Real-time data analysis for
manufacturer of foam and felt for
the automotive industry
Advantech and KFactory partnered to provide Masterfoam with significant
improvements in its production processes.
Introduction
Smart Manufacturing
The Challenge
Any manufacturing manager faces a constant
challenge to increase operational efficiency.
KFactory’s Core platform combines traditional
data acquisition and business intelligence coupled
with big data to deliver high value insights into not
only what is happening, but also why.
A critical part of the story is the need for a resilient
and rapid real time data collection system, and
this was made possible by the adoption of
Advantechs WISE-4000 product family.
The Client
Headquartered in Bucharest, Romania, KFactory
is a European pioneer in factory digitalisation
through the application of technology. Its Core
platform provides a 360o view of the production
process, detecting deviations from the production
plan as well as undesirable behaviour from
operators or support teams. Smart notifications
enable managers to act before losses occur,
maximizing production time.
Over recent years, manufacturers have been
subject to a ‘perfect storm’ of overlapping crises.
Supply chains have suffered significant
disruption and the costs of raw materials,
energy and transportation have all rocketed. At
the same time, manufacturers are dealing with
an aging workforce, and a corresponding
looming skills gap. Addressing these challenges
whilst also facing increased competition in a
continuously changing market, Masterfoam
needed to find ways to increase efficiency and
reduce costs.
Data collection from the production process was
slow and was subject to human error. The
problem was compounded by historical data
being stored in unstructured formats, making it
difficult to spot the patterns and emerging
trends upon which to base any improvement
strategy.
“The manufacturing sectors are going through
difficult times, but the implementation of our Core
platform in conjunction with the data collection
solutions provided by Advantech provides our
customers a true competitive edge.”
Vlad Cazan, KFactory, Co-founder
www.advantech.com/en-eu
KFactory selected the WISE-4051 to perform
the remote data acquisition and transmission
from the factory floor to the Core platform. It
offered the ideal mix of I/O and robust and
reliable operation, coupled to easy, quick and
cost effective installation due to its WiFi
connectivity, which eliminated the need for
costly cable installation. In fact, the first
connected machines were online and producing
actionable insights within a couple of weeks.
The data is recovered from the WISE-4051
devices by the KFactory Core platform, which
applies business intelligence to the real time
and historical data to provide insight and
proactive recommendations to the Masterfoam
managers.
The Solution
Deploying the KFactory solution resulted in
the production process being monitored in
real time with maximum precision. Data is
collected from all relevant actors, including
equipment, inspectors and support teams,
and is delivered to managers in an easily
digested and timely manner. Furthermore,
combining real time data with historical
information allows analysis to be performed
on data sets collated over a much larger
timeframe than was possible prior to
deployment, enabling identification of patterns
and trends indicative of slowly developing
problems, or other long term trends offering
scope for improvement.
The Process
Overall, Masterfoam achieved several
strategic objectives:
• Improved measurement precision.
• Improved measurement reliability.
• Data collection cost reduction.
• Data integrated from diverse sources.
• Better management oversight.
• More reliable factory operations.
• Increased production efficiency.
Before
Now
The Outcome
The decision to develop the project was
prompted by our heavy workload of manual data
processing. We can now track production
activity in real time, have a better knowledge of
how production orders are scheduled and the
actual lead times, and identify operators who
require the closest support and training.”
Monica Pascu, Plant Manager
www.advantech.com/en-eu
• Manual, error prone data
collection
• Data recorded on paper forms
• Data not correlated between
different functions
• Unstructured historical data
• Reliable, automatic data
collection
• Data recorded in historian
database
• Business intelligence applied
to big data
• Actionable insights
presented to managers
Advantech was chosen as a partner for the
range of data collection, industrial computing,
and communication platforms on which our
solutions are built. This allows us to approach
prospects like Masterfoam with confidence,
knowing that Advantech will be able to supply
the solutions we require.”
Adrian Dima, KFactory, Co-founder
KFactory considered a number of factors
when selecting Advantech as a partner for the
Masterfoam project.
• Cost effective, proven technology.
• Wide variety of SKUs from which to select
the optimum project fit.
• Local office and support.
• Global presence and service centres.
• Financially strong and stable.
• Independently recognised as leading
supplier for IIoT devices and systems.
Why Advantech
• Less human error.
• Real-time KPI monitoring.
• Instant, informed decision making.
• Reporting of relevant information on
equipment, orders and operators.
Advantages to Masterfoam
• Robust and reliable data acquisition.
• Rapid and cost effective installation.
• Accurate, real-time data.
• Global partner with local support.
• Wide variety of product SKUs from which
to select optimum project fit.
• Proven track record of supply.
Advantages to KFactory
www.advantech.com/en-eu
About Advantech
Founded in 1983, Advantech is the leading manufacturer of industrial computing, display and communications products. Advantech
its customers and their end-users wherever our equipment ends up. We cooperate closely with our distribution partners, software,
hardware and communication partners, system integrators and consultants to provide complete solutions to complex computing and
communications challenges. Our mission is to enable an intelligent planet by developing the automation and embedded computing
products on which it will run. With Advantech products, the application and innovation potential is unlimited.
Advantech Europe
+48-22-31-51-100
sprzedaz@advantech.com
www.advantech.com/en-eu
Slawomir Janczewski
iFactory CEE KAM
Advantech Europe
Vlad Cazan
Co-founder and Sales Lead
KFactory