Smart Factory Optimization through Packaging Line Monitoring and OEE Analysis
The Challenge
Garuda Food sought to enhance visibility and efficiency within their packaging lines by implementing a smart factory solution. The primary goal was to monitor production and quality lines in real time and calculate Overall Equipment Effectiveness (OEE) across multiple machines. The solution needed to be scalable, easy to integrate with existing factory infrastructure, and capable of supporting future industrial IoT (IIoT) initiatives.
Solution:
A LabVIEW-based industrial monitoring system was deployed using NI CompactRIO, enabling real-time data collection, visualization, and analysis of equipment performance across the factory. Data acquisition from key process points is published using OPC protocols, then streamed to an intuitive web-based dashboard built using LabVIEW NXG Web Module.
The system enables:
- Continuous OEE monitoring of each packaging machine
- Centralized dashboard for operators and engineers
- Historical data logging for performance optimization and quality audits
This robust monitoring platform integrates seamlessly with existing systems and aligns with Garuda Food’s broader Industry 4.0 transformation strategy.
System Overview :
- NI CompactRIO Controller for rugged real-time edge computation
- LabVIEW + NXG Web Module for UI/dashboard development
- OPC UA Communication for interoperability with other factory systems
- Custom analytics module to compute and visualize OEE
Key Features:
- OEE Calculation Engine – Tracks Availability, Performance, and Quality metrics
- Live Machine Status – Visual status indicators for each production line
- Production and Quality Logs – Detailed timestamped history for every shift
- Remote Access Dashboard – Monitor KPIs via browser from office or mobile device
Benefits :
- Improved Production Insight: Enables data-driven decisions on machine downtime and efficiency
- Seamless Integration: Easily connects to existing PLCs and MES via OPC UA
- Scalable Platform: Can be extended to other areas like baking or filling lines
- User-Friendly UI: Operators gain clear visibility with minimal training required
Conclucision :
With the help of NI technology and LabVIEW’s advanced monitoring capabilities, Garuda Food successfully implemented a smart packaging line monitoring system that not only calculates OEE but also enables real-time quality and performance tracking. This system is a vital step in their digital transformation journey toward a fully integrated smart factory.
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