfect real-time production monitoring system could enhance the productivity and efficiency. A right production monitoring system with OEE calculation, perfect data management, downtime & quality analysis will significantly improve productivity.

Industry 4.0 tip - 5

Pace DPR, an explicit production monitoring tool has the potential to aggregate production information and makes it available to production managers with great clarity and simplicity. This will help production managers close the gap between production processes & planning & will help you lead the industrial race.

Hope the above listed Tips will help you frame the strategic plan for your production line to win with IoT Industry 4.0. To know more…..Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.

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Impact of Downtime in Manufacturing

Impact of Downtime in Manufacturing

In any business and production process, the saying “Time is Money” holds true. Every second that a machine is running earns money in the manufacturing industry. The longer it takes to develop raw materials into finished goods, the more money it costs to get them out. What will happen if your machines are left idle for an extended period of time? There is a possibility that revenue will be lost. Downtime refers to the duration of an unplanned or unexpected outage. The Ignition OEE Downtime Module enables manufacturers to identify problem areas in a production line or across an entire business. This extensive understanding into the topic of downtime, its impact on the production process, and ways to minimise it.

Actual Cost of Manufacturing Downtime

Downtime is something that no industry likes to deal with. Every industry in the world is living in a nightmare. According to one estimate, practically every industry loses 5 to 20% of its production due to downtime, with the expenses being outrageous. Machine failures can bring production to a halt and cost a company millions of dollars. This surprising statistic demonstrates the high cost of downtime. As a result, every industrial industry must consider the financial cost of downtime. Unplanned outages can cost a lot of money and have a major impact on the industry’s bottom line. It is not an option to ignore the expense of downtime, and limiting downtime is critical to a company’s bottom line. To meet financial objectives and maintain a healthy bottom line, it’s important to understand the true cost of downtime and how to minimize it.

Why do Machines Sit idle?

Tool failures, machine faults, process failures, unplanned stoppage, and other factors can all contribute to downtime. While most people associate downtime with breakdowns, it is actually an unplanned event that has a significant impact on your production process. Excessive changeovers, a lack of operators, and unplanned machine repairs are all examples of unplanned downtime. To deal with it, you must first understand each downtime and how it affects your industry’s revenue.

How to Calculate Downtime for Equipment:

Because this term can refer to any event that causes a halt in manufacturing, it’s critical for a company to first determine what kind of downtime they want to calculate. Assume a factory is experiencing some issues with machines failing. They’ve determined that this is the majority of their downtime, making it the most important type of downtime to track. One method for calculating the cost of equipment downtime is to consider the revenue lost during downtime periods. We can do this by comparing the number of products produced in a given time period (per hour) to the amount of money made from each product. Then we compare these figures to the amount of downtime that has occurred.

According to this equation, if we produce 20 units per hour and profit $100.00 per unit, each hour is worth $1000. If we have 4 hours of downtime, we have lost $4,000.00 in just those 4 hours. Consider how much revenue can be lost if the downtime is longer or the product is more profitable. It’s easy to see why this is so critical to track down and fix as soon as possible.

Tracking Manufacturing Downtime

You can prevent and control excessive loss by tracking how, when, and where downtime happens. Only when downtime is measured carefully and thoughtfully can an early start toward minimising it be taken. The typical method of obtaining data, which includes operators manually recording downtime on log sheets, usually misses downtime incidents. As a result, adopting comprehensive monitoring software that provides a real-time view of the shop floor will provide considerable data on downtime situations. OEE DPR, the powerful software for measuring manufacturing OEE, will give a clear view of your production line and help you detect inefficiencies, determine bottlenecks, maintenance concerns, and other downtime-causing events. Recording downtime and determining the cause will drastically decrease production issues and increase the rate of production. Reducing the amount of time that people or machines sit idle will improve the bottom line of the company. Take a look at the suggestions below for reducing manufacturing downtime.

  • Regularly provide safety training to limit the risk of dangerous user errors.

  • Make a dependable preventive maintenance schedule.

  • Establish a routine for inspecting critical equipment.

  • Keep track of equipment lifespan to determine when it’s time to upgrade.

