Mitsubishi Electric Corporation (MELCO) as a leading of factory automation system in South East Asia collaborate with Factorium, a Thai startup specializing in machine maintenance platform was joined to develop a new concept of machine intelligent solution after Factorium are winning MELCO’s award from Tech Planter program in Singapore. This project was piloted at the CPF plant in Saraburi, Thailand as the first location in South East Asia. The machine intelligent platform collects data from a Programmable Logic Controller System (PLC) to display, analyze, and produce structural models in eye-catching 3D format. These models assist engineers and technicians to monitor machine output in real-time, allowing accurate preventive and predictive maintenance planning.
The machine intelligent platform upgrades redundant factory systems. No additional sensors are needed. This new solution operates by integrating several technologies into one platform. Mitsubishi Electric Corporation, a Japanese multinational electronics manufacturing company, operates by collecting comprehensive data to control machine systems. However, gathered data was not used to fine-tune future operations, as no analytical software existed. Therefore, Mitsubishi Electric Thailand installed data transfer modules (PLCs) at all the ammonium cooling controllers in CPF factories to transmit data to the Factorium machine intelligent platform.
The machine intelligent platform, termed Factorium Machine Intelligence, integrates the data and supports multi-industrial protocols through cloud-based data storage and open application programming interfaces (APIs) to connect with and keep Big Data at client data centers. The machine intelligent platform comprises four data analysis displays as follows:
- Realtime machine simulation
A Digital Twin represents a physical machine in virtual 3D form on a screen that displays an animation of working machine parts in real-time. Digital Twins allow engineers and technicians to monitor machines anywhere and at any time.
- Anomaly detection
Irregularities in machine signals are detected as an early warning device that identifies actions to prevent machine failure. Anomaly detection allows clients to select a data set and algorithm based on machine types for precise data processing. If an anomaly is detected, the system automatically opens a work ticket on the mobile Factorium computerized maintenance management system (CMMS).
- Machine components utilization
Factorium CMMS tracks machine utilization and lifespan, allowing engineers to optimize planned maintenance as Precision Maintenance. The system also tracks and evaluates spare parts for cost efficiency.
- Tickets generator to mobile CMMS
If a fault is detected, the system generates a work ticket and assigns the repair task automatically via the mobile CMMS app. This integrates the overall maintenance platform into one place for easier management. Engineers can monitor machines remotely, while also planning Predictive Maintenance using data gathered from anomaly detections.
After delivery of the machine intelligent platform to the CPF factory at Saraburi, our clients, especially engineers and the Plant Manager were very satisfied.
Mr. Adisak Chaiput, the engineering manager responsible for the cooling system, said that previously, monitoring and collecting machine data from different factory locations was a complicated and labor-intensive task. The machine intelligent platform has greatly facilitated this process and reduced reliance on excessive human resources.
Mr. Surapong Chaseang, a maintenance manager working in CPF Central Engineering Department, stated that the machine intelligent platform responded effectively to predict possible failures (Predictive Maintenance) as an efficient method for cost reduction. He planned to deploy the solution to other plant locations. From now on, Mitsubishi Electric and Factorium, along with CPF engineers will work together to advance technology in the machine intelligent platform.
This project is a collaboration between Mitsubishi Electric Japan and potential startups to accelerate industrial innovation in factory automation for Southeast Asian (SEA) clients.
Mr. Bovon Thiansawat, Head of the Alliance and Project Development Program at Mitsubishi Electric Thailand stated that Mitsubishi Electric’s e-Factory project promoted the smart factory concept to optimize production by cooperating with various partners. Collaboration with Factorium was another important step for Mitsubishi Electric to add value for their clients and increase long-term competitive advantages.
Collaboration between the three parties allows a Thai startup to earn trust and acceptance from global enterprises that possess long successful histories as factory automation leaders. The Thai startup is grateful that a leading player in food manufacturing like CPF granted this opportunity and gave useful advice throughout the project. Innovation through practical technology successfully overcame the difficulties encountered in factories.
Sittikorn Nualrod, CEO and Co-founder of Factorium stated, “Even though Factorium CMMS has gathered more than 3,500 corporate accounts and gained acceptance from big brand manufacturing companies in Thailand, Japan, Europe, and the USA that use our CMMS program in local factories, it is still a big challenge to increase value in our solutions and expand to SEA and globally. Becoming a strategic partner with Mitsubishi Electric is our core strategy. We call it ‘standing on the shoulders of giants’. Factorium can expand its networks and clients through the connections offered by Mitsubishi Electric.
This partnership is still in its infancy; however, we will push forward to regional, continental, and global market expansion as Factorium’s ultimate goal three years from now. We will work closely with Mitsubishi Electric to promote the machine intelligent platform to our clients
Behind the success story, I also want to thank you to the collaboration team from each side that working hard pushing our proposal to the goal, Mr. Ryuta Takeda the Director of Global Bridge Lab from Leave a Nest who connecting us to MELCO and help us following the project to the end, Mr. Kenji Minefuji the manager of business innovation & DX strategy div. of Mitsubishi electric corporation that assist in part of MELCO and connecting us to the MELFT. We also thank to all the person in charge of the project too”
For those interested in the machine intelligent platform, Sittikorn confirmed that the solution is now available for commercial use. He said, “Please note that the data link technology from Mitsubishi Electric is very flexible, and can be applied with Mitsubishi Electric PLCs and also other PLC brands”. This is a great opportunity to move forward together. Visit www.factorium.tech for more information or contact the Mitsubishi Electric team in your area.