Manufacturing

Powering the Smart Factory: Real-Time Visualization for Manufacturing

In the competitive landscape of modern manufacturing, operational efficiency, quality control, and data driven decision making are paramount. Lygos transforms the manufacturing floor by providing a powerful, centralized platform to visualize real-time production data, monitor critical processes, and foster a collaborative environment. By integrating with existing factory systems, Lygos turns complex data streams into actionable insights, displayed on dynamic video walls and dashboards that empower teams to optimize performance from the shop floor to the top floor.

Use Cases:

Enhancing Shop Floor Visibility and Production Monitoring

Proactive Quality Control and Anomaly Detection

Streamlining Maintenance and Asset Management

A lack of real-time data presents significant challenges for manufacturers, leading to delayed responses to disruptions and difficulties in optimizing resource allocation. Lygos provides a comprehensive, at a glance view of your entire production environment, enabling proactive management and continuous improvement.

Imagine a plant manager's office overlooking the factory floor, with a large Lygos powered video wall serving as the central command center. This view displays:

Live Overall Equipment Effectiveness (OEE) Dashboards: The Visualization Module with Manufacturing Execution System (MES) data displays real-time OEE metrics for each production line. Operators can instantly see availability, performance, and quality scores, with color coded alerts flagging any deviations from target.
Production Schedule Attainment: The Data Module integrates with your ERP to track work orders in real-time. The video wall shows progress against the daily production schedule, highlighting potential delays and allowing managers to reallocate resources proactively.
Live Machine Status and Andon Alerts: The Expert Module Sensors can be configured to display Andon system alerts, immediately notifying the entire floor of a machine stoppage or quality issue. This visual communication drastically reduces response times.

Therefore, this centralized visualization, ensures that everyone from operators to senior management is working from the same up to the minute information, fostering alignment and accelerating problem solving.

Maintaining consistent product quality is a critical aspect of any manufacturing operation. Lygos provides the tools to monitor quality in real-time, enabling teams to identify and address deviations before they lead to significant scrap or rework.

In a quality control hub, a Lygos video wall can be configured to display:

Statistical Process Control (SPC) Charts: The Visualization Module can generate real-time SPC charts that monitor critical quality parameters. Any process that starts to drift out of specification is immediately visible, allowing for early intervention.
Live Video Feeds with AI Overlays: By integrating machine vision systems through the Media Module, Lygos can display live video from the production line. Allowing operators to detect visual defects, alerting operators instantly.
Scrap Rate and First Pass Yield Analysis: Dashboards created from visualizations with the Display Module can track scrap rates and first pass yield in real-time, helping to pinpoint processes or shifts that may require additional attention or training.

With the Control Module, quality engineers can interact with these visualizations, drill down into the data behind an alert, and collaborate with production staff to resolve issues quickly, minimizing waste and ensuring customer satisfaction.

Unexpected equipment downtime is a major source of lost productivity and revenue in manufacturing. Lygos helps shift maintenance strategies from reactive to predictive by providing clear visibility into asset health and performance.

A maintenance team's central office can utilize a Lygos dashboard to:

Monitor Asset Health: The Data Module can connect to sensors on critical machinery, streaming data on vibration, temperature, and other health indicators. The Visualization Module then displays this information in an intuitive format, with alerts for any readings that exceed normal parameters.
Centralized Maintenance Dashboard: Access all maintenance activities, schedules, and reports in one unified view. Gain total control over asset management without switching between tools.
Interactive Plant Maps: The Expert Module Floorplans can be used to create a digital twin of the factory floor, showing the location and status of all major assets. When a maintenance alert is triggered, its location can be instantly highlighted on the screens.

The Presentation and Signage Modules can be used to cycle through key maintenance KPIs, such as Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR), keeping the entire team focused on improving asset reliability and reducing costly unplanned downtime.

The best dashboard and video wall software for data visualizations and maps (GIS)

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Manufacturing

Powering the Smart Factory: Real-Time Visualization for Manufacturing

Use Cases:

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The best dashboard and video wall software for data visualizations and maps (GIS)