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Predictive maintenance & efficiency: How will MODAPTO transform manufacturing?

In the dynamic landscape of manufacturing, staying ahead requires more than traditional approaches. Small and medium-sised enterprises (SMEs) need solutions that optimise the production processes, reduce costs, and maintain high-quality standards while retaining the capacity for agility and responsiveness in demand. In this article, we explore how MODAPTO – which combines modular manufacturing and digital twin (DT) technologies – can transform SMEs’ operations and drive success.

What is MODAPTO?

MODAPTO transforms manufacturing through advanced interaction between the modules, providing standardised communications between production units. Each module is provided with a DT, mirroring the performance of the module, as well as integrating distributed intelligence for seamless and real-time adjustments. These DTs communicate seamlessly, and without problem, interact with other manufacturing assets. In the MODAPTO enabled factory, the layout design of the production lines, line balancing, scheduling, and maintenance are handled through optimisation algorithms.

Imagine an orchestra of advanced machinery and robots, every one of which plays its part with precision and fluidity, easily adapting to the changing tempo of production demands. That’s what MODAPTO brings to the industrial stage.

What is a digital twin?

A DT is more than a simple virtual replica, it’s a mathematical model representing a physical device, process, or system. While creating a DT, data about production processes, equipment, energy consumption, and production volumes are gathered in detail. These systems are then described mathematically, and calculations in the cloud occur in real time at regular intervals, say, once every 5 minutes.

But the real value is in what the DT does with this data. It continuously analyses the information regarding product quantity, quality, technological efficiency, and energy usage. And here’s the main value—it enables automatic adjustments with real-time data toward the perfect management. Through this optimal management, SMEs can achieve both technological and energy efficiency, which can reduce unnecessary costs.

Extending beyond optimal control: Predictive maintenance

While MODAPTO twins excel at real-time optimisation, but their functions go beyond just that. Now, let’s dig deeper into predictive maintenance and its huge impact on manufacturing:

  • Enhancing asset information

Each asset in the manufacturing system provides information in the form of either direct real-time measurement data or through indirectly collected information. From real-time data, it would be possible to determine asset condition and remaining lifespan. SMEs can study such data to predict their maintenance needs and avoid a costly breakdown.

  • Extending equipment lifespan

Optimal process control is enhances efficiency and prolongs equipment life…think of it this way: just as maintaining the right oil levels in your machines reduces wear and tear, optimising the operating conditions of your equipment minimises stress and maximises longevity. For example, adjusting the speeds and settings of production machines to match demand boosts efficiency and reduces wear during low-use periods. It’s akin to providing your machines with a tailored maintenance regimen, ensuring they operate at peak performance for years to come.

  • Agility in disrupted environments

In today’s rapidly changing landscape, flexibility is key. MODAPTO facilitates easy module-to-module interaction, allowing reconfigurable lines in plants. Whether it’s supply chain disruptions or societal shifts, collaborative modular systems enabled by the digital twins adapt seamlessly.

  • Design-time decisions

MODAPTO is not only about today but also about tomorrow. It makes introducing new production modules simpler using design and reconfiguration capabilities. Virtual commissioning and test-before-invest simulation ensure seamless integration. Advanced optimisation methods and sustainability analytics guide the decision-making process. It is like hiring the most experienced engineer crafting a bridge, ensuring it can withstand heavy traffic and extreme weather conditions.

Pioneering sustainable manufacturing

Incorporation of DT in key decision points of the production enables SMEs to maintain sustainable production at varying lots. As the importance of sustainability continues to rise within the industry, it becomes imperative to enhance efforts in this area. Using predictive maintenance and optimisation strategies applicable to changing lot sises, industrial SMEs can increase the productivity of staff and reduce production time. This kind of efficiency reflects on the well-maintained machine in which all the parts work in symphony to achieve maximum productivity and longevity of the equipment.

Moreover, SMEs improve their sustainability by employing advanced DT analytics, optimisation, and standardisation to actively take a position equivalent to good gardening: trimming and nurturing for long-term health. This enables smart decision-making, and active supply chain management, through life cycle management of modules by remanufacturing and refurbishment, strengthens the sustainability initiative—providing a holistic view toward sustainable manufacturing.

Unlocking efficiency and sustainability

MODAPTO is not just about reducing decision-making time from a day to under an hour. It’s about flow stability, gains in productivity, and smooth production. Furthermore, it fosters sustainability by minimising resource wastage and optimising energy consumption, thereby contributing to the long-term ecological balance of manufacturing operations.