Concrete block machine
A connected concrete block machine feeds production data, alarms and utilisation into a customer portal. Operators see their OEE, plan maintenance from a calendar and order wear parts directly, while the manufacturer digitises service and after-sales.
Concrete block machine at a glance
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Concrete block machine: OEE, maintenance and spare parts
In the solution example, the HESS GROUP connects concrete block and mixing plants to SmartCloud, based on the EquipmentCloud from Kontron AIS. A single tool shows machine master data, documents, shift logs and a dynamic maintenance calendar. Alarms, throughput and almost any KPI appear on an individual dashboard, and analysis tools display cause-and-effect relationships and metrics such as OEE. Service requests can be sent straight from the app, with AR support if required. Via SmartParts, all parts of the machine are available in 3D in a catalogue, and tutorials support self-service.
The example comes from mechanical and plant engineering. Since 1948, the HESS GROUP has built concrete block machines and complete plants on which customers produce paving stones, slabs, kerbs or steps. Its existing customers run machines of very different ages: machines under two years old can be connected directly, older ones after a feasibility check, sometimes with additional hardware. One goal was to make the knowledge of experienced staff available to newcomers. In podcast episode #93, Sandra Oerter (HESS GROUP) and Martin Falsner (Kontron AIS) report on the project.
Podcast episodes featuring Concrete block machine
Concrete block machines: frequently asked questions
When does a wear part on a concrete block machine need replacing?
The machine's data provides the answer, so that the quality of the blocks does not suffer. Typical customer questions at the HESS GROUP are when a scraper brush or a rubber buffer is due, for example. SmartCloud shows the dynamic maintenance calendar for this. Via SmartParts, all parts are stored in 3D in the catalogue, including order suggestions and order history.
What does a customer portal offer for running a concrete products plant?
It brings together all of the plant's data in one place, from machine operators to management. Up-to-date KPIs are available on demand to HESS GROUP customers and create a shared understanding across departments. Shift logs, which often existed only on paper, are documented centrally. Tutorials in one place make it easier to train new staff.
How can maintenance of a concrete block machine be planned digitally?
A dynamic maintenance calendar in the cloud shows which work is due on the machine. At the HESS GROUP, it is part of SmartCloud and is displayed directly to operators. According to the project report, overall equipment effectiveness rises through more efficient maintenance and better planning. As a next step, the collected data is to develop SmartCloud further towards predictive maintenance.
Can older concrete block plants be connected digitally?
Yes, the HESS GROUP aims to connect all customers, regardless of how old the machine is. Machines under two years old can be connected to the cloud directly. For older plants, a technical feasibility check comes first, and additional hardware may be required. Only once the machine is communicating can production data be obtained and utilisation shown.
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