Controlling the curing phase of a precast element is a complex task – and slight variations in heat or climate can prolong or shorten the curing time. To minimize waste, capacity is sacrificed by adding safety margins by adding time to the curing process. Maturix monitors the maturity of any element in real-time, so the exact curing time can be predicted and your are guaranteed never to waste time on elements that are ready faster than expected – or throw away elements with a slow strength development due to (production) defects. The precise demolding time reduces waste by more than 35% while production capacity is increased by up to 15% (based on figures from current customers) – at the same time the risk of human errors is avoided.
Documenting quality is essential to improving processes and understanding your own production. Monitoring an element is a labour-intensive process, where the installation of the sensors, retrieving the data loggers, transferring the data to a computer and analysing the data takes the better part of a day. With Maturix as an integrated part of your processes, monitoring an element takes less than a minute per element. All data is transferred wirelessly and analysed automatically, giving you instant insight or alarms when concerns arise. You end up with top-rank documentation and essentially a better product for your customers.
Visibility in the Facility
The lack of visible indicators of the maturity development in the elements is one of the most difficult aspects of concrete manufacturing. This uncertainty can leave the workers on the factory floor in doubt when assessing if an element is ready to be removed from the tables or the prestressed wires can be cut. Maturix knows the exact maturity of an element and can predict the remaining curing time, which can be displayed on dashboards in each production environment. This allows the workers to see exactly when they can start the next step of the production without the risk of errors. Maturix creates incentive for the workforce, resulting in a self-initiating mentality in each worker.
Analysis & statistics
Optimization and efficiency is a daily headline in order to stay competitive. Maturix provides analysis and statistics about your facility and helps you optimize your production every day.
- Are you using too much heat or not enough?
- Could you improve your compounds to cure faster?
- Or should it be slower and cheaper?
Since monitoring occurs on a daily basis, see the results of your optimizations immediately. The level of production insight provided by Maturix also allows you to make the right decisions about labour shifts, capacity usage, planning and investments.
Maturix uses a patent pending installation process to ensure correct placement of the temperature sensor in the mold of the element. A wireless data logger sends the data to Maturix with no need for wifi or any connection to your network.
The data is received securely by the Maturix cloud and analysed right away. As soon as the data is analysed, all devices – both mobile, desktops and dashboards in the production environment – updates with the new results and predictions. As soon as an element reaches the target maturity or strength, the dashboards gives green light to remove the element and the data logger is made available for use in the facility again.
Elements selected for monitoring can be typed in manually – or imported directly from an ERP system in order to make daily monitoring run seamlessly.
By creating visibility into the curing process and making the workforce self-driven, we are able to increase the capacity of a facility of 15% while reducing waste by 35% (cf. current figures from our clients). This can be used to either increase manufacturing output or reduce costs of manufacturing while maintaining the same output. As a full-service solution Maturix offers everything required for monitoring an element. The cost of running Maturix typically represent less than 20% of the profitability obtained. ROI less than three months when fully implemented.