The starting point
As a global player in developing complex machining systems, from raw part to finished part, SEMA Technology Group faced a central challenge: to reach the next level of efficiency, it needed an even deeper understanding of its machines in real-world customer use.
The aim was to acquire valuable data directly from the field via IoT. This was not only about the technical implementation but above all about selecting the use cases that generate real added value for both SEMA and its end customers.
The joint approach
Working closely together, from initial workshops through to implementation, the partners realised a concept that covers selected use cases end to end: from physical data acquisition and the IT infrastructure through to visualisation in the portal.
Within an intensive lead time of three months, this produced an MVP (minimum viable product) that forms the basis for all future digital services. SEMA's specific domain knowledge of its highly complex machines with their many variants was fed in purposefully at every stage.
The solution in day-to-day operation
With the go-live of the portal, SEMA has laid the foundation for data-driven business models. Greater transparency of field data increases equipment availability and paves the way for predictive maintenance strategies.
Today, the new IoT service portal serves as the central control hub for device management. The transparency provided by live data creates the basis for smart maintenance, proactively reducing downtime and significantly increasing the availability of the highly complex systems.
Via OEE dashboards, customers and technicians gain instant insight into overall equipment effectiveness, can monitor software versions and analyse sensor data in detailed charts. Each machine has an electronic maintenance manual, and the machine software is backed up at regular intervals. SEMA actively uses the data from ongoing operation to offer customers optimised information and services, helping its machines deliver high value in the field.
On request, a complete digital twin can be created for each machine. This allows customers to test production equipment, optimise processes or train staff even before actual commissioning.
Technical highlights
- End-to-end IoT concept: Integration from the data source in the field to the display of values and KPIs in the web portal.
- OEE reporting: Real-time dashboards for analysing machine efficiency.
- Device management: Central management of software versions and sensor data across the entire installed base.
Technology stack
- Cloud infrastructure (managed by the customer's IT, no vendor lock-in)
- Web front end & dashboard frameworks
- Data acquisition interfaces
„With condition monitoring in the DAISY portal, we at SEMA support our customers in operating their systems efficiently."
– Tim Liebetrau, Head of IT & Digital Services
Source: blue-zone
