This wireless network is a WIN-win for production managers

WERMA’s novel wireless-based workshop and machine monitoring system, the andon light based WIN (Wireless Information Network) for workshop and workstation efficiency monitoring, is proving a big hit among lean production management and process improvement teams throughout UK industry.

The background to the product concept is home grown. Production engineers at WERMA’s own factory in Southern Germany were looking for ways to monitor machine efficiency and improve communications between manufacturing areas and service providers such as stores and maintenance.

They quickly realised that their own manufactured products – signal towers – already provided the most basic of efficiency monitoring parameters and by coupling these status lights to a wireless network, they could transfer information and calls for action around the facility virtually instantaneously.

As a result of this, a new product called WIN (Wireless Information Network) was developed to provide a simple, low-cost machine monitoring system based on andon lights. The in-house team subsequently developed a software application for WIN implementations that greatly simplifies the monitoring process and which is compatible with all major operating systems .

Essentially, a green light signifies that a machine is working and or available for work, whereas an amber light may mean that the machine is available but has reached the end of a cycle. A red light, however, would normally signify a serious error and disruption of production.

Different light colours can used as 'calls to action' to notify the appropriate department that intervention is necessary.  All of these status light changes are transmitted wirelessly to PCs where monitoring - aided by easy-to-follow visual displays - can be carried out to reduce the incidence of productivity losses and thus improve overall plant or machine utilisation efficiency.

No interference
Occasionally users may be concerned about the possibility of interference between the WIN wireless system and other wireless networks employed on site. The WERMA system uses the harmonised EU approved standard EN 300220 low frequency 868MHz band and can thus be used safely without any fear of interference, either with or from, other systems.

And it's easy to install
Users may be further reassured by the fact that a WIN system is very easy to install. Being a wireless based system, there is no need for any hard-wiring, trunking or additional works to the infrastructure in order to accommodate and operate the system.

Moreover, it can be retrofitted to existing WERMA KS71/70 signal towers or can simply be cabled up in parallel to an existing beacon or signal tower using the same output signals used to fire the existing signal tower installation.

Green light – I’m making money!
The very simplicity of the system will suit both the the small operator and the more complex multi-machine operator. Customers who have implemented WIN range from the single or small workshop machine operator, machine shops with up to 100+ machines in operation to vast retail warehouses where over 200 units have been installed in just one facility.


As one shrewd operator remarked to WERMA soon after the system had been installed at his facility: “I like to see a landscape of green lights out on the shopfloor – that way I have the feeling that we are making money.  Too many amber and red lights do not give me a good feeling.”