The Challenge
A leading global healthcare product company with over 110,000 employees, faces disruptions in their European manufacturing plant – one of the largest globally. This plant employs automated production lines for sterile vial filling. Occasional component failures necessitate the entire line to be switched off, requiring replacement of broken parts and subsequent re-sterilization. This disrupts the manufacturing process, delaying product delivery and diminishing revenue potential.
The Approach
Given our extensive experience in wireless sensor applications, we were entrusted with the challenge of developing a predictive maintenance solution. We explored innovative methods to implement predictive monitoring techniques on the client’s filling line, aiming for early identification of potential failures and their associated failure modes.
The Approach
Given our extensive experience in wireless sensor applications, we were entrusted with the challenge of developing a predictive maintenance solution. We explored innovative methods to implement predictive monitoring techniques on the client’s filling line, aiming for early identification of potential failures and their associated failure modes.
The Outcome
We then developed miniature battery-powered sensor systems encased in sterile enclosures. These devices were strategically deployed on the manufacturing line, monitoring various environmental conditions and logging relevant data. We analysed the data then developed and implemented advanced processing techniques to detect features indicative of imminent component failure, providing the necessary predictive maintenance functionality. This condition monitoring allows for timely replacement or repair of components between shifts or during scheduled maintenance intervals, mitigating the risk of costly shutdowns.
