Rockwell Automation: LeMatic Extends Value with IIoT Technology

Challenge

• Streamline proof-of-concept and machine development cycle – and improve customer data utilization, training and troubleshooting.

Solutions

• Emulate3D dynamic digital twin software
• ThingWorx IIoT platform
• Vuforia augmented reality (AR) solutions

Results

• Optimizes proof-of-concept machine testing with emulation leading to $1.8 million order. 
• Improves access to critical information with expanded analytics and intuitive dashboards.
• Streamlines worker training, thanks to powerful AR tools.
• Enables development of new software as a service (SaaS) bundle – Auto iNet – to support optimal operation throughout machine lifecycle.

Since 1972, LeMatic has prided itself on delivering not only leading bakery solutions – but outstanding customer service throughout the lifecycle of their equipment.

“Our specific expertise is in slicing and primary packaging,” said Richard Kirkland, president, LeMatic. “While most of our customers today are large, wholesale bakers, we are developing equipment to help the mid-size baker get the job done.”

From headquarters in Jackson, Michigan, the family-owned company supports an installed base extending across more than 40 countries. LeMatic is part of the Rockwell Automation® PartnerNetwork™ program.

Early Technology Adoption Drives Differentiation

LeMatic traces its success to its ability to quickly recognize evolving industry challenges. And to harness the power of new technologies to address customer needs.

“Historically, LeMatic has been an early adopter of Rockwell Automation solutions,” said Kirkland. “We embrace new technology and devote much of our product development to incorporating it into our offerings.”

One example: The company now offers remote connectivity on all major equipment to better serve customers.

“Instead of spending 15 hours on a plane, I completed a 10-minute repair over Ethernet on equipment in Eastern Europe,” said Chris Wojton, controls engineer, LeMatic. “We also used remote connectivity and on-machine cameras to commission a bagger line in South America when we were unable to travel due to the pandemic.”

Impactful Proof-of-Concept with Emulate3D Software

LeMatic is also incorporating new digital tools into its machine development process.

For instance, the company recently used Emulate3D® digital twin software to guide product design and customer engagement for a new machine, the P7 pattern former.

Built on a Rockwell Automation® control platform, the P7 is a complex machine designed to arrange single packaged products into larger package configurations. The products enter the machine via conveyor single file and are intercepted on the fly by an overhead robotic gantry system. The system orients the product and releases the grouping to a retractable conveyor, which drops the product onto a tray.

“With Emulate3D, we used our CAD models to create a simulation and demonstrate machine operation to our customer during proof-of-concept,” explained Glen Wheaton, electrical engineer, LeMatic. “We also loaded the machine program into a PC to emulate exactly how product would run online – before any PLCs were purchased.”

“The presale demonstrations of machine functionality ultimately led to a five-machine order valued at $1.8 million.”

New Insights. Better Troubleshooting. Faster Training.

LeMatic’s increasingly sophisticated machines produce a wealth of data. And in recent years, the company has keenly focused on helping customers capture and analyze that data to improve operations.

“Our goal is to help customers identify trends and use information to proactively address equipment issues,” Kirkland said. “Also, when machine data is shared at the corporate level, it can enable equipment and plant comparison – and help determine why something is working at one plant, but not another.”

To improve access to useful information, the company is developing Auto iNet, a customized software as a service (SaaS) solution based on the ThingWorx Industrial Internet of Things (IIoT) platform. The platform connects disparate data sources – and provides a single source to collect, aggregate and access operational data through intuitive dashboards and analytics.   

LeMatic also aims to digitalize all operation and maintenance manuals and incorporate augmented reality (AR) in the SaaS bundle, based on Vuforia® AR solutions.

“Oftentimes, operators stay on the job six months or less,” said Kirkland. “Initially, the AR portion of our solution will be used primarily for repetitive training – to relieve supervisors from constantly training new workers.”

But the company envisions the AR capabilities to quickly expand beyond training to support operation and maintenance activities.

Not Just IIoT-Ready. IIoT-Implemented.

For LeMatic, the adoption of IIoT technology across its portfolio is just one more way the company supports its best-in-class vision.

“We’re serious about IIoT technology,” Kirkland said. “We are quickly getting to the day when I can tell a baker our machines aren’t just IIoT-ready – they’re IIoT-implemented.”

This content was originally published on the Rockwell Automation website.