Transitioning from traditional proccess to smart automation
- Category Smart Manufacturing
- Services : Smart Manufacturing
- Clients : Enerwire
- Location : San Salvador
- Date : July, 2025
At Enerwire, we are implementing an advanced monitoring and analytics system designed to optimize our cable extrusion process. This innovative solution continuously measures the speed of cable extrusion and the temperature throughout the production line. By capturing these critical parameters in real time, the system enables precise monitoring of process stability and product quality.
The collected data is not only visualized for operators and engineers but is also analyzed using advanced analytics and machine learning algorithms. This allows us to detect patterns, identify anomalies, and predict potential issues before they impact production. With predictive maintenance capabilities, the system can anticipate equipment wear or failures, enabling proactive interventions that minimize downtime and extend the lifespan of our machinery.
Beyond maintenance, the system provides valuable insights for process optimization. By correlating speed and temperature data with product quality outcomes, we can fine-tune production parameters, reduce waste, and ensure consistent, high-quality output. The platform is scalable and can be integrated with other sensors and data sources, paving the way for future enhancements such as automated process adjustments, energy efficiency monitoring, and integration with our enterprise resource planning (ERP) systems.
With this digital transformation, Enerwire is taking a significant step towards Industry 4.0, leveraging real-time data, advanced analytics, and intelligent automation to deliver superior products, improve operational efficiency, and maintain a competitive edge in the market.
Technologies Adopted
- Advanced Sensing & IIoT
- Edge-to-Cloud Architecture
- Advanced Analytics & Machine Learning
- Statistical Process Control (SPC)
- Interoperability & APIs
- Cybersecurity
Key Features & Functionality
- Continuous data acquisition: High-frequency capture of extrusion speed and multi-point temperature along the line, with time-synchronized signals.
- Advanced analytics and ML: Anomaly detection, drift monitoring, and predictive models to anticipate deviations, wear, or incipient failures.
- SPC and quality correlation: Control charts, Cp/Cpk tracking, and automated correlation of process variables with scrap, defects, and tensile/insulation tests.
- Real-time visualization and alerts: Role-based dashboards for operators and engineers, with thresholds and intelligent alerts for out-of-control conditions.
- Predictive maintenance: Health indicators for key assets (e.g., extruder, heaters, pullers) and early warnings to plan interventions and minimize downtime.
- Optimization workflows: Recommendation engines for speed/temperature setpoints to stabilize the process and reduce energy and material usage.
- Integration-ready: APIs to connect with ERP/MES/LIMS for orders, genealogy, test results, and maintenance tickets; scalable to additional sensors (vibration, pressure, energy).
- Secure, scalable architecture: Edge-to-cloud pipeline with data buffering, encryption, and audit trails; designed to expand across lines and plants.
Impact and Benefits
At Enerwire, we have implemented an advanced industrial monitoring and analytics system that continuously measures the speed and temperature of the cable extrusion process. This solution enables real-time visualization and analysis of production data, allowing us to detect anomalies, optimize process parameters, and predict maintenance needs before issues arise. By integrating high-precision sensors, cloud-based analytics, and user-friendly dashboards, the system not only improves product quality and operational efficiency but also reduces downtime and maintenance costs. As a result, Enerwire is able to ensure consistent, high-quality output while embracing the principles of Industry 4.0 and driving ongoing innovation in our manufacturing operations.
The implementation of this system at Enerwire has delivered significant benefits, including:
- Improved product quality and consistency through tighter control of critical parameters and early detection of instability.
- Reduced scrap and rework by correlating process signals with defects and adjusting setpoints proactively.
- Lower unplanned downtime and maintenance costs via predictive insights into wear and failure modes.
- Higher throughput and yield from stabilized operations and faster recovery after disturbances.
- Energy efficiency gains by optimizing heater profiles and line speed relative to quality targets.
- Stronger data foundation for continuous improvement, audits, and customer certifications.