THE VIRTUAL TWIN

With its Smart Mobile Operator Support (SMOS), Hauni is developing a digital service package that transforms machines for cigarette production into a networked system in the spirit of Industry 4.0 that is always ready to perform self-analysis and communicate intelligently with its human operators. If a disruption occurs, it is identified immediately and digitally. The accompanying tablet app alerts the service technician, guides them directly to the right machine, and even identifies the reason for the functional error in abbreviated form. Having arrived at the machine, the technician is guided in a mobile manner through the steps needed to solve the problem with the help of a “twin,” which is visualized on the tablet in real time. If the spare part needed is not on hand, it is possible to order it online in the future.

Focusing on parameters

This method can be understood using a concrete example in a simulation: The app displays a diagram of a production hall with a large number of machines at a cigarette manufacturer. One of them stands out: The type designation of the PROTOS-M4 is flashing red because the cigarette machine has stopped operating. The supplementary explanation in the red field on the display reads “Stop: tube wheel too high.” Thus, in the event of a disruption, the service technician knows at a glance which machine and which component are concerned. Using the virtual twin, which contains all of the machine’s current parameters, the technician can immediately get an overview of which functions are affected and which are not. Previously, people needed to go and find a huge maintenance tome on the shelves, haul it to the machine, and consult it – only to discover it was outdated in some instances. That is not the case with SMOS: Three additional buttons allow technicians to select options for circuit diagrams, handbooks, or replacement parts catalogs. All of them are stored in the system in digital form and can be called up in their current version at any time.

Hauni’s SMOS solution can be used with all cigarette manufacturing machines built from 2005 on – e.g. with the PROTOS-M4