NETTUNO | Intelligent Operational Management Platform
The Nettuno project was created in response to the Call for the selection of innovation, industrial research, and experimental development projects on Industry 4.0 enabling technologies issued by the Competence Center Meditech.
The project partnership involves collaboration between Netgroup SPA and Unilever with the participation of CeSMA and Stress Value.
The identified needs are:
- digitalize quality control of the Cornetto Algida production lines;
- manage maintenance of all machinery and equipment at the Unilever plant in Caivano in an integrated and preventive manner.
The proposed solution integrates advanced artificial intelligence and IoT technologies, leveraging proven experience in other production sectors.
We have applied our Smart Industry expertise to refine AI and Visual Recognition techniques in the Unilever context, specifically for detecting defects in Cornetto Algida and for maintaining production line equipment and machinery.
The adoption of Visual Recognition systems reduces human intervention along the production line for defect control, increasing human capital efficiency and upskilling the employed resources.
Furthermore, the digitalization of maintenance processes enables more structured management of routine and extraordinary interventions, applying prognostic algorithms to improve production line efficiency.
Our Smart Industry platform offers an innovative technological solution through two dedicated application modules: the maintenance module (AMS) and the defect inspection module (DIS). These modules interface effectively with field devices for data and image acquisition, facilitating the analysis and processing of automated processes.
AMS Module – Advanced Maintenance System
The AMS Module is a powerful CMMS (Computerized Maintenance Management System) application designed to plan and track machinery and equipment maintenance processes, using both predictive and scheduled logic.
Main features of the AMS module:
- Master data management of production lines and equipment: organizes and maintains updated data related to production lines and equipment;
- Analysis of machinery efficiency status;
- Monitoring of machine operating times and modes;
- Reporting of issues requiring extraordinary maintenance interventions: promptly identifies problems requiring immediate attention;
- Management of maintenance interventions;
- General reporting.
DIS Module – Defect Inspection System
The DIS Module – Defect Inspection System uses advanced artificial intelligence algorithms to analyze frames captured by cameras along production lines. This module is specifically designed to recognize defects and non-conformities in Cornetto Algida wafers.
Main Benefits of the DIS Module:
- Simplification of quality control activities;
- Reduction of customer complaints;
- Reduction of costs related to production waste.
With the integration of the AMS and DIS modules, our Smart Industry platform represents a complete and advanced solution for predictive and scheduled maintenance, as well as defect inspection, improving operational efficiency and reducing overall costs.
The Nettuno Project has brought significant benefits to the production processes of the Unilever plant in Caivano, both from an economic and technological perspective. Thanks to the implementation of the AMS and DIS Modules, important objectives have been achieved that have improved production efficiency and quality.
The AMS Module has contributed significantly to optimizing maintenance management, achieving the following results:
- Reduction of machine downtime: decreased machine inactivity times, improving production continuity;
- Cyclical scheduling of routine maintenance: efficient planning of maintenance interventions, ensuring regularity and timeliness of operations;
- Automatic management of deadlines: automation of maintenance deadlines, reducing the risk of human errors and oversights;
- Reduction of intervention times: optimization of the time required to perform maintenance interventions, increasing productivity;
- Personnel upskilling: enhancement of personnel skills through the adoption of advanced technologies.
The DIS Module has revolutionized inspection and quality control processes, achieving the following objectives:
- Cone verification through visual inspection;
- Reduction of human intervention;
- Automation of wafer/sleeve coupling processes;
- Limitation of waste;
- Reduction of consumer complaints: decrease in consumer complaints thanks to more rigorous and reliable quality control.
Thanks to the Nettuno project and the adoption of the AMS and DIS modules, the Unilever plant in Caivano has been able to significantly improve operational efficiency, reduce costs, and increase product quality. These results demonstrate the effectiveness of advanced technological solutions in the industrial sector, bringing concrete and lasting benefits.
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