Transforming IoT Challenges into Operational Excellence
Business Problem
A leading semiconductor company catering to multiple automobile manufacturers, encountered challenges in their Internet of Things (IoT) setup within an automobile manufacturing plant. This setup comprised of diverse Zigbee sensors responsible for monitoring parameters like temperature, humidity, position, proximity, collision, ultrasonic readings, and the connections between nodes were dynamically updated and optimized through built in mesh routing table. The IoT system comprised of Zigbee sensors monitoring crucial parameters, yet issues like performance bottlenecks, configuration complexities, and communication reliability concerns were impeding smooth operations.
Business Analysis
The manufacturing plant heavily relied on the accurate functioning of IoT sensors working in a mesh network for smooth operations and to maintain product quality. The identified issues were affecting overall efficiency and creating hurdles in the production process. The challenges ranged from performance degradation and difficulty in re-configuring sensors to unreliable communication between devices. Additionally, any delay or latency issues in networking led to real-time operation failures that are difficult to quickly identify and fix.
PureSoftware Solution
PureSoftware formulated a comprehensive solution to tackle the client’s IoT challenges. The company established a dedicated testing and debugging laboratory, which closely emulated the conditions of the automobile manufacturing plant. Within this simulated environment, a Zigbee mesh network was also implemented.
The team deployed Zigbee kits simulating different sensors within the lab setup. This included creating a Zigbee mesh network, Zigbee to Wi-Fi gateway, control bridge, end devices, multiple coordinators, and integration of third-party sensors from various other manufacturers (sensors apart from our client). Network data was gathered using a sniffer, allowing for a comprehensive analysis of the network behavior. This facilitated the initiation of identifying root causes behind performance issues, configuration difficulties, and communication reliability problems.
PureSoftware incorporated software-based simulations of events, alarms, and control sequences involving Zigbee end devices, routers, and gateways. This allowed the team to assess the behavior of the device under different mesh connection scenarios and identify potential problem areas for latency issues.
The team utilized a debugged version of the Zigbee stack and made modifications to the stack image at the Physical (PHY) and Medium Access Control (MAC) layers with various counters. These counters assisted in diagnosing issues and helped enhance the stack to report additional parameters, messages aiding in the identification of root causes and patterns. All aspects of the client’s documentation, including reference manuals, application notes, user guides, and setup guides, were thoroughly validated. Clarity and the recommended sequence of steps were explained to the client.
PureSoftware Result
Through the implementation of this comprehensive solution, PureSoftware successfully addressed the performance, configuration, and communication reliability concerns in the IOT system.
The dedicated lab setup allowed for in-depth simulation, testing and debugging, leading to accurate identification of issues and their subsequent resolution.
By modifying and debugging the Zigbee stack, the team not only mitigated existing issues but also enhanced predictability of performance issues.
The documentation review and validation contributed to an enhanced user experience and streamlined operations within the IoT setup.
As a result of these efforts, the manufacturing plant experienced smoother manufacturing operations, improved product quality, and increased overall efficiency.
