Modernizing a factory doesn’t have to feel like a massive undertaking. While operators often worry about integration with legacy systems or potential downtime, the path to real-time insights and improved efficiency can be simpler than expected. With Snap Signal from Banner Engineering, you can unlock actionable data from equipment already on your floor—empowering better decision-making without an overhaul.
Imagine turning decades-old machines into smart data sources with a plug-and-play solution. This guide walks you through five practical steps to modernize your factory, leveraging Snap Signal to enhance operations with minimal disruption.
In This Post
Identify actionable data within your machines. | Discover how Snap Signal unlocks data without disrupting operations. | Learn to enhance insights with additional sensors. | Simplify data collection using unified protocols. | Transform machine data into real-time decisions. | Additional resources
5-Step Guide to Factory Modernization
Factory modernization is simpler than ever. Snap Signal makes it possible to stay ahead of the competition without unnecessary complexity or downtime. The journey to a smarter factory starts now with these five steps.
Step 1: Discover Hidden Value in Your Machines
Legacy equipment often holds valuable data that goes unnoticed. For instance, sensors on a conveyor belt or tower lights on packaging machines can offer insights into performance or efficiency. Banner Engineering calls this “actionable data”—information that can drive operational improvements.
With Snap Signal, you can unlock this data and start tracking metrics like downtime trends or Overall Equipment Effectiveness (OEE) without re-engineering your system. This low-risk approach creates opportunities for continuous improvement by targeting underperforming areas.
Unlock hidden insights today. Contact our experts to learn more.
Step 2: Unlock Data Without Disrupting Operations
Accessing data from legacy systems used to require invasive changes or equipment upgrades. Snap Signal changes that by introducing a simple overlay network. By connecting a splitter to existing sensors, you can “listen in” on machine signals without interrupting their functionality.
For example, adding a splitter to a photoelectric sensor can let you monitor product counts or uptime while keeping the original control system untouched. This seamless integration minimizes downtime and maintains operational continuity.
For a deeper dive into how Snap Signal achieves this, read our detailed blog post, How to Collect Data from Existing Sensors & Control Systems | Meet Snap Signal by Banner.
Step 3: Expand Your Insights with New Sensors
Once you’ve unlocked existing data, adding new sensors can provide deeper visibility. For instance, vibration or temperature sensors can predict maintenance needs for motors and other critical equipment. Snap Signal makes integrating these sensors effortless, enhancing your overlay network with minimal configuration.
This approach is cost-effective and future-proof, allowing your factory to grow into a smarter, more efficient operation over time.
Curious about new sensor capabilities? Schedule your free consultation today.
Step 4: Simplify Data Collection with Unified Protocols
One of the biggest challenges of factory modernization is managing multiple communication protocols. Snap Signal simplifies this by converting diverse sensor outputs into a unified protocol. Using in-line converters, such as those in the Snap Signal portfolio, you can streamline data from analog signals to a centralized system, like a SCADA or cloud dashboard.
This unification eliminates the headaches of managing incompatible systems and creates a cohesive, scalable network for actionable insights.
To see Snap Signal in action, check out our video, How to Update your Industrial Maintenance Solutions with Remote Monitoring | Banner Snap Signal.
Step 5: Turn Data into Game-Changing Decisions
With your data unified and accessible, it’s time to put it to work. Real-world applications include:
- Monitoring raw material levels and automating refills to reduce waste.
- Tracking OEE to identify underperforming machines.
- Predicting maintenance needs using vibration and temperature data.
- Managing tank levels and dust collection systems with cloud-based alerts.
These capabilities transform machine data into actionable insights, empowering teams to make informed decisions and drive efficiency.
Why Modernization Has Never Been Easier
Gone are the days of costly overhauls to achieve smart factory capabilities. With Snap Signal from Banner Engineering, you can seamlessly unlock, enhance, and unify your data flow without disrupting existing operations. Start small by upgrading one machine or scale to a full-factory solution. Either way, Snap Signal offers the flexibility to meet your goals.
Additional Resources
- Shop Snap Signal By Banner
- Banner Engineering
- Blog Post: How to Collect Data from Existing Sensors & Control Systems | Meet Snap Signal by Banner.
- Video: How to Update your Industrial Maintenance Solutions with Remote Monitoring | Banner Snap Signal.
- Overall Equipment Effectiveness (OEE)
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