Facts on Autonomous Factory

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Facts on Autonomous Factory

Factory of Future & Industry 4.0

Forthcoming Industrial Revolution | Factory of Future

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Industry 4.0 Modernization

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■ Modernization refers to a model of a progressive transition from a traditional to a modern Industry.

■ Industry Modernization is not a new concept or process, which has emerged very recently. It is a process that brings desired types of changes in an industrial organization by value addition.

■ It is a process of transformation of an enterprise from its backward framework to a forward-looking, progressing & prospering structural build-up.

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Key factors which facilitated & accelerated the process of industry modernization are:

■ 1. Achievements in the field of science and technology

■ 2. Growth of industrialization

■ 3. Rapid urbanization

■ 4. Rationalization of social life and emergence of a rational outlook in every walk of life.

■ 5. The rapid development of mass phenomena like mass production, mass communication, & mass education.

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■ Industry 4.0 is the way forward for manufacturing enterprises looking to modernize their businesses and technology.

■ Following are the 4 Stages of Industry Modernization as an evolution or a maturity model.

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■ The first stage is visibility into what is happening on the shop floor – an initial point of the industry 4.0 journey for factories with no closed-loop system in place for ongoing feedback. At this stage, the shop floor is integrated with other business functions by an information flow.

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■ After establishing the awareness of what is happening, the next question is why? Answering this question helps enterprises to understand the root cause behind critical incidents happening on the shop floor. We can use this RCA, to deduce the reasons behind events and create prediction models to identify similar problems before they occur.

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■ Next to what and why are the how and what-if questions. Performing simulations can answer questions about a system’s state of operation under different operating conditions. Any indications of a breakdown predicted in the virtual system can be identified to take timely action long before the physical system actually breakdowns.

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■ As a concept of Dark Factory, the ideal Industry 4.0 system needs no human intervention; can answer a range of what, why, and how questions; and responds proactively. Such an autonomous system leverages emerging technologies, such as AI/ML to enable the progressive transition from automatic operations to autonomous operations.

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Industry 4.0 Operational Excellence

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■ A Big Question! More precisely the 3 Questions!

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■ 1. Relevant to each other?

■ 2. or Competent to each other?

■ 3. or Complement each other?

■ Truth is that Operational Excellence is a mandatory prerequisite to cultivating the benefits of Digital Transformation.

■ Interestingly operational excellence is equally important in the "current state" of business. We cannot avoid it in any state (As-Is or To-Be).

■ Given that, whatever would be the future state of our transformed business, we must manage it in the most efficient & optimized way.

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■ 1. Optimized Efforts

■ 2. Optimized Resources

■ 3. Optimized Quality

■ 4. Optimized Technology

■ 5. Optimized Process

■ 6. Optimized Time

■ 7. Optimized Budget

In this way, we can say that not only Operational Excellence is a Catalyst to Digital Transformation, but it is a mandatory prerequisite to realize Digital Transformation.

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■ Whereas, Continuous Improvement is defined as the ongoing effort to improve an organization’s processes, products, or services, taking place incrementally over time rather than through some revolutionary innovation or step-change in performance.

■ On the other hand, Operational excellence is considered as a mindset that supports specific principles & tools to create sustainable improvement within an organization & these principles & tools primarily referring to Operational Excellence are Lean, Six Sigma, Kaizen & Agile.

■ As we all can observe that current pandemic has significantly impacted the operational practices of manufacturing organizations, driving companies to accelerate their digital transformation journeys to respond in real-time to these abrupt market changes & become more agile, productive & operationally resilient.

■ Manufacturers Organizations must find a way to achieve Operational Excellence by continuing to accelerate their digital transformation, leveraging a common digital thread from engineering to operations that uses performance intelligence to improve agility, reliability & efficiency by building operational resilience and sustainability.

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THE INDUSTRY FOUR????????? ??????????????

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Industry 4.0 Way Forward for Autonomous Factory

■ The Dark Factory is one of the most talked loudly topics of “Industry 4.0”. Dark Factory is a philosophy, not a specific process. The phrase Dark Factory explains an industrial location that is entirely automatic so that manufacturing takes place without direct human involvement at the manufacturing site.

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■ An automatic factory is a place where raw materials enter, and finished products leave with little or no human intervention. The word “Dark Factory” describes an industrial production site that is fully automated, so that production takes place without direct human intervention at the production site itself.

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■ The ghost of the dark factory is haunting industrialized countries. It is dark because there aren’t any people in it and no need to turn on the lights. Machines will do all the work. If this vision were to become reality, it would challenge the very foundations of our societies.

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■ The phrase “Dark Factory” indicates the fact that a manufacturing facility in which no people are employed who require light for their work could theoretically be operated without lighting, i.e., in the dark. This is known as “Lights Out Manufacturing”. Behind this is the idea that a fully automated production can take place purely by the implementation of emerging technologies e.g., Cloud, AI, and Digital Twin.

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Autonomous Factory is about the Rise of Machines on the shop floor.

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■ Dark Factories are fully automated and require no human presence on-site. The whole production process – from the delivery of the raw materials at the factory to the delivery of the finished products – is carried out completely by automatically controlled machines.

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■ Historically machines have created far more jobs than they have replaced, but this time will be different. With the advent of Emerging Technologies, machines are swiftly getting better at performing both manual and cognitive tasks without much human intervention. In the past machines have augmented human labor but now, they are going to replace it.

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■ Lights-out manufacturing may increase productivity and lower upkeep costs. Companies incorporating lights-out methodologies into floor plans only need to consider robotic workers, which minimize space and climate-control requirements.

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■ However, human is still required for tasks such as inspection and quality assurance. Even with the best possible automation, a variety of tasks currently still demand human involvement or at least the likelihood to do so in some cases, particularly in quality inspection and maintenance operations. Consequently, the operation of some of these manufacturing works in fully automated mode is only temporary, for example in certain shifts.

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THE INDUSTRY FOUR?▌ www.theindustryfour.org

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THE INDUSTRY FOUR

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▌?www.theindustryfour.org

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A knowledge artifact by -?KULDEEP KAUSHIK

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