This solution demonstrates how converging mature technologies (5G+PLC) with cutting-edge AI enhancing Industrial Safety & Efficiency, proving that Industry 4.0 transformations can start with operational pain points rather than full-system overhauls.
Client Challenge
Safety Vulnerabilities
Unauthorized personnel entering hazardous zones caused several incidents monthly.
Production Blind Spots
Legacy PLC systems lacked real-time coordination with quality control processes.
Data Fragmentation
Isolated PLC networks prevented centralized monitoring of 120+ production cells.
Solution
A converged architecture combining 5G connectivity, AI vision analytics, and PLC modernization
- Intelligent Safety Monitoring System
- AI-Powered Surveillance:
- Deployed 5G-connected cameras at high-risk zones (press lines/chemical storage).
- Deployed TruGem’s edge computing gateway AIoT-5G-G06 which integrates AI algorithm and can be realized :
- ▶ Personnel Intrusion: Instant alerts when personnel breach geofenced danger areas.
- ▶Personnel Identification: Detecting authorized vs. unauthorized staff.
- 5G-Enhanced PLC Network
- Real-Time Data Aggregation:
- Connected PLCs across 4 production halls through 5G industrial routers C503.
- Acquisition real-time data from PLCs and securely transmits it over 5G networks via proprietary protocols to a remote management platform for analysis.
- Edge-Processed Analytics:
- Localized analysis of PLC cycle times to detect abnormal machine states.
- Online real-time monitoring of the production process, fast and efficient feedback
- Centralized Industrial IoT Platform
- Unified Visualization:
- interactive dashboards showing real-time:
- Safety compliance status (green/red zones).
- Machine utilization rates.
- Energy consumption heatmaps.
- interactive dashboards showing real-time:
- Decision Support Tools:
- Automated daily reports comparing PLC performance across shifts.
- Root-cause analysis module for production delays or problems.
Benefits
- Safety Transformation
- 100% detection of unauthorized entries within 0.8 seconds.
- 76% reduction in safety protocol violations.
- Enhancing Industrial Operational Efficiency
- 22% faster response to equipment anomalies.
- 14% improvement in overall equipment effectiveness.
- Data-Driven Culture
- Enabled cross-department access to unified production/safety dashboards.
- Reduced manual data collection efforts by 320 labor-hours/month
Related Products
5G Edge Computing Gateway
Industrial Router