CASE STUDY- Bosch Rexroth Controllers and VIMANA Software Delivers Industry 4.0 Solution

VIMANA's IoT Solution for Smart Manufacturing:
IoT Connectivity, Machine Monitoring.

Company Background

Bosch Rexroth and VIMANA provide a solution to a large power generation equipment company.  This company manufactures essential parts, the turbine blades and foils. The company mills these turbine blades with the Liechti TurboMill machines with Rexroth CNC controllers. 

Challenge

Improve utilization, productivity, and cost-efficiency of 70+ Liechti milling machines with Bosch Rexroth’s IndraMotion MTX CNC controllers.

Solution

Steam Turbine Manufacturer Selects VIMANA’s Industrial Analytics Software

Using VIMANA’s IoT connectivity, they captured and harmonized data from the Rexroth controllers, multivendor assets, and legacy factory devices across the shop floor. The reality is that manufacturers have varied vendors, software systems, hardware systems, and data standards, and analytics solutions must connect to everything. VIMANA provided this flexibility and read the CNC and PLC data across many device types. VIMANA’s interoperability between OPC UA, OPC DA, and MTConnect standards brought simplicity to building standardized, accurate data for better analytics.

VIMANA Elevate, smart manufacturing analytics application, was used to generate dashboards for real-time machine monitoring and proactive operational performance management. VIMANA enabled this manufacturer to leverage its machine data for insight to improve machine utilization, maintenance, operator resource optimization, and quality. Smart alerts from enriched data communicated the potential machine health or safety problems before they occurred and helped identify opportunities to reduce downtime and production risks.

Business Outcomes

Bosch Rexroth and VIMANA provided a total Industry 4.0 solution, harnessing real-time data for analysis that improved asset performance and productivity. As a result the manufacturer:

  • Increased machine utilization by 15% in a single cell, with savings of $500,000 in the first year.
  • Improved problem-solving reaction time and skills.
  • Enhanced their ability to determine maintenance and productivity issues proactively.

© MANUFACTURING SYSTEM INSIGHTS 2020