Factory Automation & Predictive Maintenance Platform
Overview
A manufacturing customer approached RDS looking to improve operational efficiency across multiple production lines. Existing machine monitoring was fragmented, with operators required to manually check individual systems, maintenance schedules based on fixed service intervals, and equipment failures often identified only after production had been disrupted.
Drawing on over 40 years of experience in industrial display, embedded and system design, RDS developed a bespoke factory automation platform that combined machine monitoring, predictive maintenance and real-time production visibility into a single integrated solution.
Challenge
The customer faced several operational challenges:
- Machine status and performance data were spread across multiple local HMIs, making factory-wide monitoring difficult.
- Maintenance activities were scheduled at fixed intervals regardless of actual equipment condition.
- Mechanical failures often resulted in unplanned downtime and production losses.
- Engineers were required to spend significant time manually inspecting equipment and collecting performance data.
- Consumer-grade display and computing hardware had proven unreliable in harsh factory environments, leading to increased maintenance and replacement costs.
The customer required a robust, industrial-grade solution capable of consolidating data, improving maintenance planning and providing real-time operational visibility.
Solution
RDS designed and manufactured a bespoke automation platform centred around a 40" industrial touchscreen display, embedded computing architecture and SensConnect IoT connectivity.
The system collects and consolidates data from multiple machines, presenting live operational information through a single intuitive interface. Equipment performance, production metrics and maintenance indicators can be monitored locally or remotely, providing operators and maintenance teams with instant access to critical information.
Using SensConnect, machine data is securely transmitted to the cloud, enabling remote monitoring, automated alerts and long-term performance analysis. By tracking trends such as operating hours, temperatures, vibration levels and equipment utilisation, maintenance activities can be planned based on actual equipment condition rather than fixed service schedules.
To ensure long-term reliability, the solution utilised industrial-grade displays, embedded computing hardware and custom-designed metalwork engineered specifically for demanding manufacturing environments.
Outcome
The completed system transformed how the customer monitored and managed production assets.
By centralising machine data and introducing condition-based maintenance strategies, the customer reduced unplanned downtime, improved maintenance efficiency and gained greater visibility of factory operations, Remote access to operational data reduced the need for routine manual inspections, allowing engineering resources to focus on higher-value activities.
The scalable architecture also provides a platform for future automation initiatives, enabling additional machines, sensors and production lines to be integrated as operational requirements evolve.
Key Benefits
- Centralised factory-wide monitoring
- Predictive and condition-based maintenance
- Reduced unplanned downtime
- Lower maintenance and labour costs
- Remote monitoring and automated alerts
- Industrial-grade hardware for maximum reliability
- Scalable platform for future automation projects