Feb 15, 2019

Case study REMAK S.A.

Preliminary information

 

Remak S.A. – European leader in the installation of power boilers, monitors the work of welders and welders from a smartphone. Thanks to the cooperation with EBKF, the company has increased the efficiency of working time of welders and its operators. All thanks to the access to current information enabling full optimization of management processes.

Remak employs over half a thousand employees. The staff consists of people with well-established knowledge gained during the implementation of many investments in Poland and abroad. Designers and technologists of REMAK S.A. are the authors of many unique solutions and repair technologies.

Project objective

 

Remak, known for its professional approach and implementation of innovative technologies, informed us about the need to implement a solution that will facilitate the management of a large number of welders, located in the area of power plants in Poland and abroad. Monitoring of machines was not the only challenge. The company was also interested in access to data monitoring the efficiency of welders, by assigning the machine to the operator and access to periodic reports of their work. As far as the effectiveness of welding machines is concerned, Remak was interested in examining various elements, including: the welding current voltage parameter.

How did the project proceed?

 

The work began in mid-October 2017 and was completed at the beginning of March 2018. Initially, we installed EBKF modules with additional current sensors in the test welding machines working on the construction of a power plant in Turow. At the same time, new welders were added to our system, which worked in our client’s production hall in Opole. Our customer tested our solution for one month and then decided to purchase an additional number of modules to be implemented in other machines operating under contract. Before signing the contract, together with the customer, we agreed on additional functionalities of the system and added them at the customer’s request before the completion of the implementation.

The contract was signed in December 2017. The first stage of implementation took place at the beginning of February 2018. The EBKF modules were assembled in locations indicated by the customer.

How long did the implementation take?

 

The implementation was divided into 3 stages. During each of them, a number of welders designated by the customer was connected to the monitoring system. The whole process of EBKF Manager solution implementation (from signing the contract to completion) was closed within 17 weeks.

How many machines are connected to the system?

 

In the first phase of implementation, Remak installed 156 modules. After some time the company decided to mount 100 additional modules on its own. In total Remak has installed 256 modules monitoring the performance of welders and its operators.

Results

 

By investing in IoT technologies, by implementing an innovative system to monitor and optimize the performance of welding machines and welders, Remak:

  • increased the competitive advantage on the market
  • increased the efficiency of the working time of welders
  • optimised operator uptime by identifying the weakest and best links
  • improved remote management of machinery and operators’ work remotely
  • has access to data it did not have before (when and how long the welder is switched on, when and how long the arc glow lasts, what is the welding current, where the welder is located).