Our extensive experience in the field of industrial automation frequently involves post-sales support and troubleshooting issues that arise after the commissioning of a plant.
Whereas just a few years ago on-site support during the initial production phases was virtually indispensable, today—thanks to increasingly advanced and efficient connectivity solutions—it is possible to provide effective assistance remotely. Simulation environments and digital twins enable remote diagnosis and resolution of plant stoppages in the food industry, allow for risk-free software modifications, and facilitate the secure deployment of updates.
Example Scenario
Consider, for example, a cheese and dairy production facility, handling everything from raw material processing to primary and secondary packaging of the finished product. The overall process includes milk storage tanks, production lines for semi-finished and finished products, salting and ageing facilities (maturation warehouses), packaging lines, and final storage. Typically, such plants operate with high availability and continuous production, 24/7. Consequently, any issue or stoppage demands prompt intervention by maintenance personnel, with rapid and effective actions aimed primarily at minimizing process interruptions, which could have significant implications for food safety and waste reduction.
Practical Case Analysis
In recent days, a packaging line has experienced frequent intermittent micro-stoppages, temporarily halting the product flow and causing partial spoilage. Moreover, conveyor stoppages often result in misalignment of incoming items, many of which fall out of sync and are erroneously discarded. In such cases, the operator must intervene to restore normal operation, leading to further production delays and a decrease in OEE (Overall Equipment Effectiveness) metrics.
In this scenario, our support team plays a key role, relying on a digital twin architecture for remote diagnosis and correction.
The digital twin encompasses:
– Plant Model: 3D layout of conveyors, labelers, diverters; kinematics and collision detection; motor torque profiles; sensor models (latency, thresholds, and parameterization).
– Soft-PLC: A replica of the PLC program (identical libraries and recipes).
– Process Twin: Thermal dynamics of tanks and process equipment to ensure that any modification does not compromise food safety.
– Historical Data & Snapshots: Event logs and “time capture” of the 180 seconds preceding each stoppage.
– AR/Remote Assistance: Overlay of the model onto the real world to guide safe troubleshooting.
Problem Analysis and Resolution Steps
Here’s how the problem analysis, fault resolution and subsequent phases are carried out.
- Diagnosis via “Replay” on the Digital Twin
A “playback” of the 120 seconds preceding the fault is initiated using the digital twin. The virtual PLC, an exact replica of the machine’s controller, reproduces the precise sequence. The simulation reveals that, due to external factors (e.g., humidity exceeding a threshold), the photocell’s latency increases by approximately 30 ms, resulting in double readings.
- Problem correction and virtual testing
Non-invasive modifications are applied within the twin, such as debounce filters on the sensor signal and alignment of the signal reading with the conveyor’s encoder. Automated tests are run across numerous cycles, simulating various supply scenarios and changes in process parameters (temperature, humidity, etc.). These analyses demonstrate that the machine’s long-term operation stabilizes, and OEM efficiency returns to target values.
- Operator training via virtual model
Using a 3D headset, the operator becomes familiar with the machine’s altered behavior while receiving real-time instruction from a technician regarding key operational parameters. Since a modification was made to the feed conveyor, the machine’s realignment procedure after a stoppage has also changed. Through simulation, the remote technician guides the operator in executing the correct steps to restore the line.
- Deployment of the modification
The change is replicated on the actual system in a controlled manner, without interrupting production. A “rollback” to the original state can be performed at any time if necessary.
- Remote support via augmented reality
The machine operator wears smart glasses and, even at this stage, is guided by a technician through a remote connection. Using augmented reality, the operator sees real-time overlays of production data: process parameters, safety zones, conveyor directions, and “waypoints” for safe realignment maneuvers. If needed, the remote expert provides step-by-step guidance and real-time confirmation of each action.
Conclusion
In summary, we have illustrated how advanced remote assistance can be implemented through digital twin solutions. These technologies not only enable safe analysis and updates but also empower plant operators to use resources efficiently and responsibly through immersive experiences such as 3D visualization and augmented reality.
The integration of digital twin technology and augmented reality represents an evolutionary leap in industrial plant support, ensuring safety, efficiency, and continuous training: a new frontier for enhancing operator value and supporting the technological transformation of enterprises.
