Case study category: Production

Augmented reality helps Gotec Group optimise manufacturing processes

Augmented reality helps Gotec Group optimise manufacturing processes

Soitron has been a valuable partner throughout this journey providing expertise and solutions for our challenges.  

Daniel Walendy, Chief Information Officer  

Background

The Gotec Group is a dynamic manufacturing company with a wide range of products, which means they regularly need to reconfigure their production lines. One key element in their production is the bonding agent that is applied to various materials. While the company had previously implemented partial automation of several manufacturing processes, the critical task of properly setting spray guns continued to be done manually.

The company faced a major challenge in optimising the spray gun settings for manufacturing various components for the automotive industry. Inefficient use of material, delays in setting the production equipment, and subsequent modifications to finished products all prolonged the manufacturing times.

This process was especially challenging because a single production cycle can involve 3 to 4 changes of settings, requiring the spray guns to be reset each time. Every change required fine parameter setting, directly affecting material consumption. Additionally, the customer faced challenges in training operators at their manufacturing facilities across the world. The need for experts to travel from Poland to various continents resulted in substantial travel costs. Traditional operator training methods required these experts to be physically present at the training sites.

Project implementation process

We addressed the problem by deploying the innovative VR technology, RealWear Navigator 500 – specialised VR smart glasses designed for hands-free communication with remote experts, even in challenging production environments. These smart glasses are very durable, easy to use with voice commands, and equipped with an integrated camera that streams real-time video. This allowed experts in Poland to train operators remotely, whether they were in Mexico, China, or Slovakia, without the need for the expert’s physical presence on site.

Factory workers put on the RealWear smart glasses and remote experts monitor their work on a computer screen and provide instructions using drawings,

voice commands, or screen sharing through TeamViewer or MS Teams, which we integrated into the devices.

This combination of technologies brought about immediate improvements in operators’ work performance without disrupting the production process. As part of the Proof of Concept (PoC), we tested the solution in a real production environment to verify its functionality and efficiency. Based on the findings, we proposed additional enhancements to further boost productivity. Finally, we handed over the entire system to the client as a fully operational solution, ready for further development.

Results and benefits

improved efficiency in operator training

continuity of manufacturing processes

improved spray gun setting quality

reduction of material waste

Customer Profile

The GOTEC Group is the world’s leading specialist for surface treatments and application of bonding agents for rubber-metal/plastic parts for the automotive industry. It has 17 branches in 12 countries across Europe, the Americas, and Asia. The company is headquartered in Wülfrath, Germany.

Technologies used

RealWear Navigator 500, TeamViewer, Microsoft Teams

Cybersecurity at the Chvaletice Power Plant: OT and IT networks under close scrutiny of a security audit

Cybersecurity at the Chvaletice Power Plant: OT and IT networks under close scrutiny of a security audit

Cybersecurity has been a long-term priority for us. It plays a crucial role in ensuring the reliable and safe operation of our power plant. Thanks to Soitron’s professionality and technical solutions such as Soitron Security Sensor, we have improved our in-depth overview of our OT and IT networks even further. Solutions tailored to our specific needs help us minimise potential risks related to outages while strengthening the security of the energy system. 

Jiří Rokyta, Head of Instrumentation and Control Department  

Background

The Chvaletice Power Plant is acutely aware of the critical importance of the cybersecurity for its operational technology (OT) as it is the foundation of its critical infrastructure. They also put emphasis on information technology (IT) that supports its business and administrative processes. While the OT network is responsible for controlling and monitoring key power generation processes, the IT networks ensure the smooth functioning of the organisation as a whole. Targeted solutions for protecting both OT and IT systems allow the plant not only to guarantee uninterrupted and reliable operation, but also to demonstrate a responsible approach to meeting regulatory commitments. As part of its efforts to enhance cybersecurity across its networks, the power plant sought solutions to improve OT and IT systems protection. In this endeavour, we acted as their technological and consulting partner.

