Contact us anytime to know more — Kuldeep K., Founder & CEO CISIN
The goal of the smart manufacturing industry, sometimes known as the "Smart Factory," is to streamline the manufacturing process.
The term "smart manufacturing" describes the use of computer modeling, controls, and other technologies to boost industrial productivity.
Making physical processes more adaptable is one method to fulfill the demands of a global market through smart manufacturing.
often known as smart manufacturing, is expected to be the following Industrial Revolution. Like many other recent developments, it all boils down to cloud technology connectivity and data contextualization innovations.
Let's examine the distinctions between smart factories and smart manufacturing by comprehending their concepts and connections.
Describe Smart Manufacturing
Despite the Fourth Industrial Revolution's existence for ten years, there is still no accepted definition of smart manufacturing.
The words "enablers" and "enhancers" were first used by ISO to describe the effects of smart manufacturing. The term "enablers" describes both the disruptive technology that paved the way for smart manufacturing and the design concepts that ensure its success.
The "smart factory" represents a transition away from conventional automation and towards networked systems that use data to satisfy growing commercial demands.
Smart factories should be adaptable, able to control complete production processes, optimize their performance, and self-adapt in real time. While operating locally, smart factories may also be able to link to a worldwide network of related technologies. The Industry has always required data, rapid decision-making, and ongoing change.
The significance of incorporating connection into new equipment is increasing as the manufacturing sector becomes more interconnected and complicated.
What is the Smart Manufacturing Process?
Finding the areas of overlap between client requirements and firm production capability is the first step in this procedure.
If we have perfect control over manufacturing cycles and timeframes, we can schedule this sequence. Even stock coverage will decrease as a result.
The manufacturing process then begins in its real meaning. Planning and coordination are made possible with the integration and use of AI.
As a result, a self-organizing factory with technology for planning, manufacturing, and maintenance is created.
The trend towards digital and intelligent manufacturing is continued by Industry. Due to the growth of manufacturing techniques brought about by this, new technologies and business models are now possible.
Hence, innovation in manufacturing will benefit design, R&D&I, and the supply chain, as well as every other link.
Tracking and monitoring are essential in a smart factory at every stage of the manufacturing process. By making a production traceable throughout its full life cycle, it is feasible to swiftly and correctly assess the causes and effects of any form of production.
Describe a Smart Factory
Making your factory smarter through smart manufacturing. To enhance current production processes, smart factories make the best use of smart manufacturing "enablers." Smart factories are increasingly going paperless because they have a lot of digital data.
Without needing to visit certain production departments or employees physically, smart factories can obtain the data in real-time. Every aspect of life is mechanized and networked. Smart factories examine and enhance processes using accounting software for smart production.
To communicate data across various manufacturing lines and machines, intelligent factories use highly digitalized technologies.
Automation and connection are considered in the design of the factories. They incorporate a range of cutting-edge technologies, including artificial intelligence (AI), machine learning, the industrial Internet of things, big data, cloud computing, and cloud computing.
A smart factory has networked machines and devices that are all capable of communicating with one another. To increase productivity, deal with problems as they arise, or adjust to shifting demands, they can exchange data across the organization.
With technologically advanced connections like this, smart factories can keep an eye on production from start to finish.
Highly connected surroundings that can be digitized and connected are smart factories. The present industrial revolution is a technology shift that includes smart factories.
These enable machines and equipment to automate and optimize processes. These advantages extend beyond the creation of commodities. These cover activities, including planning, logistics for the supply chain, and product development.
The Four Stages of Smart Factories
These four levels can be used to gauge your advancement towards being a smart producer.
Level 1: Access to Basic Data
The lowest level at which a building or factory may be deemed "smart" is this one. Despite there being data, it is challenging to access or interpret.
Although time-consuming, data analysis can boost your production process's efficiency.
Level 2: Proactively Analyzing Data
Access to the data is made simpler at this level. To aid in processing, data will be centrally accessible and structured with visualizations and displays.
Although proactive data analysis is now possible, some work will still be required.
Level 3: Present Data
At this level, data analysis utilizing AI and machine learning is possible, providing insight without the need for human oversight.
