Factories of the Future - I

As COVID-19 necessitates greater agility and speed, companies across the globe have started engaging in smart manufacturing ecosystems to drive results in the next normal.?to accelerate digital transformation. The term “smart factory” was initially coined at The Hanover Fair in 2011, although the ideas and practices known as smart manufacturing today have been developing for decades. ?

Manufacturing is the creation of a wide range of goods based on human labor and machine utilization. Connectivity within the manufacturing process is not new.?Contemporary trends such as the rise of the fourth industrial revolution, and the convergence of the digital and physical worlds [information technology (IT) and operations technology (OT)]— have made the transformation of the supply chain increasingly possible.?The proliferation of smart things has reached critical mass as the industry has been implementing various digital technologies that have gradually reduced human participation in production processes. ?

Digitalizing an industry brings with it numerous benefits that affect the planning, quality and development of products and logistics in the supply chain. Here are the most important competitive advantages:?

• Speed and flexibility in the face of the unforeseen.?
• Real-time digital and physical connection through sensors and Iot devices.?
• Resource optimization.?
• Reliability of stored data.?
• Two-way data flow between elements.?
• Tracking products across value chain
• Real-time data visibility
• Increased Knowledge Sharing and Collaborative Working

Smart Factory Components??

1. Modularity -?Modularity is the capability of system components to be separated and combined easily and quickly. System components are loosely coupled and can be reconfigured on a plug-and-play principle to allow the production system to respond to changing customer requirements and to overcome internal system malfunctions.?
2. Interoperability?- The ability to share technical information within system components, including products, and to the ability to share business information between manufacturing enterprises and customers.?
3. Decentralization -?The key to decentralization is that system elements – modules, material handling, products, etc. – will make decisions on their own, unsubordinated to a control unit, in real time and without violating the overall organizational goal.?
4. The Power of Prediction - One of the greatest benefits of the IoT is how it can dramatically improve operating efficiencies. If a machine goes down, for example, connected sensors can automatically pinpoint where the issue is occurring and trigger a service request. More importantly, IoT can also help a manufacturer predict when a machine will breakdown or enter a dangerous operating condition before it ever happens.?
5. Strategize, before you digitize?- Companies should have a strategy in place for understanding how they would differentiate in the market. Simply copying a strategy that another organization has implemented will seldom yield results. If it is difficult to start from nothing, companies should look at collaboration.?One means of kickstarting new industrial IoT projects is to follow some best-practice recommendations which help to deliver a structured and considered approach to implementation.?
6. Real-time capabilities - the data angle - Smart factories are as much about generating data and analytics – including predictive workflows – as they are about making physical goods. As we begin to see the impact of the constant stream of real-time data that is used to connect operations and production systems, we can gain end-to-end visibility for process improvements. ?
7. Teamwork is key - Digital transformation is as much about people as it is technology, and effective communication lies at the heart of any successful business change. People are likely to have various levels of IT abilities, and this needs to be carefully considered when outlining the scope of activity and allocating responsibilities.?

Smart Factory Examples (Source)?

1. Siemens Electronics Works Amberg (EWA)?

The?Electronics Works Amberg (EWA)?is a Siemens facility that produces circuit boards, controllers, and other electrical devices. With 17 million components produced per year, the EWA utilizes an equally impressive level of technology.?For example, the facility's production equipment employs artificial intelligence in analyzing data picked up by sensors. This system uses an AI-based algorithm that automatically evaluates the quality of soldered portions of a circuit board.?

2. The Tesla Gigafactory, Berlin?

On its official website, Tesla mentions the use of a new dimension of casting systems and an efficient body shop, pushing forward the boundaries of vehicle safety. The Paint Shop introduces a new generation of color tone depth and complexity. ?

3. The Connected Factory, Bosch, Blaichach?

Implementing innovative technology of connected manufacturing, the company uses 20 tablets every day to track processes, inspect machines and check parts, data which is overlooked by 150 machine operators at the plant. Bosch’s performance tracker system detects cycle-time deviations of mere milliseconds, enabling operators to react quickly and intervene at the earliest stage possible.?

4. Micron Technology, Taichung (Source)?

To drive the next wave of productivity improvement, Micron’s high-volume advanced semiconductor memory manufacturing facility developed an integrated IoT and analytics platform. This ensures manufacturing anomalies can be identified in real time, while providing automated root-cause analysis to accelerate new product ramp-up by 20%, reduce unplanned downtime by 30% and improve labor productivity by 20%.?

5. Schneider Electric,?Lexington?

To maintain a business and technological edge, Schneider Electric’s more than 60-year-old facility has implemented 4IR technologies to achieve a complete end-to-end transformation of its operations from supplier to customer. This has improved customer satisfaction by 20%, demand forecast accuracy by 20%, and reduced energy costs by 26%.?

The same essential components that make up a traditional manufacturing plant apply to a smart factory as well. What makes a factory “smart” is its prominent level of digitalization in terms of the control of its machinery and production processes. It utilizes sensors, AI (artificial intelligence), ML (machine learning), and many other IIoT technologies to enable real-time data gathering, transfer, and analysis. The smart factory represents a leap forward from more traditional automation to a fully connected and flexible system setting a new trajectory for growth. ?

Sources - ?

1. https://www.nanowerk.com/smart/smart-factory.php?
2. https://www.weforum.org/agenda/2020/09/manufacturing-lighthouse-factories-innovation-4ir/?
3. https://blog.geekplus.com/company/news-center/3-key-elements-of-smart-factory ?