Project implementation process

deployed the Soitron Security Sensor—a security solution designed to analyse network traffic and file security. A single physical device integrates several security products tailored to detect advanced threats and provide network visibility. These products are always customised to the specific needs of the customer. In this case, we combined solutions suited for analysing both OT and IT networks: FlowMon, Nozomi Guardian, and Cisco ICS CyberVision.

The Security Sensor was physically installed on-site at the power plant. Once deployed, the solution monitored and analysed network traffic within both the OT and IT environments. Based on the collected data, our experts prepared a final report that included findings, recommendations, and further development opportunities. With the audit the customer learned how well it is protected against potential security incidents and what are the most suitable technologies for its OT and IT environments.

Results and benefits

comprehensive insight about OT and IT networks

reduced risks of OT and IT network outages

enhanced energy system security

compliance with legislative requirements

Customer Profile

The Chvaletice Power Plant is part of the Sev.en Česká Energie a.s. group. With its strategic location, it serves as the energy hub of Eastern Bohemia and is the only power plant in the region certified to stabilise the power system voltage fluctuations, restore power supply after a system collapse, and operate in island mode. The plant ensures a stable supply of electricity from local sources. Its four units generate electric power to cover both base-load (24 hrs) consumption and peak demand (12 hrs) with dynamic output ranging from 100 to 840 MW.

Technologies used

FlowMon, Nozomi Guardian, Cisco ICS CyberVision

Migration of IT infrastructure to the cloud for Gotec Group

Migration of IT infrastructure to the cloud for Gotec Group

Build a new infrastructure using a cloud-first approach allows us to grow globally as a company being able to support our growth and future needs. Soitron has been a valuable partner throughout this journey providing expertise and solutions for our challenges. 

Daniel Walendy, Chief Information Officer  

Background

The Gotec Group operates in 12 countries, with each of its 17 subsidiaries having historically had its own IT policy for infrastructure procurement, management and administration. However, this decentralized approach was often inefficient, time-consuming, and problematic. Thus, the primary requirement from the customer was to centralize infrastructure and access to the corporate IT strategy.  We proposed a complete migration of their IT environment to the cloud as the most suitable solution.

The customer contacted our office in Poland directly regarding several projects that needed to be addressed. Gotec Group was looking for a reliable provider capable of overseeing multiple areas simultaneously while also providing IT consulting. Thanks to our broad portfolio of services and solutions, we were able to meet these needs and consult on individual parts. Additionally, our similar geographical coverage also contributed to Gotec choosing us as a partner.

In terms of infrastructure projects, it is one of our first customers to migrate the majority of its infrastructure to the cloud.

Project implementation process

The migration to the cloud was conducted in several phases. The customer chose the company headquarters in Wülfrath, Germany, as the pilot office for the complete migration. The US and China offices followed next.

The migration of the German headquarters was preceded by an audit of the internal IT environment, which included summarizing the various individual infrastructure elements, backup processes, disaster recovery plan, network infrastructure, monitoring, applications, databases, security systems, and existing cloud solutions. This was followed by a comprehensive analysis of the customer’s IT environment and its readiness for cloud migration.

Based on the findings, we developed a solution design and a detailed migration plan to the AZURE cloud environment. After completing the preparatory phase regarding their existing infrastructure, the actual migration began.

A similar approach was applied to the migration of the IT environment of the US branch. An interesting aspect of the project that involved the Chinese branch was the creation of Microsoft Azure, which is isolated from the rest of the Microsoft Azure infrastructure.

All tasks of the preparatory phase as well as the migration itself were conducted remotely.

The project of migrating the IT infrastructure to the cloud was also noteworthy as it brought together know-how from our multiple specialist departments. The joint efforts of our colleagues from the Infrastructure department (servers, Active Directory, synchronization of local solutions to the cloud), Security (Fortinet Firewall, VPN access, access management), Networking (infrastructure segmentation and communication), Outsourcing, and the Smart Solution division led to the successful completion of the project and satisfaction of our client.

