This automotive company has taken a step forward by implementing an innovative SCATI video surveillance solution that enhances safety and efficiency in every production process.
CHALLENGE
The automotive company faced several challenges in different areas of its production plant, all related to the need for accurate monitoring and efficient management of automated processes. In its laser production line, constant and effective monitoring was required to ensure quality and efficiency, with the aim of maintaining a clear view of critical points and detecting any incidents. In addition, in the vertical warehouse area, it was necessary to implement a solution for detailed, real-time monitoring of part handling in a dynamic environment.
On the other hand, this company was also looking for a portable video recording system to visually report breakdowns in their machines, which was compact, easy to transport and adaptable for use in different areas of the plant. Finally, the press area and pit needed to modernize its video surveillance system, migrating from analog cameras to a standardized IP solution to manage cameras and recorders on a single platform.
The solution had to guarantee continuous and reliable operation, even during power failures, avoiding interruptions in production.
SOLUTION
SCATI designed and provided a fully customized turnkey solution for this automotive company, addressing their specific needs and operational requirements. The solution was organized into various applications according to the areas of use of the cameras:
1. Production line supervision
In the laser production line, four high-resolution IP cameras were installed, strategically located to monitor each step of the automated process. Three of these cameras were used for detailed monitoring of critical areas such as part handling by the operator and part storage or removal, facilitating the identification of anomalies in real time. The fourth camera provides an overview of this work environment.
In addition, SCATI integrated a 55-inch monitor, which allows the team to visualize live all angles of the production line, optimizing the workflow by connecting to a SCATI VISION G500 Series recorder with the capacity to manage up to 8 channels and 8TB of storage.
With SCATI WALL software, operators can manage cameras intuitively and quickly.
2. Vertical warehouse control
SCATI implemented two state-of-the-art, compact, high-performance cameras to control the movement of parts, ensuring traceability. These cameras are connected to a recording system that allows real-time visualization and control from the administrative area.
3. Portable recording for inspection and maintenance
In addition to the fixed installation, SCATI implemented a portable recording system for inspection and maintenance tasks. This system, consisting of compact Pinhole IP cameras and a recorder, allows operators to visually record and document machine inspections. The system offers flexibility to capture images in hard-to-reach places and allows the system to be moved to any area as needed.
4. Migration and centralization in the press area and the pit.
SCATI performed a migration from analog cameras to IP cameras. The current recording system consists of three SCATI VISION recorders that can manage 16 cameras. Thanks to this system, operators have centralized access to the images from the press and pit cameras, facilitating homogeneous management and improving the capacity to respond to any incident.
A key aspect in each of the phases was the implementation of four Uninterruptible Power Supply (UPS) systems, ensuring the continuous operation of all cameras and recorders, even in the event of power outages. This ensures that surveillance operations are never interrupted, protecting both the integrity of the images and the control of the production process.
SCATI’s technical team was responsible for the commissioning of all systems, making specific adjustments and ensuring that each device was correctly configured and operating at full capacity. These services included monitoring rounds, periodic equipment performance reviews and the delivery of detailed reports on the status of the applications, enabling rapid implementation and optimizing the use of the systems from day one.
BENEFITS
SCATI ‘s solution has transformed the operations of this automotive company, enabling detailed and accurate monitoring of critical areas of the plant. The cameras have facilitated real-time error identification and correction, optimizing production accuracy and efficiency, reducing downtime and improving overall productivity. Implementation in the vertical warehouse has transformed part control and traceability and reduced handling errors.
Power backup with the Uninterruptible Power Supply (UPS) ensures that surveillance and monitoring operations continue without interruption, providing peace of mind by maintaining control over production at all times.
In conclusion, SCATI’s end-to-end solution not only strengthens the physical security of the facility, but also boosts efficiency and improves the operational processes of this automotive company. With the combination of high-quality cameras, an intuitive video management system and a UPS-backed infrastructure, this company has optimized its daily operations, maximizing both security and efficiency in its processes.