Just like any other mechanical equipment, packing scales and process weighers are prone to malfunction and inaccuracies due to damage, loss of calibration and many other faults. I have experienced first hand the impact of having a packing scale over-fill. In fact, we can do the maths right here. Typically a scale would tip on average 12 times a minute. So if a scale is over-filling say a 10kg bag by only half a kilo, an 8-hour shift would result in losses of over 2 tonnes of product. Under-filling the bags would be just as detrimental as it would result in regulatory fines or loss in production time if the product has to be repacked. The scale has to be as accurate as possible.
Further, if a packaging machine fails it is taken off the production line until it is fixed. Resulting in downtime that could have been prevented had there been measures in place to detect the failure in advance.
It gets worse. Most manufacturers who employ packaging and weighing equipment lack systems that provide detailed descriptive analytics such that decision-makers are often reduced to guesswork.
This is mainly due to legacy technology systems that are not interoperable. For example, there is no link between PLCs on packaging equipment and the Manufacturing Execution Systems.
Packaging equipment manufacturers, therefore, owe it to themselves and their clients to cast a wide net and find new ways of solving these challenges among many others.
Modern IoT advances offer the most ideal arrangement. Mechanical IoT can enable leaders to advance in and stop the procedure close to recognizing a blame, for example, a scale glitch or a traded off creation run. To put it plainly, it offers the chance of constant bits of knowledge on how things are going not how they went.