As part of the security solutions for the AZURE CLOUD, we offered the customer the option to classify and protect all documents and emails using content labelling. In addition to the migration, we also assist Gotec Group in developing their own ERP applications.

Results and benefits

simplified infrastructure management

better overview of resources in use

enhanced security

access to modern services

Customer Profile

The GOTEC Group is the world’s leading specialist for surface treatments and application of bonding agents for rubber-metal and plastic parts. It is an important partner for the international automotive industry. Presently, the company has 17 offices in 12 different countries across Europe, America, with headquarters in Wülfrath, Germany.

Technologies used

Microsoft Azure IaaS
Microsoft Azure China IaaS
Fortinet Firewall in Microsoft Azure

International engineering company HD Hyundai Infracore Europe has a new warehouse with state-of-the-art network infrastructure

International engineering company HD Hyundai Infracore Europe has a new warehouse with state-of-the-art network infrastructure

I would like to thank Soitron for the excellent, professional, and, most importantly, successful cooperation on the project in Boom, Belgium. In this location we have a new warehouse that required various tasks, including the installation and commissioning of the internal network, infrastructure design, and hardware supply. Communication with Soitron IT specialists was professional, fast and friendly. They had the whole project well thought out and prepared. They successfully completed all the required work and were willing to help with things above and beyond their duties, which I greatly appreciate. 

Milan Paták, IT Operation Specialist 

Background

The European branch of HD Hyundai Infracore Europe s.r.o. oversaw the construction of a new warehouse in Boom, Belgium. As part of the project, they were looking for a reliable IT partner to deliver the network infrastructure. We were successful in the tender procedure, which made it possible for us to help them build a warehouse from scratch. We provided our technological and consulting services to the customer.

Project implementation process

At the beginning of the project, we developed the network infrastructure design and topology. With our extensive experience in similar projects, we were able to recommend the most optimal installation of switches, access points (APs), and cabling to the customer. The installation plan included a very detailed description of the component layout in a warehouse of approximately 25,000 square metres.

For the best possible Wi-Fi signal coverage, we proposed installing APs with directional antennas within the warehouse, which are specifically designed to cover narrow spaces between high racks. For open spaces such as offices we recommended standard APs.  We took the same careful approach when selecting switches to cover two server rooms and the entire warehouse.

We also integrated their automated Kardex Shuttle warehouse system into the warehouse spaces via the network infrastructure and developed an IP plan and network segmentation according to customer’s requirements.

We supplied the customer with both the infrastructure and terminal devices. We equipped the warehouse with barcode scanners and the offices with laptops.

In this international project, we also collaborated with other subcontractors. We communicated with a Belgian cabling company and the telecommunications company AT&T as the MPLS service provider. As part of consultations, we also helped the customer select a solution from an internet provider in Belgium.

Results and benefits

designing a reliable network infrastructure

help in building a new warehouse

supply of suitable hardware

provision of technology and consulting services

Customer Profile

HD Hyundai Infracore Europe s.r.o. is part of the global engineering brand HD Hyundai Infracore. The parent company is based in Korea. Over its many years of operation, it has established a strong position in all business areas of its specialisation, such as the manufacture of construction equipment, engines, accessories, and utility equipment. This international company has a network of local offices and warehouses all over the world.

Technologies used

Cisco technology, HPE server, Zebra barcode scanners, Dell notebooks

The manufacturing plant Brovedani Slovakia has acquired new infrastructure

The manufacturing plant Brovedani Slovakia has acquired new infrastructure

The Brovedani Slovakia plant is undergoing an important digital transformation including all production processes and the entire structure. That's why we needed to update our infrastructure and integrate digital technology into all our processes to implement projects safely and achieve the right performance. As our professional partner, Soitron guided us through all phases of the project with expertise and precision. With SLA Gold, Soitron continues to have everything under control on a day-to-day basis. 

Edoardo Mascherin, Lean Manufacturing & Industry 4.0 manager 

Background

We helped Brovedani Slovakia to build a new virtualization infrastructure, which ensures the operation of all systems of the manufacturing plant. As the original systems were obsolete, both in terms of hardware and software, they had to be replaced with a newer solution. The modernization was brought about by a complete replacement of both hardware and software components of the virtualization platform.

