Discrete Manufacturing - Speed Management Controller
SMC: Intelligent Speed Control for Maximum Production Efficiency
Reduce downtime, boost throughput, and optimize material flow with Aleph’s Speed Management Controller—the AI solution that synchronizes your production lines like adaptive cruise control.
Speed Management Controller
What is SMC?
The Speed Management Controller (SMC) is a causal AI system that dynamically adjusts machine speeds in real time to prevent bottlenecks and maximize uptime.
Developed for Philip Morris International (PMI), SMC acts like "adaptive cruise control for production lines," ensuring optimal material flow across legacy and modern machines.
Developed for Philip Morris International (PMI), SMC acts like "adaptive cruise control for production lines," ensuring optimal material flow across legacy and modern machines.
How it works
Connect Machines
• Aleph FlexServer: Exposes data from legacy and modern machines via OPC UA, including buffer levels and speed setpoints.
• TMC Servers: Standardize communication across PMI’s heterogeneous machine park.
Learn & Adapt
• Causal AI: Analyzes historical stoppages and material flow to predict optimal speeds.
• Auto-Adjustments: Slows machines when buffers fill; speeds up when buffers deplete.
Optimize Production
• Just-in-Time Sync: Maintains tight coordination between upstream/downstream machines.
• Operator Trust: Aleph Visual dashboards show AI decisions with chain-of-thought explanations (e.g., "Slowed Machine B to prevent downstream blockage").
• Aleph FlexServer: Exposes data from legacy and modern machines via OPC UA, including buffer levels and speed setpoints.
• TMC Servers: Standardize communication across PMI’s heterogeneous machine park.
Learn & Adapt
• Causal AI: Analyzes historical stoppages and material flow to predict optimal speeds.
• Auto-Adjustments: Slows machines when buffers fill; speeds up when buffers deplete.
Optimize Production
• Just-in-Time Sync: Maintains tight coordination between upstream/downstream machines.
• Operator Trust: Aleph Visual dashboards show AI decisions with chain-of-thought explanations (e.g., "Slowed Machine B to prevent downstream blockage").
Why Choose SMC?
Legacy-Friendly
Works with 20-year-old machines via FlexServer. No hardware upgrades needed.
Proven at Scale
Deployed across PMI’s global factories with consistent results.
Transparent AI
Explains every decision, fostering operator trust.
Works with 20-year-old machines via FlexServer. No hardware upgrades needed.
Proven at Scale
Deployed across PMI’s global factories with consistent results.
Transparent AI
Explains every decision, fostering operator trust.
SMC Solution
SMC Deep Dive
Key Features
Configurable Priorities
Choose between maximizing uptime (MTBF) or throughput.
Choose between maximizing uptime (MTBF) or throughput.
Real-Time Adaptation: Adjusts speeds based on buffer levels, downtime patterns, and machine wear.
Minimal Data Requirements: Works with basic inputs (production counters, speed setpoints) for broader applicability.
OPC UA & TMC Integration: Seamlessly connects to machines via Aleph FlexServer and complies with Tobacco Machine Communication standards.
Steps to Implement SMC
Connect Machine
Step 1: Deploy Aleph FlexServer to expose machine data via OPC UA.
Step 2: Integrate TMC-compliant servers for standardized communication.
Outcome: Unified data layer for AI optimization.
Visualize & Validate
Step 1: Use Aleph Visual to monitor real-time speeds and buffer levels.
Step 2: Build trust with a Digital Twin comparing manual vs. SMC performance.
Outcome: Operator buy-in and actionable insights.
Optimize Production
Step 1: Launch SMC on your Edge device of choice to learn from operations.
Step 2: Configure priorities (MTBF or throughput) via intuitive interfaces.
✔️ Outcome: Self-learning system that improves over time.
✔️ Outcome: Self-learning system that improves over time.
Results at PMI
Challenges
Manual speed adjustments caused downtime in heat-not-burn (HTP) production lines.
Smaller buffers increased reliance on precise speed control.
Manual speed adjustments caused downtime in heat-not-burn (HTP) production lines.
Smaller buffers increased reliance on precise speed control.
Solution
Deployed SMC globally, integrating with TMC-standardized machines.
Outcome
Uptime Increase: Fewer stoppages from material shortages/blockages.
Scalable AI: Now applied to conventional tobacco and filter production.
Aleph connects to the world's most popular industrial data sources
Why Manufacturers Choose Aleph
Our clients' success is our top priority. Here's how Aleph has transformed their manufacturing with our technology solutions.
"We engaged with Aleph Digital Industry to create a robust, scalable, and adaptable edge solution to control machines exclusively through OPC UA."
"Aleph authored a rich OPC UA information model driving interoperability in the tobacco industry."
"Aleph Digital Industry brought new life to a very old machine!"