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EMB Global enhanced chemical manufacturing by providing a custom machine monitoring solution. We implemented high-precision load cells, an IoT platform for data analysis, advanced machine learning analytics, and a user-friendly dashboard. These innovations offered real-time insights, optimized processes, and improved efficiency. Transform your operations with our cutting-edge solutions!
The company faced significant challenges in its chemical mixing processes, which led to considerable financial losses and operational inefficiencies. The manual weighing of chemicals resulted in a 17% increase in product defects, causing approximately $460,000 in rework costs annually. Additionally, inaccurate dosing led to chemical waste amounting to around $320,000 per year. The manual process also posed safety risks, increasing the likelihood of accidents and injuries, further impacting employee morale and productivity.
To address these challenges,EMB GLOBAL developed a customized machine monitoring solution, featuring:
High-Precision Load Cells
Integrated into the chemical mixing tanks, these load cells provide real-time, highly accurate weight measurements.
Industrial IoT Platform
Deployed to collect and analyze sensor data, offering actionable insights into the mixing process.
Advanced Analytics
Machine learning algorithms identify patterns, trends, and anomalies, facilitating predictive maintenance and process optimization.
User-Friendly Interface
A dashboard that displays real-time data, enabling operators to monitor and control the mixing process efficiently.
The implementation of this machine monitoring solution yielded significant benefits:
Achieved a 14% decrease in product defects, leading to enhanced customer satisfaction and a reduction in rework costs.
Chemical waste was reduced by 19%, resulting in annual savings of approximately $270,000.
Optimized mixing processes led to a 23% increase in production output, improving overall plant efficiency.
The successful implementation of the machine monitoring solution has transformed the company's chemical mixing processes, resulting in substantial cost savings, improved efficiency, and enhanced safety. By continuing to invest in advanced digital technologies, the company is well-positioned to maintain its leadership in the chemical industry and achieve sustainable growth. Further opportunities for optimization include exploring predictive maintenance, digital twin technology, and advanced process control algorithms.