Analysing the data

The availability of a system concerns unplanned downtime and breakdown losses. As a result, evaluating OEE is a critical factor in eliminating production losses and gaining a better understanding of production. However, simply monitoring OEE and gathering statistics would not help you increase your output. It is critical to develop a strategic enrolling plan based on the acquired data in order to reduce downtime. OEE DPR will help you in analysing the data, determining the cause of downtime, and determining how the information acquired can be used to improve predictive maintenance.

The metric that does not correlate with machine data will not provide you an accurate view of your production loss. The real-time data view of what’s happening on the manufacturing line will give the downtime events in context. As a result, OEE DPR will allow manufacturers to move away from production difficulties and toward a more efficient manufacturing process. As a result, OEE DPR will allow manufacturers to move away from production difficulties and towards a more data-driven business model.

We will be happy to discuss about your requirements at your shop floor to help you reduce downtime & improve your productivity.

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You can also write to us via support for any queries.

Thank You 2019, Hello 2020!

Thank You 2019, Hello 2020!

2019 has been a great, wonderful and successful year. The success of the year has boosted us to cherish ourselves and work still hard for the better 2020. We are more excited to close out 2019 and look forward to a more opportunities and achievements awaiting with lots of hope. To kick start the dawning year with more energy we would like to thank 2019 for the lessons learnt.

Thank You 2019

Thank You 2019 for making us stronger and for bringing lots of achievements and success. This would not have been possible without a great team. We know that every business needs customers. We have a great deal of respect and thanks to our customers who have put trust on us. Could not ignore to thank those who tried our tools by downloading and visiting our website & giving us feedback. We had 40 % more downloads and 20 % more customers in 2019. A special thanks to our partners from India & Brazil who believed and taken us to the next level with their huge commitment and active contribution.

A heartfelt thanks to our family and friends for their great support towards us that helped us to achieve great things.

A Little Throwback

The progression of the world over internet is taking place at a rapid rate than expected. Hence, A defining trait of a successful IoT product is a clear, well-defined reason for the product to exist and also its cost effectiveness. We have done great launches and product updates in 2019.

Devops is one of the most important need for the IOT Solution. Unfortunately all product vendors will not have the bandwidth to have their own team to manage their servers. As a framework provider, we are determined to help our customers with a hosted MQTT Services on a dedicated server and to make it available for all Business organizations with an affordable price. 63 % of manufacturers believe that deploying IoT technology will increase profitably over next 5 years and are set to invest $267 billion in IoT. This is because manufacturing Industries are gaining more insight about crucial & real time informations through IoT to make informed strategic decisions. Hence we developed a production monitoring system, Pace DPR / OEE DPR to provide manufacturers a complete visibility and analytics into production. This can help them reduce the cost by saving more than 12% on repairs & 72% on decreasing downtime.

To Ensure, future generations are aware of upcoming trends is a social responsibility. Every student cannot afford premium products for their non-commercial / educational projects. Hence, by recognizing the limited budgets available for academic, we unveiled a specially-priced version of our Bevywise IoT for Education pack. We also provide FREE license for IoT products for students academic projects. As a startup, we know the painstaking efforts every entrepreneur will take and hurdles they face to achieve their goal. Hence we introduced a startups pack for MQTT Broker & IOT Simulator which is more affordable with all the features.

Special thanks to YourStory media and Vishal Krishna, who gave a great write up about Bevywise Networks and closed 2019 for us with great memories.

A Great Year ahead

The world has started tasting the fruit of the Initial IOT deployments. We can control our houses without straining. Industries like Manufacturing were able to view reports and control production environment without moving their fingers. Health care is getting remote and dream of home care is coming alive.

Undoubtedly, 2020 will be a big & exciting phase for IoT. By 2020, there will be upto 21 million devices connected with IoT across the globe. The number is huge, because it is practically impossible for any business organizations to stay away from IoT. The peak reach is due to the worldwide rise in IoT technology development & implementation. We are quite excited to connect with more business to make their lives easier and more powerful. Let us wrap 2019 with a bow and start 2020 with the bang!

Wishing everyone a fulfilling & promising year ahead!