Compared to the previous level, this one is more automated and can foresee important anomalies or problems to avoid failures.
Level 4: Actionable Information
The operational aspect of level 3 continues onto the fourth level. Without the help of a person, they can come up with ideas and, in some situations, take action to fix or lessen a problem.
This level gathers data, analyzes it to find problems, and then comes up with solutions. When possible, decisions are made with the least amount of human involvement.
Smart Manufacturing vs. Smart Factory
On this page, several technological words and their developments will be covered in detail. We'll talk about the Internet of Things, big data analytics, and the fourth industrial revolution.
We will also talk about innovative manufacturing techniques like additive manufacturing and the Industry's future. Before continuing, we shall first examine the fundamentals and advantages of smart manufacturing and smart Industry.
The manufacturing sector is a dynamic one. Statistics demonstrate that it makes a considerable financial contribution to any nation.
Because they provide numerous advantages to managers and executives working in this medium business, industry leaders are moving their attention from traditional manufacturing to smart manufacturing employing Industry 4.0 solutions. Another smart move is to collaborate with the correct Industrial IoT app development firm.
Let's examine how smart manufacturing technologies work in manufacturing processes inside smart facilities and the answers they offer.
Smart Manufacturing Processes
Automation and digital technology are commonplace, even in conventional factories. Smart factories, on the other hand, use smart technology throughout their operations and have higher levels of automation.
Artificial intelligence (AI) and IoT are used to their fullest potential in production via intelligent machines, tools, and equipment.
Using sensors and machine learning, these networked intelligent robots may share data and educate one another. This is a wonderful technique to identify and anticipate issues, carry out preventive maintenance, and swiftly adjust to new manufacturing processes or modifications in the manufacturing environment.
Both collaborative and industrial robots can be built and controlled by intelligent machines. With autonomous mobility, they may roam about a factory floor, improving the accuracy and productivity of production.
Smart Manufacturing Systems
In smart factories, almost all processes are computer-controlled, which makes administration and process monitoring easier.
PLM and CMMS are just two examples of the software used to manage these operations. Some examples are ERP, CAFM, and CAFM. These systems are frequently implemented on computers and intelligent machinery that can be accessible by human workers, managers, and other key stakeholders of the smart factory, such as suppliers, subcontractors, customer service, and others.
Big data, cybersecurity, and IoT-enabled manufacturing systems provide open, real-time data access and analysis.
Additionally, they offer enhanced production methods. These cutting-edge options can assist business strategy in achieving considerable cost and efficiency savings.
The main objectives of linked, optimized, transparent, proactive, and agile smart factories are being met. By using smart manufacturing technologies, approaches, and solutions, this is made achievable.
Benefits of Smart Factory
This demonstrates that business transformation continues to pick a Smart Factory due to its efficiency. Improve productivity and cut costs.
One of the many benefits of a smart factory is an improvement in overall equipment effectiveness (OEE).
Production Costs Are Lower
This is mainly because there is less waste and downtime.
Smart Manufacturing Tools
Virtual reality in the form of augmented reality (AR) can be used to improve planning, control quality, and expedite business assets operations.
Product development, logistics, and production all benefit from this.
Production Capacity That Isn't Being Used
Production capacity that isn't being used enough can be found and removed. This is how it works: business intelligence are utilizing their resources to the fullest.
The smart factory outperforms conventional production in terms of efficiency since all processes are precisely in line.
Data-Analytics
Virtual reality, for example, is not only useful for smart factories' actual operations but also for evaluations.
Lean manufacturing and waste-free operations are essential for effective production. Applications for process mining and data analytics can assist in optimizing the factory architecture by locating bottlenecks in the value stream design.
Workstation layouts that are as close to reality as possible can be easily created using virtual reality software. Digital scaling has made factory planning possible. The factory, which serves as the value stream's digital counterpart, is currently being developed.
Challenges of the Smart Factory
A smart factory setup could seem simple. Yet, the development and administration of a smart factory can run into a lot of problems.
Which are:
Disjointed Approach
Business processes units with many functions must cooperate and communicate with one another. They must collaborate to create the proper rules and procedures for overseeing the technology used in smart manufacturing.
