Indian Railways has reaped a 20% increase of production efficiency by deploying a real-time machine monitoring and manufacturing data collection system at its 10 factories and workshops in different regions of India.
The system was developed by Finnish-Russian firm Zyfra, which focuses on industrial digitalisation technologies for machinery, metallurgy, mining and oil & gas. Its solutions portfolio includes predictive analytics and data analysis, tech processes optimisation, automatic dispatch systems, autonomous dump trucks and teleoperated equipment.
Launched in September 2019, Indian Railways started using Zyfra’s MDCplus system – collecting overall data from all types of machines and monitor energy consumption, which results in substantial increase in machine utilisation and energy saving. Zyfra deployed the system, trained personnel, and is now providing technical support.
Since implementation, 9% increase in machine utilisation has been achieved immediately after deployment. Further productivity growth was generated thanks to reducing unplanned downtime.
The system allows identification and classification of downtime reasons, assisting operators in the performance of production tasks, notifying specialists and production departments regarding accidents and unplanned downtime and compiling analytical reports on the operation of equipment and production efficiency.
Commenting on its project with India Railways, Pavel Rastopshin, managing director of Zyfra, said: “India has become the key foreign market for Zyfra with more than 500 CNC machines connected to its MDCplus system in 2019. By 2021, the company is looking at more than 2,000 MDCplus installations in India.
He added: “This year, we have devoted a lot of time to research and development. We have introduced a powerful new solution for predictive analytics which can even predict a machine or tool breakage. This solution will help our clients make discrete manufacturing more efficient.”
Indian Railways, the premier transport organisation of India, is the largest rail network in Asia and the world’s second largest under one management. It runs around 11,000 trains daily, of which 7,000 are passenger trains