Digital transparency instead of a vague gut feeling

Barely manageable investment costs, knowledge of the benefits of existing machinery and the lack of comprehensive IT structures – these are usually the reasons why many small and medium-sized producers, craft businesses and manufacturers are reluctant to embark on extensive digitalisation projects. However, EXPRESSO has developed the mobile radio-based IoT system EXPRESSO Connect to strengthen the competitiveness of these SMEs and open up the possibilities of process management at Industry 4.0 level. This is a highly flexible retrofit solution that can be customised to the requirements of different companies and industries using modules and apps. ‘Our system adds a digital layer to a company’s existing technical infrastructure and offers the user enormous added value. It generates data that makes processes transparent, visualises functions, secures decisions and identifies optimisation potential,’ says Jan-Peter Schulz, who heads the Service & Digital Solutions business unit at EXPRESSO.

Efficiency impulses for value creation

EXPRESSO Connect is designed both for equipping new machines (OEM solution) and for retrofitting existing equipment and systems. It is installed on site by attaching compact Connect Boxes, which can be customised to specific tasks and performance by activating various modules. Among other things, there are modules that use modern sensor technology to record the performance of machines, pumps, compressors, conveyor systems and loading processes, as well as modules that specifically cover the aspects of energy efficiency, maintenance and access. Product-related modules for EXPRESSO’s handling and transport systems are also part of the range. All operating and status data is recorded in real time via the Connect Boxes, encrypted and automatically transmitted to a central server in Germany via mobile communications. In analysed form, they appear on a dashboard that can be accessed by company managers, production and operations managers, foremen or quality assurance officers from any location via apps or QR codes – around the clock and regardless of the device they have at hand (smartphone, tablet, notebook, etc.). ‘Thanks to the professional preparation of the data and its visualisation in tables, graphs and diagrams, both efficiency deficits and optimisation potential can be quickly identified. The customer can also request a detailed data report from us with recommendations for process optimisation. With this service, our specialists analyse and interpret the data and formulate specific suggestions for improvement that are tailored to the customer’s individual situation,’ explains Jan-Peter Schulz.

Digitalisation and Industry 4.0

In addition to the possibilities of targeted process optimisation, the smart IoT system from EXPRESSO Connect enables an SME to significantly expand its expertise in the field of digitally supported Industry 4.0 activities. In concrete terms, this means, for example, that the user can realise professional condition monitoring including remote monitoring and implement predictive maintenance measures based on the processed data. The system allows the user to recognise where in the company it is worth saving resources, increasing safety levels, reducing electricity or media consumption, refining quality management, installing a CIP process or considering technical modernisation. ‘EXPRESSO Connect also makes it easier to identify demand patterns and operating peaks, to adapt to seasonal and temporary changes and ultimately to plan future investments,’ says Jan-Peter Schulz.   

Scalable and cost-effective

EXPRESSO Connect offers SMEs a cost-effective and simple entry into the digitalisation of value-adding processes. The system can be easily adapted to different company sizes, machinery and industry conditions. Installation and commissioning are usually completed within just one day. Operation does not require extensive training, IT administrators or dedicated IoT teams. EXPRESSO Connect works independently of the brands of the connected systems, can be used across plants and is future-proof, as it can be expanded at any time with additional Connect Boxes, modules and apps. ‘These Connect Boxes are the only thing that the user has to purchase; there is only a monthly usage fee for the entire service package, from data collection, transmission and analysis to visualisation on the dashboard,’ explains Jan-Peter Schulz.

As EXPRESSO Connect replaces traditional, largely analogue processes with data-based structures, it offers SMEs a great opportunity: many decisions that were previously based on gut feeling can now be underpinned with concrete process data. On the basis of this newly gained transparency, not only can important changes be implemented, but long overdue investments can also be secured.