If this is not done, the factory may become divided into silos. Business operations may find it challenging to maximize the productivity or efficiency of their factories as a result.
Monitor Equipment Failure
IoT devices of all kinds can be used to operate smart factories. To make sure that every gadget operates as efficiently as possible, the factory also needs equipment monitoring systems.
A company runs the danger of needing to make expensive repairs because it cannot monitor the functioning of its equipment in real-time. If one of the components breaks down, the company can encounter operational delays. It could be challenging for the manufacturing business to fulfill client expectations.
This may result in lost sales and harm to a brand's reputation.
Poor Security
Smart gadgets, including those used in smart factories, are a target for cybercriminals. A company must also train its staff on how to safeguard data both locally and on the cloud.
A smart factory and any associated gadgets could be exposed by employees who lack the required security training.
Read More: What are the Biggest Benefits from Smart Manufacturing Software
The Advantages of Smart Manufacturing
For a variety of reasons, a digitalized production system may be a smart idea. These are a few instances:
Optimization of Resources
Your business leader will be able to reduce excess waste, improve production forecasts, and modify manufacturing operations to suit the actual demand if you concentrate on the most crucial processes.
The Manufacturing System enables smart supply chain management on a global scale (End-to-End).
Predictive Maintenance
With smart manufacturing, you can monitor and stop potential wear and breakages at every point along your production line.
Thanks to artificial intelligence (AI) and machine learning, you are now able to employ predictive maintenance to help your company stay ahead of numerous potential issues in the future.
Manpower Reduction
These procedures can also be automated via smart manufacturing. To assist organizations in managing their projects more successfully, we will optimize and automate processes.
By granting us access to data via various platforms, we will enable a segment of the team to be relieved of some duties and allow them to concentrate on more crucial ones.
Data Insights Improved
You may improve the efficiency and effectiveness of your operational plant by using digital information. More data can be obtained more quickly.
More productivity, improved problem-solving, and higher uptime are all made possible with real-time reporting.
Increased Plant Productivity
The smart factory can eliminate manual handling by utilizing automation. The plant is more effective because production can respond quickly.
Issue Resolution Faster
The real-time availability of all information makes issue-solving and decision-making possible more quickly in smart manufacturing.
Enabling simpler requests for assistance, additional channels of contact, and simple access to digital documents, boost productivity.
Monitoring Products Throughout The Value Chain
The digitization of processing and packaging has also been utilized. From raw supplies to manufacturing and distribution, every step of manufacturing can now be monitored and analyzed.
As a result, efficiency is increased, and waste is decreased. You gain the capacity to make well-informed strategic decisions.
Continuous Data Exchange
You may manage all of your plants as one system. You may collect data inside your factory and integrate multiple systems that were previously thought to be independent, thanks to smart manufacturing.
Quality And Safety Control
Intelligent manufacturing systems automatically collect data, allowing you to use that data to raise the level of quality and safety.
It is possible to add quality control processes and automated reporting to the system. Data analytics can enhance actions like staff training or feedback loop creation.
Continuously Increasing Production
Plants can boost productivity because they can forecast failures using accurate, current data. An EDigitalized Production Environment can facilitate the adoption of Total Productive Maintenance and Prescriptive Maintenance.
Ascertain Prompt Delivery
Using assets to their fullest potential assures timely delivery. With more useful data, delivery techniques can be improved.
Reduce Human Error
Digital technologies can boost operational effectiveness and guarantee food safety. Digital technologies can make using machine instructions, inline quality controls, and real-time monitoring simpler and more direct.
This can nearly eliminate human error.
Maximize Your Energy Efficiency
To enhance energy efficiency, smart manufacturing may examine every component of the operation. Everything, from factory lighting to production scheduling, can be managed using real-time data on energy consumption.
Cooperation And Information Exchange Should Be Strengthened
By facilitating staff communication and skill development, smart manufacturing boosts output and engagement. It is possible to adapt and customize information to match it with business and production goals better.
Increased Productivity
Any business should prioritize efficiency. As already stated, it is not worthwhile to waste time on unimportant chores if you want to succeed financially.
