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Automated Visual Inspection

Machine Vision offers very superior levels of quantitative measurement for Visual Quality Inspection of manufactured parts.

  • identify defects in injection moulded parts, circuit boards, confectionary and baked products (such as cookies and biscuits). This can also be used to detect the presence and absence of child parts in an assembly such as a vehicle bumper or assembled consoles inside the car.
  • Reduce maintenance time and cost by inspecting hundreds of parts per minute, and by removing contact between the test system and the produced parts. This will also eliminate the chances of defects occurring due to physical handling.
  • Detect flaws earlier in the process, and reduce rework and scrap while simultaneously increasing safety levels for workers.

 

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Smart Industrial Automation

Automation covers a complex chain:

  • Chip / Board / Hardware Manufacturers
  • Sensor / Actuator / Camera Manufacturers
  • Machine Learning / AI
  • Software & App Developers
  • System Integrators
  • Network Service Providers
  • Operating Service Providers
  • ERP vendors
  • Big data Analytics Services
  • Data Security

Surya has in-house expertise in Software Development and System Integration. The other services are brought in through our strategic partners as per the needs of individual projects, and integrated into the solution by us.

 

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Industrial IOT

IIOT allows Industry to connect Regions, Suppliers, Factories, as well as Outsourced Production lines in different geographies and time-zones.

  • Monitor plant performance from remote locations, and view all critical parameters such as production status, downtime, rejection rate, operational efficiency etc through visual dashboards, in Real-Time.
  • Enable Condition-based monitoring  (CBM), and reduce expensive downtime, give advance warning of safety issues, and continuously monitor the health of machines
  • Use remote cloud-based monitoring of installations at your Customer's environment, to enable a high level of integration with customers, and create a sticky model with high levels of customer lock-in
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Data Analytics & Reports

Manage the over-whelming Data overload. Unlock greater value through Data and Connectivity. Integrate all Data to a common platform.

  • Connect Data from all machines and auxiliary equipment to your ERP; access a Management Console for reports and analytics; download customized advanced reports on every Plant.
  • Tag, Process and Store of all Data assets as well as of the millions of Data points coming in every day from the machines and other digitalized systems of the organization. Also sort and back-up all this data securely on the Cloud
  • Use Analytics to make sense of the Data to predict customer needs in advance, trigger timely interventions, augment human capabilities, and control Process efficiencies
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About Surya Automation

We offer inter operable Smart Factory Solutions integrating:

  • Machine Learning, Deep Learning, AI
  • Industrial IOT
  • Robotics  & Mechatronics (Cyber Physical Systems)
  • Process Control Systems
  • Cloud Computing
  • Data Visualization, Big Data Analytics
  • Data Security
Achievements
40
Industrial
Applications
8
Industrial
Domains
15
Million
Industrial Operations
7
Upcoming
Projects

The Surya Automation

Core Team

The Surya Process

 

Our Project Execution Methodology is based on iterative and incremental project development  practices, where we interact closely with the client's internal teams to collaboratively evolve the business goals, functional & supplementary specifications, as well as the design approach to the Automation Solution.

Our projects follow the broad steps below, starting with the Discovery Phase, and ending with the Transition to end-users.

Discovery Phase

That Discover phase plays a very critical part in the success or failure of the Industrial Automation project. All the Knowledge Transfer taken from the client, and the Research helps to map out very specific goals, as well as the framework and methodology that  should be used.

At this stage we Scope out the problem areas to be solved, which could be to reduce cost, increase speed of production, reduce handling errors, decrease the rejection rate, bring transparency into the operations, increase machine efficiency and so on.

Business Goals, User Research, Project Plan

This phase encompasses the following:

  1. Establishing Business Goals so that there is no misunderstanding on Scope
  2. Defining successful Outcomes (this is essential to reduce unnecessary functionality and simplify the project)
  3. Conducting User Research (to understand and uncover the actual User needs)
  4. Map the project stages , based on the exact components of each project.

An important outcome of this phase is not just an understanding of the project's high level requirements, but also a deep insight into the implicit drivers, which may not be the same as the mode of solution asked for by the client.

Engineering Design

A quick study of the high level requirements is followed by an iterative design process. Schematics, diagrams, layouts,  and CAD-based 3D drawings are generated to provide the early project configuration. If required simulations are run to establish feasibility of the system design.

During this phase the fine detailing of the system is established, including the exernal dimensions, material requirement, type of auxilliary equipment, surface treatments, the operating parameters  the acceptable range of tolerances, and so on. The supplementary specifications too are detailed in terms of the requirements for robustness, maintainability, reliability, security and so on. The output from this phase is the design approval by client and mutual sign-off .

Construction Phase

During this phase, the physical structure of the machine is built, all the physical components and auxiliary systems and sub-systems are built or acquired, and the software features are developed.

All the components and sub-systems are integrated into the machine, rigorous testing is done, and the beta version is released. The output from this phase is the initial Operational capability of the machine.

Transition

This occurs when the the SPM is ready for deployment at the client environment. At this stage, the Phase 1 subset of the Design Requirements have been met, and an acceptable level of quality has been established in our internal testing.

At this point, the client's internal team visit our construction site to do the final beta testing. Invariably the client's team comes up with change requests, which are implemented if considerd to be within the initial Scoping of the project.

On receiving sign-off from Client on the deployment readiness of the SPM, it is moved to the client's production environment. At the client's end a parallel operation is carried out simultaneously with the legacy or manual system that is being replaced. During the parallel operation, we provide training to the users of the SPM, as well as to the maintenance team of the client.

On successful completion of the training as well as the parallel run, the SPM becomes a part of the production process of the Client.

Discovery Phase
Business Goals, User Research, Project Plan
Engineering Design
Construction Phase
Transition

Data Management & Analytics

Benefits of data management

  • Connected intelligent shop floor
  • M2M: Sensors, PLC’s, machines talking to a centralized platform
  • Middleware to connect the central platform to the ERP
  • Two-way integration of data with Management Systems
  • Channeling the data through a Data Visualization & Analytics engine
  • Turning data into actionable information
  • Manage data throughout the lifecycle

Industrial IOT

Predictive Maintenance

This is done through Condition-based Monitoring:

  • Maximize Revenues
  • Reduce expensive down-time
  • Synchronize maintenance with scheduled down-time
  • Reduce total cost of Maintenance
  • Eliminate secondary damages due to catastrophic breakdowns
  • Perform tasks only when warranted
  • Maximize Safety, reduce accidents
  • Reduce interaction of humans with hazardous machines
  • Use Data Analytics to anticipate issues with each production line

Sample Use Cases

IIOT + Cyber Physical systems

Using Robot arms.

Increase worker safety standards

Air traffic control is a good use case fo rthis

Such as detection of noxious gasses

This includes not just the health of machines, but also of humans!

Phone

+91-020-25694455

Working hours

Mon. - Set. 9AM - 7PM

Reach out

Contact Us

Address

19 Golden Court, 50 Aundh Road, Pune (411020)