Highlights

• Comprehensive Wi-Fi Survey: Conducted a thorough Wi-Fi survey, including initial site assessment, requirements gathering, RF heat map creation, and pre-deployment testing to identify optimal AP locations and configurations.
• Overcoming Industrial Challenges: Addressed unique challenges posed by the industrial environment, such as high electromagnetic interference, physical obstructions, and the risk of downtime, to ensure reliable and secure Wi-Fi connectivity.
• Enhanced Operational Efficiency: Achieved real-time tracking of components, reduced manual tracking errors, and improved data accuracy, leading to increased operational efficiency and optimized inventory management.
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‍Overview

Our client, a leading automobile manufacturer, is at the forefront of Industry 4.0 adoption, integrating advanced technologies and principles into their production processes and operational strategies. With a focus on enhancing efficiency, productivity, and flexibility, they wanted to create a highly interconnected and automated manufacturing environment.  

They seek to leverage real-time data collection and analysis to enable predictive maintenance, optimize resource management, and streamline asset tracking.

Requirements & Existing Challenges

To support their automation initiatives, the automobile manufacturer identified the following key requirements:

1. Wi-Fi-Enabled Automation: Implement a Wi-Fi solution that facilitates the automation of tasks along the conveyor belt system through Wi-Fi-enabled tablets and Bluetooth-supported barcode scanners.

2. Reliable and Secure Connectivity: Ensure reliable and secure connectivity across the conveyor belt area to enable uninterrupted communication between the tablets and the central manufacturing system, as well as seamless integration with Bluetooth-enabled barcode scanners for efficient inventory tracking and management.

The automobile manufacturer faced several existing challenges in their existing Wi-Fi infrastructure:

1. RF Interference: The industrial environment posed significant challenges due to high levels of electromagnetic interference from various machinery and equipment, as well as physical obstructions such as metal structures, walls, and heavy machinery, causing signal reflection, diffraction, and scattering.

2. Downtime Risk: The risk of downtime was a major concern, as disruptions to the assembly line operations could lead to significant productivity losses. Ensuring consistent and strong signal coverage from multiple access points throughout the large manufacturing facility proved difficult.

3. Multiple OEM Wi-Fi Components: The client's Wi-Fi infrastructure comprised components from different vendors in limited areas of the plant, leading to complexity in management and maintenance.

4. Operational Criticality: The assembly line represented a pivotal aspect of the automobile manufacturer's operations, making uninterrupted Wi-Fi connectivity imperative to avoid costly delays.

Solution

To address the challenges and meet the client's requirements, we followed a systematic approach for designing and deploying a robust Wi-Fi network, with a focus on the 5GHz band to reduce interference:

1. Initial Site Survey: Conducted a physical walkthrough of the facility to identify potential sources of interference, physical obstructions, and areas of operation requiring coverage.

2. Requirement Gathering: Determined the bandwidth, coverage, and performance requirements through consultations with stakeholders from different departments, including OT and IT.

3. Ekahau RF Heat Maps Creation: Utilized software to create RF heat maps that simulated Wi-Fi signal coverage and strength throughout the facility, considering the use of the 5GHz RF band for reduced congestion.

4. AP on a Stick Survey (Pre-Deployment Testing): Performed temporary AP on a pole (the "stick") testing to mimic the final installation and validate the RF heat map predictions, adjusting AP positions to identify optimal locations for coverage, signal strength, and redundancy.

5. Installation, Configuration, and Optimization: Installed the APs adhering to design specifications, configured them with a focus on 5GHz RF settings, and optimized channel selection, power levels, and bandwidth to minimize interference.

6. Post-Deployment Testing: Conducted thorough testing of the network to ensure it met the desired specifications.

Business Outcomes

The implementation of the robust Wi-Fi network yielded significant benefits for the automobile manufacturer:

1. Real-time Tracking: Enabled real-time tracking of components as they move along the assembly line, ensuring accurate accounting of each part.

2. Enhanced Data Accuracy: Reduced manual tracking errors and improved data accuracy, contributing to increased operational efficiency.

3. Optimized Inventory Management: Facilitated just-in-time inventory management, reducing excess stock and associated costs.

4. Data-Driven Decision Making: Empowered decision-makers with actionable insights derived from OT data, enabling more informed strategic decisions.

By leveraging Velocis' expertise in designing and deploying robust Wi-Fi networks, the automobile manufacturer successfully overcame the challenges posed by their industrial environment and achieved a highly interconnected and automated manufacturing ecosystem. This transformation has positioned them at the forefront of Industry 4.0, driving efficiency, productivity, and flexibility in their operations.