Project implementation process

During the presales phase, we presented the proposed solution to the customer and explained its advantages. Throughout the process, Soitron provided expert consultations, as part of which we discussed the complete implementation step by step. The main challenge for us was the implementation part – important components of the new solution had to run on one of the original servers after implementation, while the server was simultaneously used for production applications until the last moment.

In addition, we had to be careful not to disrupt production, which was running 24×7. Our team carried out the replacement without any downtime. The project also included a partial extension of the network infrastructure. In conjunction with/Together with this project there was also another one – backing up the new virtual environment.

Results and benefits

a more modern and reliable solution

more efficient system operation

Gold SLA agreement

Customer Profile

Brovedani Slovakia s.r.o. is part of the Brovedani Group SpA based in Italy. In Slovakia, it specializes in mass production of metal micro-components for the automotive industry. It is one of the most important employers in the Galanta area.

Technologies used

HPE ProLiant servers, VMware vSphere virtualization platform, VSAN solution from VMware

Firewalls by Palo Alto Networks protect IT and OT networks in a manufacturing company

Firewalls by Palo Alto Networks protect IT and OT networks in a manufacturing company

Thanks to the expertise and experience of our technicians, the deployment of the new solution was carried out quickly and seamlessly, without affecting the normal 24/7 production operations. 

Soitron team 

Background

A Slovak manufacturing company with 1,500 employees, part of an international group, was looking for a suitable firewall solution. One of the essential requirements for the chosen solution was to meet a number of next-gen functionalities. The legacy solution was outdated and not compliant with the current requirements. The client requested application-level visibility and a higher level of security.

Project Progress

We proposed a new technological solution based on Palo Alto Networks firewalls. The solution we provided to the client was the current market-leader in terms of firewall security. One of the main requirements of the client was to have separate firewalls for IT and OT networks, i.e. to have a separate network environment for managing industrial production technology elements.

This made it possible to achieve an even higher level of security against potential cyber threats and to make the environment more resilient against outages. The challenge was not to disrupt production processes.

Results and Benefits

high level of security

greater application-level visibility

more resilient environment against potential cyber threats

replacement of traditional firewalls with next generation firewalls

Technologies Used

Firewall Palo Alto Networks

Remoska launches a revolution in manufacturing with modern IT systems

Remoska launches a revolution in manufacturing with modern IT systems from Soitron

Our vision was to build a plant with world-class industrial automation technologies that is fully digitalized and well-secured against cyber threats, and potential technological failures that could disrupt production continuity. 

Petr Vaněček, CEO and Managing Director 

Background

The traditional Czech brand Remoska needed to build a new greenfield plant to expand their capacity and maintain competitiveness. The intention of the company’s management was to use cutting-edge technologies for industrial automation, robotization and digitalization in the new factory. Remoska decided to select through a selection procedure a technological partner for the architectural design, project management, and the implementation of information, communication, and software technologies. Strong security was one of the key requirements.

Project implementation

Soitron experts designed a modern and secure technology architecture to keep costs under control, including virtualization, the use of existing servers, and the integration of Software as a Service (SaaS) services, such as Microsoft 365.

The digitalization included building a network communication infrastructure, establishing an on-premise data centre with cloud integration, deployment of energy monitoring (IoT), implementation of cyber security measures, implementation of IP telephony, coordination and integration of systems such as ERP, MES (Manufacturing Execution System), warehouse management, and attendance.

Results and benefits

increasing competitiveness, sustaining production in Europe

process improvement, better production planning and streamlining

high security and minimization of downtime risks

energy consumption optimisation

Soitron was responsible for integrating and aligning all systems and technologies

Customer profile

Remoska s.r.o. is a traditional Czech producer of quality kitchenware with more than 65 years of tradition. It produced its first baking pan as early as 1957. Later, production expanded to include a new line of pots, pans, kitchen accessories, stainless steel cookware and electrical dishes. Today, Remoska is a renowned brand that offers new trends in modern cooking. In Kopřivnica, it built a new production plant with top technology. A new division of the company – EFC Design, dealing with OEM production, was also created. They organize their own cooking school in the professionally equipped culinary centre.

