Modula Cloud: Heading off problems through remote monitoring and analytics

Thanks to artificial intelligence and machine learning, complex machinery can be kept up and running with what’s known as predictive maintenance. That is, using software, algorithms and information gathered for IoT sensors, machines can “self-report” on their servicing needs. The data an individual machine collects is added to a pool of similar machines, and the accumulated knowledge tells technicians when to schedule maintenance operations. 

The upshot is more efficient processes. Not only does an organization avoid unplanned downtimes when a machine stops working without warning, it also avoids scheduling maintenance earlier than required, thus getting the optimal use of parts that are of limited lifespans.

Here’s how it works: The data collection systems, typically routed through a cloud, connect to the company software and its information about a given machine. The platform then processes it with mathematical calculations and takes note of deviations from the norm. These anomalies from the average range are used to plan interventions and avoid production stoppages or machine downtime with indirect costs on production.

Modula Cloud: the secure integrated logistics management system

Modula vertical lift modules have adopted this approach, using the Modula Cloud platform that connects to them through Modula WMS software.

Modula Cloud collects and processes the information and activities coming from the warehouses (even on various systems in various cities and countries) so that the data of each individual VLM is available, including:

  • tray saturation
  • performance, throughput, cycles
  • system registry data
  • warehouse status (online, offline, error)
  • consumption
  • tasks
  • maintenance
  • opening assistance ticket
  • machine log 

and much more.

This data is collected in chronological order and uploaded to the cloud through a communication protocol. It’s accessible to supervisors through unique usernames and passwords. 

To keep the information secure, Modula Cloud was developed entirely with Microsoft technology and is hosted on the Microsoft Azure cloud platform. As one of the leading public cloud providers, Microsoft equips its cloud with all the latest safety certifications for information management as well as cryptography systems for authentication and data exchange.

The only prerequisite for the client on the IT side is a stable and continuous internet connection from the Modula Server PC workstation.

Anticipating maintenance needs to avoid production stoppages

As the data from various Modula VLMs is accumulated, the algorithms create a mathematical model that helps identify signs of wear over time. With this information, the system can help head off failures before they occur. The data aggregated is displayed and communicated in real time from the platform to the client, as well as to Modula’s customer care service.

The remote monitoring shows critical information through custom dashboards, alarms and predictive notifications. Additionally, this information can be used to automatically generate work orders associated with maintenance activities.

Being able to anticipate breakdowns gives our clients a concrete opportunity to improve processes, prevent unexpected production stoppages and reduce management costs to a minimum. It also maximizes the maintenance plan efficiency by eliminating all unnecessary and wasteful activities.

Resolving machine stoppages remotely with Modula Cloud

With Modula Cloud, remote diagnostics means problems are easy to identify and resolve. Additionally, Modula Cloud provides a direct line to technical support just by touching a button on the Copilot console. This feature eliminates the need for calls or emails. All the data necessary for an analysis of the malfunction is sent live to Customer Care.

The combination of all these technologies means that technicians can work almost 100% remotely and provide guidance to the operator attending to the VLM onsite. Statistically, 80% of machine stoppages can be resolved this way. 

With this powerful combination of predictive maintenance and remote servicing when problems arise, it’s easy to understand why Modula Cloud is being embraced by more and more organizations seeking to keep their operations running optimally and efficiently, year in and year out.