• Usman Wajid

Monitoring of Production Environment Using Advance Digital Solutions

Updated: Jul 4


Many SMEs lack fundamental digitisation that can allow them to connect their machines and devices to digital networks without significant investments. Such connectivity and digitalisation can enable SMEs to unlock the value of their data and increase the efficiency of production processes. In a specific EFPF pilot scenario, capturing and processing of relevant shop floor information is demonstrated through the use of federated EFPF solutions. The overall goal of this pilot scenario is to ensure that specific parameters in specific production machines and production environment are analysed in real-time to provide effective decision support. In aviation, large OEMs such as Airbus and Boing set detailed product specifications for suppliers. In some cases, certain production steps are only permitted under very specific and monitored environmental conditions. For example, aerospace paints may only be processed within a specific temperature range.


The implementation of this scenario is carried out at EFPF aerospace partners WOM and IAI. WOM requires control of temperature and humidity in their manufacturing area to ensure consistent quality and environmental conditions required for component tolerances. Similarly, IAI needs to survey raw material stored in a freezer to avoid scrapping in case of too high temperature. When a high temperate is detected the vacuum forming machine needs to be controlled to take immediate actions.

In these scenarios, the goal is to secure the stability and quality of manufacturing processes by monitoring the relevant parameters and provide alarms in case defined thresholds are underrun or exceeded. Overall goals are to make sure that:


· Products are manufactured in acc. with relevant process specifications

· Rejects and waste are reduced

· Failures can be detected early, and intervention actions can be taken if necessary

· Record history data as proof for the correct functioning of the system even when unattended


The adjecent figure shows the general system architecture for the fulfilment of the required functionalities.


The developed EFPF solution utilises small industrial computers and Ethernet-IP input-output modules linked to the relevant process sensors and actuators on the hardware side. All needed hardware was agreed upon between the partners. These are installed in electrical cabinets with supporting electrical equipment to solve a high-standard industrial level. The installation of all hardware and equipment into the cabinets has been done by the user companies WOM and IAI.


The following video describes the overall solution and the various phases in which it was developed by the project partners.



After the development phase, the solutions were validated from IAI and WOM under consideration of the specific requirements and further usability aspects. Both companies set the relevant threshold in the GUI to a value where the alarms a triggered. The correct function of the alarm system has then been tested. It turned out the all required functions worked as expected in real world conditions. The solution is available to the users through the EFPF Portal: http://portal.efpf.org/