Digital Factories and Digital Twinning by POMO Robotics

What is a Zero Capital Factory?

Nervous about investing in new equipment and infrastructure from multiple vendors, OEMs and suppliers? Using the power of industry 4.0, mathematical modelling and digtal twin technologies, POMO Robotics can help simulate your entire plant running simultaneous manual and automated operations before spending any capital to even a prototype level.

What are the main benefits?

Allowing to digitise your factory before spending capital on your equipment, Digitisation and Digital Twinning your assets allows for carrying out bottle neck analysis on your existing systems, testing and trying out new solutions without the need to build physical hardware and digitally modernising equipment prior to investing. This allows for businesses to make educated decisions and justify high risk CAPEX investments. For FMCG industries, simulate your routine operational downtime, sanitation windows, seasonal product orders and other business critical KPIs. This allows you to assess how your plant and equipment can cope with the demanding and ever shifting marketplace

Troubleshooting and Diagnostics

Looking for answers when your equipment goes down? With digital twins, you can break your machine down to a modular level and commission virtually to understand what, how, where and why it went wrong. Run diagnostic and commissioning sequences digitally on our simulation software packages to understand where your process efficiences can be improved, modify functional and operational philosophies to understand what impact it could have on your equipment and pull out reports from system to modular level to make impactful decisions.

Digital Factory

More businesses are now using the power of digital factory developments to justify their capital expenditure costs and integrate seamlessley with existing equiopment and plant. POMO Robotics is at the forefront of this technology by providing complete end to end digital factory development services including verifying equipment selections, analysis of existing plant, confirming throuhput and production rates and providing valuable data driven insights to provide the best possible outcome for a new factory in any industrial sector

As Built

We provide a complete end to end as built digital twin modelling service using a multitude of technologies including point cloud scanning, operation assesments and verifying simulation data against existing production rates

Bottleneck

As part of our as built digital twin development, we identify, simulate and analyse bottlenecks in your existing process based on reliability and downtime data. This forms the benchmark for future improvement works

Simulation

By simulating a wide range of functions including production rates, productivity rates, waste created and recycled and much more; no step or process is too hard for us identify, analyse and assess for improvement

Analytics

Performance analytics are captured from existing machinery, from our simulation models and looked at in detail to see where the room for improvements in production, productivity and cutting waste can be

Equipment

We work with leaders in your specific industry to identify plant, equipment and solutions that can bring about an averate 30% improvement in your processes. This is then simulated prior to making any invstement decisions

Decisions

With a wealth of data collected from the simulation work and with our recommendations, we then work with yourselves to identify key improvement areas and where the best investment decisions have to be made to make sure you get value for money

Monitoring

With our easy to integrate software solutions, get real time metrics from your plant and equipment to assist with adjusting your throughputs and making decisions on resourcing areas of improvement. Moniotr and log plant performance in a non intrusive fashion and make data driven capital expenditure decisions

Notifications

Our software platforms provide realtime alert analysis and notifications including priority items that need to be addressed which you give you the best performance analytics from your factory. We work with a range of PLC/HMI Systems, Controllers, Sensors and Instrumentation to ensure that you get the best perfomance analytics for your systems and processes. Easy to integrate with a mutlitude of legacy systems, make the most of our telecontrol system solutions and get the most out of your factory

Telecontrol

Telecontrol simply means realtime factory information at your fingertips. We work with leading partners in the industry to roll out telecontrol solutions to resolve productivity and efficiency issues in real time without hassle

IOT

With our Internet of Things (IOT) solutions platforms, get anytime and anywhere access to your plant performance and productivity rates, review alerts and alarms and instruct your factories to make process or equipment adjustments to resolve production or productivity issues all from the comfort of your devices

Potato Processing Plant

A prominent customer in the potato product processing industry had been experiencing production bottle necks in the past 20 years since the line was installed. As part of their expansion plans, customer was keen to invest in modern equipment, improving processes and building the future. However, to justify their CAPEX investment, they were keen to carry out a digital twin and digitisation exercise to simulate the whole line and to deliver a solution. POMO Robotics assisted in completing an end to end line simulation of the as built, verified the performance metrics and then carried out further work to build a new and improved line. The result was a digital twin line that proved that if they invested, it would improve their production by 57% against their current performance levels. Shown here is the digital twin of the new and improved line.

Glass Manufacturing Plant

Created a source of dynamic virtual stock data to validate decisions in the optimum warehouse layout. Determined most efficient time to make up a mixed load of glass products through the best mix of storage between racks and stillages; the photo opposite shows less than a tenth of the total storage space. Identified optimal usage of new forklift trucks, measuring time allocated to moving materials, avoiding congestion and setting minimal waiting and occupied time.

Distribution Centre

Whilst machinery lasts for many years, a regular requirement is to update the control systems that operate it to maintain functionality and ensure software is still supported. A prominent distribution centre client was keen to commission their equipment virtually and cut down the time from 8 weeks to 5 weeks. Using Plant Simulation, customer was able to cut down the time by using virtual commissioning methods which was carried out digitially. Costly on site time was reduced by 3 weeks vs a previous comparable upgrade which took 8 weeks using onsite commissining only

Zero Capital Factory