Innovation and Technology for Industry 4.0

Challenge:

Grupo Setta’s factory faced challenges in efficiently managing its electrical panel production, requiring greater real-time control, error reduction in production order management, and improved process automation to increase productivity and lower operational costs.

Solution:

Setta Digital Labs implemented Setta Factory, an app developed to optimize industrial machine management at Grupo Setta’s factory. The solution included total real-time production control, dynamic production queue management via smartphone and desktop, automation of production orders to minimize errors, and a complete history of executed projects for strategic analysis. Integration with internal systems ensured an agile, intelligent operation aligned with electrical panel production needs.

Results:

• Transparent and total production control, with real-time monitoring of each stage.
• Reduced errors and rework in production order management, boosting operational efficiency.
• Increased productivity through automated processes, ensuring greater agility and cost reduction.
• Detailed project history, facilitating continuous improvement and data-driven strategic decisions.
• Scalability for future expansions, maintaining efficiency in electrical panel production.

Products & Services Utilized:

• Setta Factory
• Integration with internal automation and ERP systems
• Interactive and customizable dashboard

With Setta Digital Labs’ expertise, Grupo Setta achieved a new level of efficiency and control in its own factory, creating a smarter, integrated, and future-ready industrial operation.

Explore the Interactive Animation:

Click on each highlighted area to discover in detail how we integrated automation, ensured real-time control, and improved production efficiency. Dive deeper into the specific solutions, understand the benefits at every stage, and see how Setta Digital Labs propelled Grupo Setta’s factory to a new level of innovation and productivity.

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Challenge:

• Implement a new industrial site (Greenfield) with the need to standardize processes.
• Employ WinCC Unified as a single platform for integration and control.
• Ensure full transparency of the production process with a unified database.

Solution:

• Automation using S7-1500 and S7-1200 CPUs + WinCC Unified, guaranteeing control and operational efficiency.
• Integration with SAP and a unified database to consolidate information and optimize management.
• Connection to multiple devices such as scales, inverters, and sensors.
• Fully integrated remote I/O system, simplifying equipment communication.
• Real-time monitoring of production KPIs.
• Remote access via SINEMA, enabling remote support and management.
• Recipe and batch management based on WinCC Unified.

Results:

• Transparent production control, with unified and accessible data.
• Real-time KPIs, allowing quick adjustments and more assertive strategic decisions.
• Centralized recipe and batch management, ensuring precision and traceability.
• SAP integration, streamlining production planning.
• Scalable system with easy updates, leveraging Siemens’ entire installed base.

Products & Services Used:

• S7-1500 and S7-1200 CPUs + WinCC Unified
• SINEMA Remote Access
• ET200SP Remotes
• Switch XB208

Through this solution, LOYDER, in partnership with Setta Digital Labs, reached a new level of efficiency and production control, ensuring a more intelligent, standardized, and transparent industrial environment.

Challenge:

• Tackle complex challenges in coffee bean processing.
• Implement an efficient traceability and routing system.
• Manage intake and precise dosing control for different blend compositions.
• Integrate production planning into the SCADA system, providing greater operational efficiency.

Solution:

• Automatic control of 1,200 routes, optimizing grain movement.
• WinCC Unified platform, delivering an intuitive interface and integrated management.
• S7-1500 system and remote I/O, with 200 actuators and 500 connected instruments.
• ERP integration, enabling real-time synchronization of production.
• WMS integration, optimizing logistics and storage.
• Transportation management system, ensuring efficient control of resources and distribution.
• Fully integrated Setta Progress as the plant management system (Xcelerator Offer).

Results:

• Transparent production control, with complete grain traceability.
• Automated management of production orders, reducing errors and rework.
• Comprehensive raw material monitoring, ensuring quality and compliance.
• Complex route management fully integrated with other plant systems.
• Unified database, centralizing information and simplifying decision-making.
• High scalability, allowing efficient future expansions.

Products & Services Used:

• WinCC Unified
• S7-1500 and remote I/O system
• MTP2200
• Setta Progress (Xcelerator Offer)

With Setta Digital Labs’ expertise, EXPOCACER reached a new level of efficiency and automation in coffee production. The result is a smarter, more integrated operation, ready for future challenges.

Challenge:

• Unify and monitor multiple photovoltaic plants under a single system.
• Consolidate energy and maintenance data to improve the performance of electrical panels.

Solution:

• Setta Connect (Xcelerator Offer) – A digital platform for integrated management.
• Mendix – Agile development of customized applications.
• Insiths Hub – An intelligent hub for centralized information.

Results:

• Integrated management of various devices: solar measuring stations, CCTV cameras, generation frequency inverters (VFD), primary cabin, and transformer.
• Reduced downtime, ensuring higher operational efficiency.
• Predictive failure analysis, enabling preventative actions before issues arise.
• Real-time diagnostics, improving decision-making.

Products & Services Used:

• Setta Connect (Xcelerator Offer)
• Mendix
• Insiths Hub

By implementing these solutions, Grupo Cobra and Setta Digital Labs accelerated digital transformation in the solar energy sector, achieving greater efficiency, control, and sustainability for photovoltaic plants.