PART 01 Project Background

With the advancement of smart manufacturing, digital construction in the tobacco industry has been steadily promoted, bringing higher requirements for the stability and reliability of production systems. As one of the major backbone enterprises affiliated with China National Tobacco Corporation, this cigarette factory runs a large-scale logistics system that undertakes core business operations of raw material warehouses, auxiliary material warehouses and finished product warehouses, which is critical to ensuring smooth production workflows. Faced with increasingly complex information systems, the original operation and maintenance (O&M) work is challenged by the following issues:

• High system complexity and fragmented monitoring：The environment is a heterogeneous architecture including Siemens PLCs, stackers, VMware virtualization platforms, Oracle and MySQL databases, leading to extremely difficult management.
• Monitoring blind spots for industrial equipment：Traditional monitoring methods fail to capture the real-time status of equipment such as AGVs and industrial firewalls.
• Invisible assets and operating status：There is no unified health view covering computer rooms, networks and business systems, making it hard for O&M staff to get a clear picture of the overall operation.
• Passive fault response and hidden risks hard to detect：Fault location relies heavily on manual inspection. Once a malfunction occurs, it is difficult to identify and resolve problems promptly, which seriously disrupts production continuity.

To address the above challenges, the client plans to build a unified and sustainable intelligent O&M monitoring platform. It aims to improve O&M efficiency, cut O&M costs, guarantee business continuity and drive the sound development of digital construction.

PART 02 Project Solution

To ensure non-stop operation of production systems, realize visualized and manageable full assets, and elevate O&M automation capability, the cigarette factory launched the construction of an end-to-end integrated O&M monitoring platform. A unified monitoring system has been built to cover IT infrastructure, industrial electric control, network security and business components.

01 Full Coverage of Monitored Objects

The Lerwee project team formulated detailed monitoring policies for various targets to achieve comprehensive coverage of all IT resources.

• Physical servers and terminal computers: Monitored key metrics include power status, CPU temperature, device temperature, fan operation, physical disk capacity, RAID status, memory usage, network adapter status, network traffic and log error alerts.
• Operating systems: Real-time monitoring is available for both Linux and Windows systems, covering disk capacity, CPU utilization, memory usage, disk I/O, network traffic, designated processes and services, as well as log error alerts.
• Databases: It supports monitoring for Oracle, Redis, MySQL and other databases, including port status, tablespace usage, table lock information, concurrent connections and backup status.
• Middleware: Monitoring focuses on Tomcat metrics such as thread count, request volume, response time and memory consumption, as well as the accessibility of web services.
• Network and security devices: Comprehensive monitoring is applied to Huawei switches, Winicssec unified security management platforms, industrial firewalls, traffic monitoring and audit systems, industrial interconnection firewalls, APs and AGVs. Monitored items include power status, temperature, voltage, fan speed, packet loss rate, device online status, port connection status, traffic volume, network latency, CPU utilization and memory utilization.
• Application components: The platform monitors the accessibility of website homepages via URLs, as well as processes and ports of other application components.
• Underlying electric control equipment: The monitoring scope also includes the online status of Siemens PLCs, code scanners, Danfoss FC360 inverters, stackers, LED screens and optoelectronic devices.
• VMware vSphere: Relevant metrics such as CPU utilization, memory usage, remaining disk capacity and network traffic are fully monitored.

In addition, Lerwee Monitoring is equipped with an automatic inspection function to resolve the low efficiency of manual patrol work.

02 Intelligent Alerting

Lerwee Monitoring delivers an intelligent alert system to unify the management of all alarms. Alerts are pushed via WeCom, ensuring that anomalies are delivered to relevant personnel in a timely manner.

O&M staff can flexibly customize monitoring thresholds and alert triggers according to actual business scenarios and equipment operating conditions to meet diverse O&M requirements.

Once real-time metrics exceed preset thresholds or abnormal operations are detected, the system will trigger alerts automatically. This greatly accelerates fault response and effectively prevents production interruptions caused by equipment or system failures.

03 Visualized Management

The platform also features large-screen display and customizable monitoring views, including core network topology, computer room cabinet visualization, database health dashboard and operating system performance dashboard. With intuitive visualized interfaces, O&M staff can grasp the status of all global resources at a glance and greatly reduce the complexity of daily inspection work.

PART 03 Client Benefits

01 Remarkably Improved O&M Efficiency

The full-stack monitoring and real-time alert functions of Lerwee Monitoring have significantly boosted the productivity of the factory’s O&M team. The traditional inefficient manual inspection mode has been completely replaced. The overall O&M efficiency has increased by 10 times after the platform deployment.

02 Greatly Reduced O&M Costs

The adoption of automatic monitoring and intelligent alerts minimizes manual intervention and substantially cuts labor costs. The platform enables predictive maintenance and reduces business losses caused by equipment failures. The total O&M cost of the enterprise has decreased by more than 50%.

03 Guaranteed Business Continuity

Any disruption in the production process of the tobacco industry may lead to huge economic losses. Featuring real-time monitoring and rapid fault location, Lerwee Monitoring shortens fault recovery time to the maximum extent, minimizes impacts on front-end business and ensures efficient and stable production operations.

Summary

Lerwee Monitoring plays a vital role in the O&M management of this cigarette factory. With full-range monitored objects, well-designed architecture, intelligent alert mechanism and intuitive visualized management, it provides all-round protection for the factory’s information systems.

For manufacturing scenarios, the platform brings tangible benefits including higher O&M efficiency, lower O&M costs, optimized management of digital resources and reliable business continuity.

The free version of Lerwee Intelligent O&M Agent is now available on Lerwee Community. Welcome to download and experience it.