Technologies used

Cisco HyperFlex, Cisco UCS, HyperFlex Data Platform, Cisco ISE, VMware vSphere, Microsoft 365, Azure AD Premium, LoRaWAN

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Logmanager simplifies the management of IT systems and enhances security at inventec

Logmanager simplifies the management of IT systems and enhances security at Inventec

Logmanager was the first product based on SIEM that we implemented in our company. Thanks to SOITRON, the implementation was easy and directly focused on each requirement. We were very satisfied. 

Jiří Tomaštík, IT Netwok Engineer Supervisor 

Background

Inventec was looking for a solution that would help them comply with the Cybersecurity Act (CSA). They have achieved that by deploying Logmanager – a product that helps obliged entities to meet their obligations under the CSA.

Project implementation

The project started with a consultation where we, together with the customer, specified the list of devices to collect logs from. In the next step, we classified these logs, and, for any device not natively supported by Logmanager, we created a parser (i.e. a code that extracts interesting parts of the log and stores them under a specific name in a database). With such normalized data, we generated views for interesting logs. For specific situations that could potentially arise, we created custom email alerts.

This platform enables much earlier detection and responses to any network problems or vulnerabilities. Notifications can alert the customer if someone unauthorized is trying to log into their key server.

We deployed Logmanager in the customer’s two datacentres. The project is continuing with the deployment of another Logmanager in the OT environment, where it will be used to collect production data.

Results and benefits

easier IT system management

comprehensive view of the status of all parts of the network

incident alerting and advanced reporting

an intuitive user interface

compliance with the legislative requirements of the CSA

Customer profile

Inventec (Czech) s.r.o. is a member of the Inventec Corporation, which is based in Taiwan. Inventec manufactures and develops electronics and information technology products. The company has manufacturing facilities and innovation centres in several countries. Their operations in the Czech Republic are dedicated to the production of computer servers.

Technologies used

Logmanager was developed as a centralized log management system, providing an easy way of viewing all machine-generated data in an organization. In the first step, Logmanager collects, unifies, and provides long-term storage of event logs and records from active network elements, security devices, operating systems, and application software. It then stores the collected data in near real-time in a well-defined and powerful database that IT security professionals can access through predefined dashboards and structured or full-text queries with results displayed in a graphic format. Logmanager also provides basic SIEM functions, such as alerts with limits and simple correlations.

An industrial IoT solution enables Linet to prevent accidents and production downtimes

An industrial IoT solution enables Linet to prevent accidents and production downtimes

Linet is one of the iconic brands of Czech industry and a leading European hospital and nursing bed manufacturer. The transport of the abrasive medium in the machine causes significant wear and tear to the machine parts. Linet was confronted with occasional failures in the abrasive transport equipment caused by malfunctioning motors.
Case study was published 30.11.2022

REQUIREMENTS

  • prevent production downtimes and damage to a blasting machine
  • prevent the blasting machine from being buried in abrasive medium
  • reduce service costs
  • extend life and preserve investments into production machines
  • create a simple yet fully functional system for switching the machine off when a malfunction is indicated

SOLUTION

  • install sensors to shafts and bearings to measure temperature and speed
  • design and deploy analytical software
  • configure the machine shutdown sequence

RESULTS AND BENEFITS

an automatic machine shutdown when a fault in the abrasive medium transport system is detected

reduced repair time

the prediction of probable bearing failure

the elimination of damage to equipment

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The new headquarters cannot do without first-class network connectivity

The new Doosan Bobcat EMEA headquarters cannot do without first-class network connectivity

