For several years, Hauni has been preparing machinery, equipment, applications, and services in readiness for Industry 4.0. These solutions intelligently link machine data and expertise and are already responsible for direct improvements in the OEE of customer plants.
The race is on to extract greater and more sustained performance from existing machines, plants and processes. Companies are seeking to generate significant improvements in overall equipment effectiveness (OEE) and/or reduce costs. They require intelligent concepts to enhance and perfect the performance, availability and quality of every component in their manufacturing systems. The smart connections between machines, applications and services needed to turn this vision into a reality lie at the heart of Industry 4.0. In the smart factories of the future, machines will communicate with each other in networks as cyber-physical systems. And by linking information and processes they will dramatically increase production efficiency. Hauni machines and equipment are already prepared for Industry 4.0. For some time, they have been fitted with monitoring and automated control systems such as MIDAS, ODM (optical diameter measurement) in cigarette makers, interfaces for networking and visualization as well as options for saving, exchanging and evaluating data. This proven technology enables us to expand our portfolio with new smart applications and services. It dovetails perfectly with the unique knowledge base we have generated as a market leader and full service provider with an unrivalled range of machinery in operation around the world. Moreover, it is supported by a global team of highly qualified and experienced employees who can draw on extensive information relating to all sorts of production environments.
Networking information with experience
By intelligently linking technology with real-time production data and expertise gathered over seven decades, Hauni has already created new service solutions, which enable customers to significantly improve their OEE.
“We collect production, environmental, and machinery data, evaluate it and link it with logic processes based on our knowledge and experience,” explains Tomas Fock. “From this, we are able to identify and target potential for improvements. These new or upgraded services help our customers to increase the availability of their machinery not only for short periods but also in the mid- and long-term. We do this, for example, by supporting the continual improvement process or taking responsibility for optimizing workflows in areas defined by the customer.”
Online service with immediate success
If there are difficulties with a machine or production output or if speed or quality are below expectations, Hauni offers a variety of services to solve the problem quickly while reducing costs and improving the transfer of knowledge to the customer. Hauni’s remote service is the first point of contact for targeted troubleshooting and rapid online help. The team uses realtime production data to solve performance and maintenance problems. “Our experts at company headquarters remotely access the customer’s machine – after the customer has given us permission – to provide time- and money-saving technical support. Fast and complete fault analysis via a secure data connection helps customers to minimize downtime,” explains Andreas Korb, project manager remote service.
“Our remote service experts solve around 60% of all problems immediately and – thanks to the constant improvements in tablet apps and options for transmitting images and data using mobile devices – in record time.” Once the remote service has identified the root cause of the trouble, further support services can quickly be provided. Hauni is continuously expanding the range of functions available through its customer portal. For example, customers can view their machinery documentation, find up-to-date information about obsolescence and, of course, order any spare parts they need.
Service partnerships add value
In addition to instant, small-scale improvements for individual machines, Hauni also offers many services, which aim to improve OEE and optimize costs over the medium- and long-term. Hauni supplies modular services and solution packages for single machines, whole production lines or entire factories of Hauni equipment. These can be individually combined and tailored to the needs and objectives of the customer. They are classified under the categories of spare parts supply, product life cycle management, and operation & processes. All depend on the smart analysis of data from machinery and production environments, digital networking with Hauni’s know-how and the expertise of the company’s global service staff.
Software suite for the next step
Industry 4.0 aims to achieve the highest possible degree of automation – plants that are self-diagnostic, interoperable and self-optimizing. This can only be achieved through a long-term process of change in the production system with successive and cumulative phases of monitoring, controlling and optimization. Companies can take a number of different digital approaches to achieve maximum transparency in all production activities and results, but real-time production and performance data on quality, waste, downtime, efficiency, uptime and other key performance indicators are critical to all of them. The AREO Software Suite has been developed specifically to meet the needs of the tobacco industry. Hauni is constantly refining and enhancing this tool to meet current and future production demands. AREO can do much more than read and transfer data. The software combines analysis, reporting and evaluation tools, which allow customers to continuously improve processes with the assistance of Hauni’s experts – whatever the machine, whatever the manufacturer and for a full factory of equipment if necessary. By offering constant advances in forecasting techniques and questionnaires, which enable operators to optimize their processes, AREO provides a valuable tool for identifying specific areas to boost the performance of an entire factory.
“Our customers can use AREO to establish intelligent connections and take a further step along the road to Industry 4.0,” explains Fock. “We have been working hard to develop our services and machines over recent years. Likewise, we are striving continuously to develop the stages we require for implementing the production structures of the future. It is our job to prepare our customers’ plants to be transformed into smart factories – a topic that will become increasingly relevant in every sector. We will continue to work closely with our customers to make this become a reality.”