Furnace Monitoring System for the Manufacturing Unit
Challenges
The customer has two furnaces with 2 bays and both of them need to be monitored to ensure that the burning efficiency of the furnace maintains the temperature above 900°C. They had deployed a team of 4 people in two shifts to monitor the bays every 30 minutes. The main challenge was tracking the periodicity of Bay Checks by the existing team and ensuring no checks were missed.
Solution
- a. Installed CCTV cameras facing the bays to capture the activity of bay checks every 30 minutes.
- b. Supported in developing the Bay Check process to ensure consistent monitoring.
- c. Provided highlights and notifications whenever the process did not occur or was delayed beyond a threshold limit of 10 minutes.
Benefits
- a) Automated highlights and notifications of the Bay Check process.
- b) Detailed weekly reports showcasing the periodicity and compliance of Bay Checks.
- c) Improved productivity by maintaining furnace temperature through timely alerts to the Production In-Charge and Supervisors.
Components Utilised
- a) CCTV Cameras with real-time monitoring capabilities.
- b) Workstation (8 GB RAM, i5+ Processor, 1 TB HDD, Windows 10, MS Office).
- c) Reliable Internet connection for remote configurations and reporting.
- d) AI-based process tracking and alert software.
AI Monitoring Chat
Results
The AI-enabled furnace monitoring system ensured continuous tracking of bay checks, timely temperature maintenance, and improved operational discipline. With automated notifications and weekly reports, the customer achieved higher production efficiency, reduced manpower dependency, and ensured compliance with operational standards.