Real-time production monitoring system

Challenge

Production managers need real-time information about all events on the production floor to timely address any emerging manufacturing problems like production line stoppage, unplanned downtime, quality defects in the manufactured products, inadequate efficiency of processes, low productivity, and many others. However, with old equipment, it’s very difficult to get any data out of production lines other than parts produced per hour.

Therefore, there’s a growing need for industrial monitoring systems that without any modification of the existing equipment would keep track of production areas 24/7 and provide production managers with real-time data on the manufacturing process.

Solution

In response to our customer’s demand, Softarex Technologies has developed a cloud-based production monitoring system powered by Computer Vision and Machine Learning. Through cameras, IoT sensors, and devices, the system monitors production areas in real time and collects valuable manufacturing data: defects of the manufactured products, the number of spent materials, cycle time, production line stops, production and non-production times, the number and coordinates of objects on the production line, workers’ movements, and more. Then production tracking software analyzes the obtained information and notifies staff about any emerging issues.

Softarex production monitoring system’s features:

  • 24/7 production monitoring
  • Real-time automated data collection
  • Providing access to the obtained information from any electronic device
  • Checking the condition of the machinery
  • Predicting workflow failures and possible congestion
  • Quick notifying of any production-related problems: downtime, line stoppage, machine failure, etc.
  • Monitoring and counting objects throughout production lines
  • Measuring the coordinates of necessary fragments or devices parts of the specified machines
  • Controlling workers’ activity

Customer

Our customer is a large U.S. packaging and recycling company. It struggled with production issues like the lack of visibility into the manufacturing process, machine failures, and inefficient staff management which caused lower productivity and unplanned downtime. It needed a production monitoring solution that would keep track of all production processes and workers’ activity, collect valuable manufacturing data, help address the emerging issues head-on and optimize daily operations.

Value delivered

Production monitoring system by Softarex has helped our customer achieve the following:

  • Production managers are provided with insight into production processes thanks to 24/7 production monitoring
  • Reduced risk of production problems due to responding to the emerging alerts in a timely manner
  • Reduced paperwork and human effort
  • Automated production line workflow
  • Streamlined production processes
  • Improved production process efficiency
  • Increased workplace safety
  • Enhanced workers’ productivity and motivation thanks to continuous monitoring of their activity
  • Reduced operational costs

What our customers say

I lead a non-profit community and in response to the global pandemic around COVID-19, we've been developing a portal to help caregivers and others find emergent guidance and information. This portal is a critical gap-filler and crucial need in these trying times. I reached out to Softarex to help this volunteer effort, and in less than a week they had not only committed to helping us but had a fully ready team and were already making a difference. The development team has been a delight to work with, and we are seeing rapid progress as well as the quality of work. I couldn’t have hoped for a better experience.

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Ken Rubin
Executive Director, BPM+ Health
Anicia Gau
Co-Founder of Waitbusters

I’ve bеen working with Softarex for more than six years and three things were the cornerstones of our cooperation: quality, communication, and accessibility. These guys have always clearly understood all the functional specs I needed and gave me the best translation into the tech specs. All the databases were structured into the utmost flexibility – you can leave all the hardcoded stuff to the ancient times. Definitely 5 stars!

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Daan Hommes, MD, PhD
CEO at DEAR Health, Inc.

We hired Softarex Technologies, Inc. for a large, complex development project. They did an excellent job. The project was done on time and on budget. We continue to work them on new projects.

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Kevin Woodward
ReadyTech Corporation President

For all the time of working with Softarex Technologies, the difference between customer-contractor relations and partnership relations has become clear. That is exactly how this company builds the working process - you both (the company and its client) becomes partners. And it is not only to sign a contract, but it is also about negotiations, discussions, compromises, constant communication and joint decision making. Softarex will deliver its client a turn-key solution that exceeds all the expectations, all on time and within the budget. And after that, they will provide with a superior customer care that will maintain the relationships for years. Noventic provides devices and systems for the consumption-based collection and billing of water and heat and serves customers worldwide. Since 2010, various solutions in preparation of the internet of things (IoT) have been developed. For us, Softarex Technologies, Inc. has developed housing and public utilities solution - the future for energy suppliers. With the new system meter, readouts can be carried out at any time and fulfill upcoming regulations. The supplier can give transparency and thereby obtain trust from tenants and housing industries in the service. The team we’ve worked with earns praise for their timeliness, collaborative approach, and technical expertise. Their transparent clarifications minimize confusion and ensure clean high-quality deliverables.

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Thomas Ahlborn
Head of corporate marketing

We’ve been working with Softarex Technologies, Inc. team for over two years. These guys have brought us from the Stone Age to the Digital Age. Their team has developed the state-of-the-art billing and information management software for SYBE as well as web-based Clinic Management Software for SYBE's clients. Both solutions are at the cutting edge, meeting all the requirements and standards: ANSI 835, 837; Meaningful Use; HIPAA, HL 7 and ODBS compliant; ICD 10 Diagnostics, CPT/HCPCS, NDC numbers; CMS-1500 claims, etc.

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Steven Garrett
President of SYBE Medical Management

What I found extremely interesting in Softarex Technologies, Inc. it is the possibilities to use a wide range of technologies and each time get the same quality and time-requirement! I strongly suggest cooperating with Softarex Technologies!

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Carmine Mattera
IT Director at Artensys S.r.l.

Softarex Technologies, Inc. delivers “what” they promise, “when” they say they are going to complete a job and that is a great thing. Most business people “over promise” to get your money, and then they “under perform”. I appreciate your great work and professionalism. You have earned my trust! Keep doing what you are doing and you will build your business with great success.

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Marc R. Bakerman
President and Founder of The Child I.D. Program, Inc.