To increase productivity and motivation on the team, many jobs can be automated. They won't have to handle laborious or repetitive chores. Uninterrupted output can be ensured by drastically reducing unplanned downtime brought on by equipment failure.
Operations and information are integrated with smart manufacturing. An IT/OT infrastructure that has been virtualized can safeguard production since it is seamless and secure.
As opposed to having information in silos, unified production environments are more secure. They also offer improved data security and intellectual property protection.
Disadvantages of a Smart Manufacturing
The implementation of smart manufacturing systems still presents significant difficulties, even though they can handle many of the difficulties and complexity faced by current industries.
There are many dependent variables that smart manufacturing systems must consider. They include obstacles with security, system integration, low ROI, finances, and finances when developing new systems for smart manufacturing or modernizing old ones.
The difficulties and potential solutions for intelligent manufacturing systems are listed below.
Problems With Security In Smart Manufacturing
Smart manufacturing systems transmit information between production and machining units with end users through an integrated network infrastructure.
It needs to be connected to a network, and it is specifically set up via the Internet. Internet information exchange necessitates data security. At all times, data and information must be encrypted. Every node in the network needs to be secured against outside intrusions and data exploitation.
The most crucial factors to take into account when creating networked systems, such as smart manufacturing systems, are efficiency and security.
System Integration
Another difficulty in the implementation of smart manufacturing is the integration of new technology equipment into current systems.
The introduction of smart manufacturing technologies has significant challenges due to the compatibility of outdated and new technology. New gadgets may employ a different communication protocol than outdated equipment that is governed by certain communication protocols.
For machine-to-machine communication and interconnection, a better communication system is necessary. IPv6 connectivity is necessary for modern production systems to link many devices simultaneously.
Interoperability
The capacity of various systems and applications to access and comprehend one another's operations is referred to as interoperability.
Due to this characteristic, data and information can be transferred between them independent of the programme or hardware they are using technical, operational, systematical, and semantic. The terms standards, directives, and fundamental procedures are used to describe systematic interoperability. Technological interoperability relates to the development of platforms, tools, and software for ICT environments.
Information sharing between several levels of institutions or persons is referred to as semantic interoperability.
If communication protocols and standards are not correctly matched, interoperability cannot be achieved. Interoperability issues can result from differences in transmission bandwidth, operational frequency, and mode, as well as hardware capabilities.
The interoperability restrictions of the system will be established.
Human-Robot Collaboration Safety
A cobot, also known as a lightweight robot, is a robot that can interact physically and safely with humans at work.
Additionally, it can cooperate by utilizing new paradigms for human-machine interaction (HMI). Human-Robot Collaboration is the ability of a robot to cooperate with humans in an industrial context to carry out specific activities, according to the International Federation of Robotics.
Consideration should be given to the site's workers' safety and occupational health. Avoid any dangerous surroundings at all costs.
Maintaining workplace health and safety is necessary. The CPS system and industrial robots systems should be put into place right away. By doing this, you may make sure that there are no workplace risks like vibration, radiation, heat, noise, radiation, substance, or material.
Multilingualism
Multilingual operations must be possible in smart manufacturing systems. They ought to be able to translate instructions from humans into machine language and tell the computer to carry out the required task.
Advanced technologies and AI in industrial systems might be referred to as "smart manufacturing." It should be able to accept commands from the operator in voice or text format.
Return on New Technology Investment
When you're thinking about switching to a more advanced production technology within your current manufacturing system, it's crucial to assess the return on investment and financial analysis thoroughly.
It's crucial to weigh the output losses during an upgrade against the additional investment needed to embrace new technologies. The length of time it takes to make up for the investment with the income from the current system affects whether or not to adopt newer technologies.
Conclusion
The terms "smart manufacturing" and "smart factory" have been used interchangeably in recent years. To provide access to numerous data sources, Smart Connected Products various devices and applications.
Although they are two very different phrases, they illustrate the necessity for manufacturing to be nimble in a time of rapid digital change. Understanding the distinctions between the two ideas will help us make the most of them.
In the modern industrial era, smart manufacturing systems are crucial to the development of new manufacturing technologies.
The global economy is significantly impacted by smart manufacturing technologies, which also boosts productivity.
