The need for Condition Based Maintenance
All Itho Daalderop’s products are produced at a single factory at Tiel, in the Netherlands. As explained in Why Itho Daalderop adopted Smart Manufacturing, the production and distribution chain has recently changed to a Make to Order process, requiring great flexibility. As Production Manager, Richard van Gelder, explains, “On demand production means that no single week is the same, …but I can say that we produce between 8000 and 12,000 products per week. And that is in all the product variants, from a complex heat pump to a very simple cover for a ventilation unit.” With Make to Order, the reliability of the production facilities has become mission critical. Operating a corrective maintenance strategy, whereby repairs are conducted once machines have broken, is no longer acceptable. A Condition Based Maintenance (CBM) strategy, enabled by innius, is the solution.
Virtual sensors and dashboards
Itho Daalderop’s implementation of innius is a testament to the platform’s adaptability to the specific business needs of users. Condition Based Maintenance with innius would usually be conducted by setting up rules on physical and virtual sensors, to trigger alert notifications to users’ mobile devices. But because Itho Daalderop’s maintenance team work in close proximity to the production line and aren’t equipped with mobile devices, they decided to simply display virtual sensors on hanging dashboards in both the production area and maintenance office.
Control Engineer, Gerard van Gelderen, has been responsible for programming the virtual sensors and dashboards. He says, “At the moment, we’re mostly using the sensors or virtual sensors with some scripts behind them. Scripts are easy to apply, and if you get stuck, you can get help from innius. I think the most useful function of innius, is the ability to make virtual sensors, whereby you don’t need to get all the functionality out of the PLC but can keep that in the online environment.” And also, “By taking the dashboards that we as Maintenance Engineers use, and hanging these up in the production area, we can create insight for the people on the production line.”