FOCUS ON DIGITALISATION sizes decrease , the expenditure for indirect processes takes the upper hand . They make up approximately 80 % of all processes . It is here that networked production has a role to play . If you can adapt the expenditure for indirect processes to the decreasing batch sizes , even batch size one becomes profitable once again ,” it added .
“ A smart factory is a digitised manufacturing facility that uses connected devices , machinery and production systems to continuously collect and share data . This data is then used to inform decisions to improve processes as well as address any issues that may arise . The smart manufacturing practices used by a smart factory are enabled by a variety of technologies including artificial intelligence ( AI ), big data analytics , cloud computing and the industrial Internet of Things ( IoT ),” explained TWI Global .
Smart factories connect the digital and physical worlds to monitor an entire production process , from supply chain management to manufacturing tools and even the work of individual operators on the shop floor . Fully integrated , collaborative manufacturing systems provide a range of benefits for operators , including allowing operations to be adaptable and readily optimised . machine in the entire manufacturing chain with IoT technology , the most proactive process is to systematically assess and identify the key areas that need an upgrade ,” cautioned HMK , automation architects .
“ As we are now on the cusp of the fourth industrial revolution , the innovative technology available can help future-proof factories and keep companies competitive as manufacturers around the world continue to embrace Industry 4.0 ,” it concluded .
With intelligent production control , sheet metal manufacturers can plan more efficiently as well as process orders more quickly and use more automated processes
Matthew Potts , project sales engineer at HMK described the foundations of a smart factory : “ It ’ s a harmonious communication between all the devices on the factory floor and the larger plant management to ensure that all the equipment is functioning as productively as possible .”
Industry 4.0 has been driving factories forward as the next industrial revolution promises to deliver a more responsive , adaptive and connected manufacturing line . From the Internet of Things to Artificial Intelligence , there are plenty of innovative aspects to be considered when upgrading to a smart factory .
The factory of the future operates autonomously and can run diagnostics required to identify and repair any malfunctions , without having to halt the entire production line . While upgrading to an Industry 4.0 led factory is a goal that many businesses are looking to attain , knowing what makes a smart factory and how to begin this transition isn ’ t always clear .
“ The introduction of Internet of Things devices to the factory is one of the most effective ways to begin the transformation into a smart factory . However , businesses need to be careful that they don ’ t rush into things headfirst . While it may be tempting to replace every
“ Focusing on the improving the key parts of the plant to their latest smart equivalents will help provide more in-depth layers of data . This can then be analysed to further identify which other parts of the manufacturing line should be upgraded next , as the factory continues to develop an automation infrastructure ,” it added .
Upgrading to a digital factory isn ’ t just the responsibility of the engineers on the factory floor , it needs the support of every part of a company ( from Board members to IT departments ). Industry 4.0 combines computers and industrialisation to create a smoother , more efficient production line and its benefits are going to be felt throughout the entire business .
“ This shift to a new industrial revolution also presents the opportunity to upskill everyone in the business . Those who are sceptical of adopting Industry 4.0 believe that the combination of Artificial Intelligence and automation will make the human aspect obsolete . However , it just means that those working in factories will have a different role to play . New technology still needs to be monitored and controlled and those who already have an expertise in helping complex tasks interface between hardware and software can turn their talents to new , exciting technologies ,” added HMK .
Digital transformation of industry
But how will smart manufacturing of the future work ?
“ In the future all machines , from the cutting machine to the welding robot , will be networked with one another . And every workpiece will have its own embedded system , storing various pieces of information for example of the customer , the workpiece ’ s desired configuration and its destination . It will be possible to uniquely identify and localise raw parts . Not only will they know the processing steps necessary , but these parts will also be networked with the production machines and will be able to communicate with one another to decide exactly when they are to undergo which production step ,” explained industrial research specialist , Fraunhofer-Gesellschaft .
“ In the future , the entire line will no longer stop when a given station fails . Instead , workpieces and machines will work together to replan the processing sequence . The result is a ‘ self-organising ’ adaptive manufacturing process that no longer requires constant human intervention , while remaining under human control .”
For smart production to run smoothly , added Fraunhofer , the humans and robots involved must continuously report exactly what they are doing and , for example , how long parts subject to wear have until they fail . Everything taking place in the real factory will be represented in parallel in the virtual factory . Experts refer to
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