Intelligent production in just a few steps
In the HEITEC-TEVA project, the main task was to connect TEVA's production systems to a digital platform in order to increase efficiency. To do this, the production plant at the Blaubeuren-Weiler site was connected to a virtual server using an edge gateway device to collect and analyse real-time production data without affecting the existing system. The main tasks included enabling data processing and visualisation through a web-based HMI application and optimising production through real-time monitoring and predictive maintenance, which increased machine availability and overall equipment effectiveness (OEE).
Realisation
In this project, a modern, scalable solution for monitoring and optimising the production facilities at TEVA was implemented. The central element is the "Edge Gateway Device", which serves as a data collector. It is connected to the existing control systems of the production machines without interfering with the already validated and GMP-relevant processes. This ensures that the legally prescribed integrity of production is maintained.
The Edge Gateway collects relevant machine data such as alarms, operating parameters and the status of servo drives and counters. This data is forwarded via Ethernet to a virtual server hosted in the TEVA data centre in Ulm. The HEITEC web HMI application is based on this and can be used on all end devices using a standardised web browser. Thanks to the use of native web technology, which requires no additional installations, and a responsive design, the application can be used flexibly on desktop PCs, tablets or smartphones.
Real-time data processing makes it possible to analyse production processes, identify faults at an early stage and take preventive maintenance measures. Improving machine availability and increasing the MTBF (Mean Time Between Failure) are key results of the new solution. In addition, the flexible architecture of the application offers scope for future expansion, be it by integrating additional machines or locations
Customer benefits
The customer benefit in this project was to significantly increase production efficiency and machine availability without affecting the existing validated systems. By implementing the "Edge Gateway Device" and the HEITEC Web HMI application, TEVA gained real-time access to important machine data, resulting in several benefits:
- Improved transparency and control: the real-time data enables the technical staff to recognise faults at an early stage and react preventively. This has reduced unplanned machine downtime and optimised maintenance processes.
- Increased machine availability: Continuous monitoring of machine statuses has extended the MTBF (Mean Time Between Failure), which has increased the efficiency and reliability of the production lines.
- Optimised maintenance planning: The data helped to better plan maintenance intervals and implement predictive maintenance. This minimised the overall maintenance effort.
- Scalability and flexibility: The solution is designed in such a way that it can be easily extended to other machines as well as to other sites. This enables TEVA to continuously digitalise and optimise its production processes.
- Overall, this solution has provided TEVA with a modern, future-proof architecture that allows older machinery to be upgraded to a higher digital level while increasing productivity and production quality.