The world’s largest manufacturer of compact loaders and excavators, Doosan Bobcat, is a household name in the industry. Over some time, the company has built a unique campus in Dobříš, bringing to one place a manufacturing facility, a development and innovation centre, a dealer training centre (the Bobcat Institute), and the most recent addition – its EMEA regional headquarters. In 2017, its EMEA headquarters were relocated from Waterloo in Belgium to Dobříš in the Czech Republic, which marked one of the most important milestones in the company’s history. Soitron had been involved in this.
Case study was published 11.08.2021

REQUIREMENTS

  • Design and implement a LAN network infrastructure in the newly-built headquarters of Doosan Bobcat, a manufacturer of compact construction machines
  • Connect the headquarters with existing buildings
  • Build Wi-Fi connectivity for the entire campus
  • Equip 26 conference rooms and the auditorium in the new headquarters building with state-of-the-art audio and video equipment a room booking system

SOLUTION

  • Connect the new headquarters with 10 GB fibre optic routes
  • Design and implement a LAN infrastructure based on Cisco technologies with 720 gigabit ports with PoE support
  • Provide Wi-Fi signal coverage for the building and the entire campus
  • Deploy Cisco Prime Infrastructure software for more effective infrastructure management

RESULTS AND BENEFITS

The headquarters is equipped with modern, fast, and reliable network connectivity.

There are highly presentable and modern meeting rooms.

There is a simplified network management.

The infrastructure has been put in place to ensure teleconferencing and the high productivity of people in their day-to-day work.

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How the internet of things helps farmers?

HOW THE INTERNET OF THINGS HELPS FARMERS?

As the Internet of Things (IoT) trend continues to grow, it does not shy away from the agricultural sector either. An exemplary case is the Agrodružstvo Miroslav farming cooperative in Moravia, Czech Republic. Soitron has built a smart sensor-based private IoT network on the farm. These sensors allow farmers to monitor and easily see the costs of water and electricity consumption in individual barns.
Case study was published 04.02.2021

IoT at farm

REQUIREMENTS

  • Uncover the root cause of why milk cooling costs are so high
  • Find out the real production costs and identify possible savings
  • Reduce operating costs, which are reflected in the price of one litre of milk and one kg of meat

SOLUTION

  • An IoT solution for efficient production management
  • Sensors for optimising electric power consumption
  • Sensor installation without the necessity to install new cabling
  • Data collection, monitoring, and evaluation

RESULTS AND BENEFITS

Optimised energy consumption in milk and meat production

Reduced cost of milk cooling: modification of power, water and gas consumption, temperature, ventilation, and lighting conditions in cattle barns

Eliminated risk of exceeding the maximum electricity consumption

Smart industrial rail guided vehicles need a reliable communications network

SMART INDUSTRIAL RAIL GUIDED VEHICLES NEED A RELIABLE COMMUNICATIONS NETWORK

What do industrial enterprises need to operate efficiently and without unnecessary downtime? Undoubtedly, many managers would say reliable machines, timely supplies of raw materials and energies, and skilled labour. Probably, only a few would highlight a communication system used for the transportation of pallets loaded with goods from an automatic packaging line to a warehouse. However, the example of Mondi SCP – a pulp and paper producer from Ružomberok, Slovakia, shows how important role communication technologies play not only in people’s lives, but also in manufacturing enterprises.
Case study was published 25.02.2019

Requirements

  • Replace an existing outdated communication system of the automated finished product warehouse for a more innovative technology
  • Eliminate downtime in the manufacturing process
  • Improve availability and stability of the pallet transport system
  • Comply with the highest quality and safety standards
  • Streamline and simplify difficult maintenance

Solution

  • Design a new WiFi-based communication system solution
  • Replace ProfiBus with ProfiNet communication protocol
  • Secure and encrypted protocol
  • PRP (Parallel Redundancy Protocol) in a wireless environment
  • Wireless Access Points integrated into the existing wireless environment
  • Cisco industrial-grade networking components

Outcomes

Uninterrupted passage across the entire wireless network

Secured and encrypted wireless communication

Effective system diagnostics

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