The Role of Process Weighing in Smart Manufacturing

Smart Manufacturing & Digital Transformation are closely related concepts in the context of Modern Industrial Processes and Businesses.  They represent different aspects and approaches within the realm of Industry 4.0.

Smart Manufacturing puts the focus on optimising the manufacturing process itself.  It involves using IIoT and automation to improve production efficiency (OEE), quality, agility and safety. It allows the production process to be more responsive to ‘real-time’ data.

Digital transformation is a strategy involving the adoption of digital technologies not only in manufacturing, but also in supply chain management and plant decision making. The goal of digital transformation is to fundamentally change how a business operates and delivers value to customers.

Fieldbus networks, like PROFINET, play a crucial role in the Industrial Internet of Things (IIoT) by providing the framework for connecting physical assets, processes and people to digital technologies, enabling manufacturers to gather and leverage data and data analytics.

Integrating industrial process weighing systems

The integration of industrial process weighing systems into the manufacturing process provides manufacturers with the data, insights, and automation necessary to optimise operations, improve product quality, and stay competitive in a rapidly evolving industry landscape.

Industrial Process Weighing Systems play a significant role in manufacturing by providing accurate, real-time data that can be integrated into digitally controlled manufacturing processes. Weighing can be used as a single universal technology regardless of material or container type. Weighing is accurate and easy to apply ideal for filling, formulation, dosing, batching and packaging processes, and works whether measuring liquids, solids or gases.  

Manufacturers expect process weighing solutions that:  

• Optimise efficiency
• Ensure quality
• Minimise downtime
• Improve sustainability
• Support problem-solving
• Increase safety

Industrial Process Weighing System Business Benefits

1. Data-driven decision making: Weighing systems generate precise and reliable data related to material usage, inventory levels, production output, and quality control. This data is essential for manufacturers to make informed decisions and optimise their processes for improved efficiency and productivity.
2. Process automation: Industrial weighing systems can be integrated with other manufacturing equipment and control systems to automate various processes. This reduces the need for manual intervention, enhances consistency, and minimises the likelihood of errors.
3. Quality control and compliance: With weighing systems, manufacturers can monitor the weight and composition of materials throughout the production process, ensuring product quality and consistency. This is particularly crucial for industries with strict regulatory requirements, such as pharmaceuticals and food production.
4. Inventory management: Accurate weighing data helps in real-time tracking of raw materials and finished goods inventory levels. This data can be integrated into the manufacturing resource planning (MRP) systems, allowing for better inventory management, reducing stockouts, and minimising excess inventory costs.
5. Traceability and lot tracking: Weighing systems enable manufacturers to trace the origins of raw materials and track them throughout the production process. This traceability is essential for identifying potential issues, such as product defects, and implementing targeted recalls when necessary.
6. Predictive maintenance: Some advanced weighing systems are equipped with sensors that can monitor the health of the weighing equipment. By analysing this data, manufacturers can implement predictive maintenance strategies, reducing downtime and unplanned maintenance costs.
7. Integration with IoT and Cloud platforms: Industrial weighing systems can be connected to the Internet of Things (IoT) and cloud-based platforms, facilitating real-time data sharing and analytics. This allows manufacturers to monitor multiple production sites remotely, identify trends, and implement continuous process improvements.
8. Energy efficiency: By accurately measuring the weight of materials and products, manufacturers can optimise energy usage in their processes. This leads to reduced energy consumption and lower operational costs.
9. Enhanced productivity and cost savings: With the help of industrial weighing systems, manufacturers can identify bottlenecks and inefficiencies in their processes. By addressing these issues, they can enhance productivity and achieve significant cost savings.

Case Study: Process Weighing during Biscuit Manufacturing

A biscuit manufacturing company aimed to improve the consistency and quality of their biscuit products while reducing production waste. They decide to integrate weight data and analytics into their production processes.

Implementation Steps

Installation:   Load Cells are installed at key points along the production line. A Junction Box is installed to sum the inputs from the load cells. A process weighing instrument is connected both to the Junction Box and the Manufacturing Control System. 

Raw Weight Data:  Multiple load cell datapoints are sent to the Junction Box and then a combined signal is sent to the weighing instrument(s) for processing/control

Data Collection:   The weight data collected by the Process Weighing instruments are sent to a centralised database in real-time. This data includes the weights of individual ingredients, dough batches, and the final product (biscuits). By analysing the weight data of ingredient additions, the mixing process can be optimised.

Process Optimisation

• Inventory Management:  Weight data helps in real-time monitoring of raw material inventory. When ingredient inventory levels drop below a certain weight threshold, automated reordering is triggered to avoid production interruptions. 
• Ingredient Usage: Can be tracked against production output. Opportunities to reduce ingredient waste by adjusting ingredient dispensing systems are based on production demand.
• Product Quality: Weight data is used to ensure each biscuit meets the desired weight and thickness specifications. If deviations are detected, the system flags those biscuits for manual inspection or removal from the production line.
• Process Weighing Analytics: predicts the number of biscuits that will be produced based on current batch weights, allowing for better inventory planning and order fulfillment.

Smart Manufacturing puts the focus on optimising the manufacturing process itself.  It involves using IIoT and automation to improve production efficiency (OEE), quality, agility and safety. It allows the production process to be more responsive to ‘Real-time’ data, such as various types of weight data.