Smart Factory Evolution
Published on : Saturday 07-08-2021
Dr Makarand Sawant highlights the key benefits of the Smart Factory and the stages of implementation.
In the Smart Factory model there are several ways to look at the mentioned staged approaches. One such maturity approach looks at the information and actual operations and manufacturing systems perspective with autonomous machines and systems.
Some key benefits of Smart Factory are to enable real-time monitoring of KPIs like OEE, OPE and Quality. Avoiding unplanned downtimes of the plants through early identification of issues by using Alerts, Dashboards and Reports of KPIs. Ability to perform preventive maintenance activities and sight opportunities for improvements in yield, production and quality. Reduction of losses by real-time monitoring and actions on consumption of raw material and utilities. Immediate corrective action with automation in SOPs and production accounting. Reduction in manual tasks and wastage of time looking for things. Reduction of human errors and improvement in productivity of plant resources. Improvement in documentation and compliances. Immediate notifications and remote access to take quick corrective actions. Authentic database-availability at any given instance.
In a phased approach, whereby each stage builds upon the next one and adds more value, we move from data to information to knowledge to wisdom and action from a data perspective.
Stages of Smart Factory implementation
Stage 1: Interconnection of cyber physical systems – integrate sensing, computation, control and networking into physical objects and infrastructure, connecting them to the Internet and to each other.
Stage 2: Data Acquisition – converts physical conditions into digital form, for further storage and analysis. Typically, signals from sensors (sometimes processed by sensor conditioners) are sampled, converted to digital, and stored by a computer, or by a standalone device.
Stage 3: Data Analysis – the process of cleaning, analysing, interpreting, and visualising data to discover valuable insights that drive smarter and more effective business decisions.
Stage 4: Automated actions – use of software to reduce the manual handling of simple tasks or a series of more complex tasks with the goal of making processes more efficient and employees more productive.
Key elements of Smart Factory
These include:
1. People
2. Process
3. Machines, and
4. Security and safety.
Adoption of new age technologies like Analytics, Cloud Computing, IIoT, Big Data, AI/ML, AR/VR, RPA, Threat Intelligence, etc., will help to quickly implement Smart Factory initiatives. Its technological foundation consists of cyber-physical systems and the Internet of Things.
Analytic Process Automation (APA) is the technology that is widely used that allows to easily share data, automate tedious and complex processes, and turn data into results. With Analytic Process Automation, anyone can unlock predictive and prescriptive insights that drive quick wins and fast RoI.
Advantages commonly attributed to automation include higher production rates and increased productivity, more efficient use of materials, better product quality, improved safety, shorter workweeks for labour, and reduced factory lead times.
With Smart Factory, sharing of data and intellectual property is done across supply chains and various stakeholders. Systems are being integrated between consumers and suppliers. Data is distributed all through the systems, which means a greater security scope.
Hardware, software and connectivity will all need to be secure for IoT objects to work effectively. Without security, any connected object, from refrigerators to manufacturing bots, can be hacked. Once hackers gain control, they can usurp the object's functionality and steal the user's digital data. IoT objects are potentially vulnerable targets for hackers. IoT security is more challenging than cybersecurity because of its enormous attack surface and the increased vulnerability of IoT devices. IoT Network Security Capabilities include traditional endpoint security features like antivirus and antimalware as well as firewalls and intrusion prevention and detection systems.
Dr Makarand Sawant is a PhD in Analytics, he is a technology and business visionary with 22 years of executive and hands-on experience in automating multi-billion dollar enterprises. He is a Computer Science engineering graduate with MBA and a Doctorate in Management Studies, Information Technology. He has led Innovation and alignment of IT with business by driving Digital Transformation through Analytics, Process Automation, Mobility, and Cloud including leading Smart Factory, IoT and Industry 4.0 initiatives.
