(Original article on BeChained’s Medium)
As manufacturers face increasing pressures to reduce energy consumption and lower costs, BeChained’s AI-driven solutions offer a powerful way to optimize energy usage across machines, processes, and entire facilities.
Even BeChained’s needs to deploy a structured process to minimize bottleneck or setback during a customer onboarding.
So, to seamlessly integrate a manufacturing facility into BeChained’s infrastructure, this article process ensures that all technical, security, and operational systems are prepared to work in unison.
Here’s a breakdown of the essential steps and a checklist to help a manufacturer prepare for onboarding with BeChained.
1. Network and Security Configuration
VPN Configuration
- Secure VPN: Establish a secure Virtual Private Network (VPN) for encrypted communication between the facility and BeChained’s cloud platform. This protects data integrity and confidentiality.
- Firewall Configuration: Firewalls must allow secure access via designated ports and protocols like OPC-UA or SCADA (through MQTT).
- Authentication: Implement multi-factor authentication (MFA) and strong password policies to safeguard critical infrastructure.
Security Requirements
- SSL/TLS Encryption: Ensure all communications between machines, smart meters, and the cloud platform are encrypted with SSL/TLS.
- Role-Based Access Control (RBAC): Define RBAC to manage access rights, allowing only authorized personnel to interact with BeChained’s platform.
- Incident Monitoring and Response: Enable real-time monitoring and incident response to detect unauthorized access or anomalies.
2. Cloud Services Setup
Cloud Hosting
- Cloud Infrastructure Setup: Prepare a Virtual Machine (VM) equipped with MQTT systems to gather data from facility machines at regular intervals and connect with cloud infrastructure like AWS or Google Cloud.
- Cloud Security Configuration: Implement encryption and access control for secure data flow between the facility and BeChained.
API Integration
- MES and ERP Systems: Integrate the Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) with BeChained’s cloud platform using APIs for seamless data exchange and optimization.
3. Virtual Machine (Software Gateway) Preparation
Linux Virtual Machine Setup
- Linux Distribution: Deploy a Linux-based OS (e.g., Ubuntu or Debian GNU/Linux) on a VM, acting as a software gateway for BeChained’s platform. In fact BeChained’s positioning is to be hardware agnostic to connect to 3rd parties/OEM devices, as well not install any physical mean to gather information and to communicate with the Cloud.
- Firewall and Network Configuration: Configure firewalls, set up secure connections, and enable remote access for BeChained to install packages and libraries, ensuring smooth data transmission.
Protocols and Communication
- OPC-UA & SCADA Protocols: The VM must facilitate communication with industrial systems using protocols like OPC-UA and SCADA, ensuring reliable data transmission to the BeChained cloud.
4. Smart Meter Deployment on Machines
Hardware Installation
- Smart Meter Devices: Install smart meters on machines to track real-time energy consumption and operational data. Ensure network connectivity via Modbus TCP or serial communication.
Meter Configuration
- Meter Calibration: Calibrate each smart meter for accurate readings, including parameters like energy usage, voltage, and power factor.
- Data Collection: Smart meters must transmit data in real-time to the VM, where it is securely sent to BeChained’s platform.
5. Manufacturing Execution System (MES) Integration
MES Connectivity
- Communication Protocols: Ensure that MES communicates with the VM using OPC-UA, REST APIs, or other protocols.
- Data Access: Allow BeChained access to machine settings and production data for process optimization.
Process Control and Optimization
- Real-Time Monitoring: BeChained will continuously monitor machine performance, leveraging the MES data to provide actionable insights for optimization.
- Feedback Loop: A feedback loop will allow automatic adjustments to machine parameters, fine-tuning operations to achieve optimal energy efficiency.
6. ERP System Integration
ERP Connectivity
- API or Database Access: Provide BeChained with real-time access to the ERP system, allowing extraction of batch production information (e.g., type of products, scheduling, and quality data).
Batch and Production Data Integration
- Data Correlation: BeChained will analyze batch information from the ERP alongside energy use data from smart meters and machine settings from MES to uncover optimization opportunities.
7. System Testing and Validation
Connectivity Testing
- Test Connectivity: Verify that all components — smart meters, VM, cloud services, MES, and ERP — are securely connected and properly communicating with BeChained’s platform.
Security and Data Accuracy Testing
- Security Validation: Conduct penetration tests and vulnerability scans to ensure the infrastructure is secure against cyber threats.
- Data Validation: Ensure all data from the smart meters and connected systems is accurate and matches the real-world energy usage and machine settings.
8. Client Onboarding Documentation and Training
User Training
- Training and Documentation: BeChained will provide customer’s team with training on monitoring the platform’s dashboard and interpreting energy optimization suggestions. Additionally, you will receive comprehensive documentation and troubleshooting guides.
Ongoing Support
- Maintenance and Support: BeChained offers continuous support, ensuring optimal performance, maintenance, and updates for client’s system. This includes real-time alerts and remote diagnostics.
By following these steps, a manufacturing facility will be fully equipped to integrate BeChained’s AI-powered energy optimization solutions.
The robustness of the platform ensures that manufacturers minimize energy consumption, reduce operational costs, and improve sustainability—all while maintaining high standards of security and performance.
Stay tuned for more updates, and feel free to reach out to BeChained for further questions on how we can help your facility achieve energy efficiency!