STEP 1
Facility review
We look at what is installed, which parameters are critical and where the losses are today.
At your facility or remote
A line never stops suddenly - the early signs are simply not being watched
Monitoring of equipment, power and energy across the production facility. Data from your controllers and from our own sensors in one system, with no lock-in to a single equipment vendor.
5-20%saved on energy each month
24/7cover between shifts and at weekends
10 kmnetwork radius across the facility
Control points
What we monitor in production
The parameters that in most facilities are either not measured at all, or measured by a walk-round once a shift.
Running hoursActual hours worked, instead of a calendar-based maintenance schedule.
Vibration and amplitudeRising vibration shows up weeks before a bearing fails.
Power qualityVoltage, current, power and phases. Imbalance is caught before a motor burns out.
Pipeline pressureLeak detection for compressed air, water and process media.
Process temperatureChambers, furnaces, tempering and cooling zones - each with its own limits.
Pumps and compressorsConfirmed starts, duty cycles, running outside the schedule.
Energy per lineSeparate metering by shop, by line and by equipment group.
Diesel generatorReadiness to start, running hours, failed starts, fuel consumption.
What does an hour of downtime cost you?
A pilot on 5-10 points gives you real data within a few weeks.
How it works in practice
Situation and system response
Situation
What the system does
What you get
Phase imbalance on a drive
The system records the voltage deviation and alerts your electrical engineer on Telegram
The motor does not need rewinding
A compressor runs outside working shifts
Consumption and running hours outside the shop's schedule are visible
A standing overspend is removed
Pressure drops in the compressed-air main
Comparing pressure across sections points to the leaking zone
Finding the leak takes an hour, not a week
Vibration on a unit is rising
The amplitude trend is visible on the chart long before an emergency stop
Repair happens as planned, without stopping the line
Proof
Screens from live facilities
Already running at
ArcelorMittal
Swiss Krono
steel pipe and railway wheel manufacturer
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Deployments to date are largely in Ukraine.
Rollout
From pilot to full coverage
STEP 2
Pilot on 5-10 points
A gateway, sensors and meters on the riskiest zones. Installed without stopping operations.
A few hours per facility
STEP 3
Dashboards and reports
We draw up the facility plan, set the limits for each point, the alerts and the report formats.
Shaped around your processes
STEP 4
Scaling up
The same kit across the remaining zones and facilities, with a single view for the whole company.
No new approvals needed
Next step
Let us cost out an unmonitored shift
Start with a review: we will look at which parameters are not measured at your facility today, and which of them are costing you money every month.
- CompanyPolymetrica LLC
- E-mailsales@polymetrica.net
- Websitepolymetrica.net