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The Secret Behind Monitoring Manual Processes

From a machine monitoring standpoint, the wide range of equipment and tactics used by manufacturers pose a challenge. For instance, Some equipment is newer and digitally compatible, whereas others are older and analog. Also, some processes are done manually by an employee instead of a machine. Manufacturers may find themselves wondering: is it possible to monitor manual processes? Luckily, at FreePoint, the answer is yes.

As the global supply of computing power and storage capacity continues to grow rapidly, the cost to access these resources continues to drop. The same is true for IIoT technologies. Sensory devices and the technology needed to interpret them have become more compact and affordable in recent years. Because of these advancements, we can monitor more than just machines, but the manual processes of factory workers as well.

Cyber physical systems freepoint technologies

By leveraging different sensors, you can create cyber-physical systems to monitor tasks ranging from welding and brazing to painting and sanding. These sensors include:

  1. Electrical Current Sensors
  2. Switch/Button Recognition Sensors
  3. Pressure Plate Sensors

Electrical Current Sensors

FreePoint Technologies Electrical Symbol

One of the easiest manual processes to monitor are those which produce an electrical current. For example, if you are performing a task involving a MIG Welder, an electrical current will pass through the tool whenever it is in use. By installing an electrical current sensor, you can monitor the use of the welder and its efficiency based on the amount of time the tool spent having an electrical current run through it. If there is no current running through the tool, that would be considered downtime. Obviously, the more time the tool spends with current running through it, the more value-added time it contributes.

Switch/Button Recognition Sensors

Another straight-forward means of monitoring a manual process is with switch/button recognition sensors. When using a tool that is button or switch activated, a switch recognition sensor will be able to determine when a switch has been flipped on or off. Like electrical current sensors, by tracking whether the switch/button is on or off – you can identify when a machine is experiencing uptime or downtime. Using downtime narration, you can attribute reasons to justify downtime, some of which may be preventable moving forward.

Pressure Plate SensorsFreePoint Technologies Pressure Plate Sensor

Pressure plates are useful to monitor any piece of equipment that exerts pressure—like a drill press. Using this in tandem with an electrical current sensor will give you valuable insight into the efficiency of certain manual processes. In addition, using a pressure plate sensor alongside an electrical current sensor allows you to tell when a machine is running, as well as performing a value-adding task. In the case of a drill press, the value-adding task would be drilling. Just because electricity is running through the machine does not mean the machine is being productive. With both sensors, you will be able to more accurately assess your processes productivity.

With our IIoT software, FreePoint can connect any machine on your shop floor and start collecting data within 24 hours. You can literally monitor any machine with an electrical current. The oldest machine we are currently monitoring is from 1914! Reach out today and let us walk you through how to monitor your manual processes!

How FreePoint Ensures IIoT Data Security

According to Million Insights, by 2025 the Industrial Internet of Things market will be valued at $933.62 billion. As we continue to unify our cyber and physical systems, vulnerabilities emerge that didn’t exist before the Industry 4.0 revolution.

The Importance of IIoT Security

Security blue finger print scan FreePoint TechnologiesIIoT, or, the Industrial Internet of Things creates networks of connected industrial devices that collect, record and assess data to provide manufacturers with better insight into their production processes. As these devices interface with your machinery, IIoT security ensures that your hardware and software remain secure and protected from malicious intent.

According to IndustryWeek.com:

“if the devices that are connected become compromised and the threat has access to that communication link, a hacker can then push malicious data, cause denial of service (DoS), or introduce viruses to the entire network.”

Before industry 4.0, machinery operated separately and isolated from one another. Taking preventative measures will ensure external entities can’t access your data or impact your machine’s functionality.

How FreePoint Enforces Machine & Data Security

As with any IoT network, sensors and applications must remain protected from operational technology (OT). Without protection, compromised devices can serve as doorways to siphon data, insert foreign code and even halt production.

At FreePoint, we have developed an approach to ensure that the security and integrity of our client’s machines and data is protected. Primarily, we accomplish this by maintaining an “air-gap”. An “air-gap” can be defined as “a security measure that ensures total isolation of a given system from other networks, especially those that aren’t secure”.

As stated by our Vice President during a recent interview with CIO Applications: “FreePoint’s non- invasive solution involves using sensors instead of attaching hardware to a programmable logic controller (PLC). The solution does not interfere with machine operations nor is it a route for cyber-attacks on the machinery”. Because there is no physical connection between our solutions and the manufacturer’s machines, we can improve security while significantly reducing the possibility of cyber-attacks.

Contact us today if you are interested in learning more about how you can maintain a secure IIoT network. One of our reps would be happy to speak with you!

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5 Reasons You Need IIoT Technology In Your Factory Today

The business of manufacturing is rapidly evolving. Being coined the Fourth Industrial Revolution, or Industry 4.0, it’s all about retrieving big data that couldn’t be accessed before. By bringing the Industrial Internet of Things (IIoT) into factories across the globe manufacturers can streamline production and push products to market faster. Are you ready to gain a competitive edge?

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