How a Pioneer in Electrification reduced Soldering Paste Spoilage by almost 6%
Overview
Our client needed a real-time monitoring solution for their Chiller and Chemical chamber to reduce the risk of material disintegration. They lacked a sophisticated system that could monitor and alert the staff if the cold storage conditions were less than ideal. Datakrew introduced MADS, our monitoring and alerting solution to effectively address their concerns.
Client Profile
Our client is a German-based multi-national company pioneering in electrification. By offering a variety of propulsion solutions for various electric vehicles, they have extended their global footprint to around 50 locations worldwide. They aim to play a leading role in automobile electrification with a strong focus on sustainability.
Problem
Our client utilizes the Chiller and Chemical chamber to store Soldering Paste which is extremely temperature-sensitive. It is vital to keep the paste within a temperature range of 4℃ - 10℃ to ensure maximum efficacy.
However, with unforeseen circumstances like fluctuating power supply or power failure, the temperature and humidity parameters could become less than ideal. This needed to be avoided at any cost but without a proper monitoring system in place, our client was not able to keep track of such parameters. Additionally, the staff were unaware of sudden power outages.
Solution
Datakrew introduced MADS, our IoT-based monitoring and alerting software which was used to monitor 5 individual electronic assets.
The monitored assets are:
- 2 x Chemical Chambers and
- 3 x Chillers.
The installation was completed within 24 hours and the following parameters were monitored 24x7:
Cold Storage Conditions:
- Temperature
- Humidity
- Carbon dioxide (CO2)
Environmental Data
- Water Leakage
- Temperature
- Relative Humidity
Individual graphs denoting real-time fluctuations in temperature and humidity were plotted from the generated data. In addition to this, an audio alerting system was set up to alert workers of power outages.
Results
With the continuous monitoring of assets with MADS and rapid intervention, the client reduced material spoilage by almost 6% and experienced improved operational efficiency. The timely detection of issues in individual chillers and chemical chambers translated into proactive problem resolution, preventing potential disruptions.
Deviations in temperature, CO2, or humidity levels triggered real-time alerts that were sent via SMS and emails to notify workers. The integration of audible signals for unexpected power outages further improved the system's reliability.
Benefits
- Approximately 6% Reduction in material spoilage
- 24/7 monitoring of Crucial Assets
- Real-time visualization of temperature, humidity, and carbon dioxide levels.
- Environmental data collection like water leakage, relative humidity, and temperature.
- Alerts were sent via emails and SMS, to notify of possible variations.
- Audible signals were set up to notify of unexpected power outages.