Less Common Metals (LCM) Is a world leader in the manufacture and supply of metals and complex alloy systems and specialises in rare earth elements, including alloys, for permanent magnet production: magneto-caloric, magnetostrictive, hydrogen storage alloys and a wide range of master alloys used to introduce rare earth materials to other systems.
Less Common Metals (LCM) Is a world leader in the manufacture and supply of metals and complex alloy systems and specialises in rare earth elements, including alloys, for permanent magnet production: magneto-caloric, magnetostrictive, hydrogen storage alloys and a wide range of master alloys used to introduce rare earth materials to other systems.
Beeta was commissioned by LCM to work on an EU funded project, creating an automated, internal, fully bespoke dashboard. The challenge we faced was that multiple different devices were needed to gather industrial measurements and there were four different types of raw data [rectifier, powder feeder, temperature and off gas] that all needed to be processed and displayed on the same internal screen.
We needed to create a system that enabled the team to display a huge amount of data on a single dashboard without causing disruptions to the system, so we created a secure, web-based GUI to display the data. Due to the complexity of the data we also needed to make room for any changes and trends, so the system needed to be capable of gathering and displaying data in real-time but also provide a facility for reviewing past events.
The first aspect of the brief was to work alongside the technical team to discover exactly what was needed so that we could scope and deliver the project efficiently. LCM required a bespoke system to capture raw data from the machines and any key process variables. Our client did weigh up the option of implementing a SCADA (Supervisory control and data acquisition) or OPC (Open Platform Communication) solution but after careful consideration, they found that a bespoke system had more compelling benefits such as precision, flexibility and control. See our article for more on bespoke benefits!
The current system was time-consuming as there was no singular place to manage all the data. This information needed to be clearly displayed on a central dashboard to enhance productivity and the overall efficiency/ ROI for the business. Beeta took ownership of the full SDLC (software delivery life cycle) of this project, from conception to delivery. In the scoping phase, we outlined the 6 project phases, determining the: requirement analysis, UI, technical design, development and unit testing, bug fixing and UAT. Our specialist team of graphic designers and front and back-end developers then worked in tangent to mock-up and deliver.
We developed a central source that displayed real-time and/or average values, whilst simultaneously constructing a database of the raw data collated, to be accessible for future reference. The software allows for overlaying information from different sources on the same timeline so that the interaction of the variables could be observed. The data can also be accessed remotely and has a reporting facility combining production data alongside other key resources. A set of critical values were created e.g. if something turns red this indicates that there is an issue with the machine. This enabled a birds-eye view of production ensuring that the team could identify any errors and make a quick decision on whether support was needed – significantly improving production and cost-efficiency. These values were designed to be tailored on an admin board [system configuration screen] so that the team could set what they wanted to measure, trigger points, offset times, etc. The software solution is built using the latest, enterprise-level software ensuring an ultra-fast response that is also scalable and can be run using a range of hosting services.
Not only did we create an internal screen, but we also ensured that this system is accessible on a variety of different devices and browsers. Accessibility was the central focus of this project so incorporating Windows AD for each user was a necessity. The bespoke system also provided long-term data reports including retrospective statistics, used to further improve processes.
Since the project has gone live it has made LCM’s production processes much more streamlined and efficient. The use of automation has confirmed their unrivalled status in the UK and they are quickly becoming a solid contender for China, who currently ‘dominate’ the mining and production of rare earth materials. See their documentary with the Wall Street Journal for more on this!
We really enjoyed working with the team at Beeta. They listened to what we wanted and ensured we were kept up to date with every step along the way. The end product is brilliant and we wouldn’t hesitate with working with them again in the future.