Ace Micromatic Group: Aligning Smart Factory Solutions With Workflows And Production Requirements

Production & OEE Analytics: Through real-time data capture, the organization provides insights into shop floor performance, including part count, downtime reasons, cycle time, and load/unload time variations. It enhances Overall Equipment Effectiveness (OEE) and production analytics, optimizing efficiency and asset utilization.

Real-time SPC and Automated Offset Corrections (AWOC): Integrating metrology equipment with production machines, it offers real-time Statistical Process Control (SPC) and automated tool wear offset corrections. This reduces manual errors, identifies dimensional deviations, and ensures superior quality.

Energy Monitoring: It provides insights into energy consumption relative to part production, electrical parameters like RYB line voltage, and power factors. This enables organizations to benchmark their energy usage and reduce greenhouse gas emissions.

Traceability and Genealogy: It enables tracking of raw materials to final products using barcodes, RFID, or serial numbers. Manufacturers can capture critical process parameters, ensuring comprehensive traceability and product genealogy.

Digital Factory: It allows transition to a paperless factory through machine-mounted displays, tablets, or computers, all driven by a centralized knowledge repository. Strict access controls ensure data authenticity.

Process Parameters: Manufacturers can capture intrinsic CNC controller data and external sensor data (vibration, flow, pressure, temperature) to monitor equipment health and ensure process traceability, yielding valuable insights and predictability.

Assembly & Line Monitoring: It helps manufacturers achieve end-to-end visibility into assembly processes, enforcing digital poka-yoke and workflows to boost line availability and performance.

Visual Factory: It offers real-time visualization of shop-floor status via industry-standard Key Performance Indicators (KPIs) presented in rich dashboards and graphs, facilitating quick decision-making and actionability.

Benefits of Digitalization Services
AMIT enhances efficiency and utilization via digitalization services, reducing component costs. Its solutions empower manufacturers to leverage data insights and enhance maintenance. Through automated data capture and reporting, the company's solutions allow customers to concentrate on productivity enhancements, ultimately boosting profitability.

Improving Competitiveness, Delivering Bottom Line Impact
One of AceMicromatic Group's clients, a prominent global turbine manufacturer, was grappling with a low Overall Equipment Effectiveness (OEE) of approximately 35 percent. The primary impediment they faced was their reliance on paper-based workflows, which led operators to reference outdated versions of drawings and process documents, ultimately resulting in rework and rejection issues.

To address this challenge, AMIT implemented a tailored solution for them, utilizing TPM-Trak Production Monitoring, eSHOPx, and Energy Monitoring. As a result, the manufacturer successfully elevated its OEE from 35 percent to an impressive 66 percent. Moreover, they were able to completely eliminate rejections and rework caused by outdated document references. The solution also made a significant impact from an environmental standpoint by saving over 500 sheets of paper and prints each month. After these improvements, the manufacturer now enjoys consistent annual savings of more than Rs 1.5 crore through the utilization of AMG’s Industry 4.0 solutions.

Connecting Every Aspect of Manufacturing Value Chain
Staying at the forefront of technology and innovation, AMIT drives productivity and transforms customer engagement and revenue models through its AMG-mIoT platform. The AMG-mIoT advanced platform seamlessly connects every aspect of the manufacturing value chain, spanning from the sourcing of raw materials to the final product delivery. This comprehensive connectivity enhances traceability and visibility throughout the manufacturing process. By digitizing this manufacturing backbone, companies can achieve complete "vertical integration" of their crucial business processes. This, in turn, results in processes that are not only faster, but also more efficient and cost-effective. It empowers decentralized decision-making through knowledge-based, predictable, and resilient frameworks.

In order to harness the advantages of Industry 4.0, the AMG-mIoT platform leverages a three-dimensional convergence of business processes, smart Initiatives, and enabling technologies. This convergence is instrumental in identifying specific business outcomes and tangible outputs. Putting information, digital workflows, metrics, and Key Performance Indicators (KPIs) into the hands of both blue-collar and white-collar workers empowers them to operate autonomously while minimizing risks. Importantly, AMG-mIoT is a versatile platform that can be utilized by end-users, machine manufacturers, and service providers alike. The platform enables and delivers outcomes that translate into heightened productivity and increased profits.

The Next Frontier
Today, AMG is positioned as one of India's foremost vertically integrated producers of precision CNC machines, automation products, and Industry 4.0 software. “Our aspiration is to secure a place among the world's top 10 global leaders in our industry. We are committed to achieving this goal by offering cost-effective solutions that yield substantial returns on investment, thereby aiding our customers in enhancing their productivity and boosting their profits,” signs off Madhusudan Kestur, Director, AMIT.