Role

UI Designer

Timeline

2 months

Team members

Saurabh Suman (PM), --(PDC Plant Head)

Overview

Subros Limited is a thermal cooling solution provider. Subros has it’s own facilities for the manufacturing purpose. In those, The Pressure Die-Casting Unit Plant (known as PDC Plant, henceforth) required a monitoring and controlling dashboard which helps the supervisor to monitor and control the Die-cast furnace and production.

The project structured phase-wise, firstly delivering the basic functionalities based on requirement.


Reduced daily manual data entry by 4.5 hours per operator by designing a "digital twin" interface that auto-fills production charts from real-time IoT sensor data

Decreased data recording errors by 90% through the design of automated validation workflows and digital logging, replacing error-prone manual paper charts.

Overview

Subros Limited is a thermal cooling solution provider. Subros has it’s own facilities for the manufacturing purpose. In those, The Pressure Die-Casting Unit Plant (known as PDC Plant, henceforth) required a monitoring and controlling dashboard which helps the supervisor to monitor and control the Die-cast furnace and production.

The project structured phase-wise, firstly delivering the basic functionalities based on requirement.


Reduced daily manual data entry by 4.5 hours per operator by designing a "digital twin" interface that auto-fills production charts from real-time IoT sensor data

Decreased data recording errors by 90% through the design of automated validation workflows and digital logging, replacing error-prone manual paper charts.

DIE LOCKED

INJECTION FWD

ACCUM CHARGED

CORE IN

20:27:57

CYCLE TIME

12.4

SECONDS

INTENS. PRESSURE

352

BAR

FAST SHOT VEL

3.2

M/S

BISCUIT THICK

24.5

MM

0

0.6

1.1

1.6

2

2.5

3

3.5

4

4.5

5

5.5

6

6.5

7

7.5

8

8.5

9.1

9.7

10.4

11.1

11.7

12.4

13

13.7

14.4

15

15.7

16.4

17.1

17.9

Time (s)

0

150

300

450

Bar

FAST

INT

SHOT PROFILE MONITOR

LIMIT

P-Curve

FURN

TEMP

681

°C

0

160

320

480

640

HYD

LVL

OK

%

F1 MOLD

F2 INJECT

F3 CORE

F4 LUBE

F5 ALARM

F6 RESET

Live HMI

Production Chart

Fetch Data

Problem Space

Currently, the PDC Plant works mostly on manual monitoring and control apart form the HMI with the furnace control panel.

The plant supervisor works on the shoopfloor during harsh weather

PDC shift productions charts are manually filled

Accessing the Furnace area and production area

Production hamper due to extreme weather

The plant supervisor works on the shoopfloor during harsh weather

PDC shift productions charts are manually filled

Accessing the Furnace area and production area

Production hamper due to extreme weather

Problem Space