SMART FACTORIES : center of Hub for Industry 4.0, IT and AR
What are smart factories ?
Smart factories are based on Industry 4.0, Co-bots, internet of things IOT, cyber security, augmented reality AR and virtual reality r¿RV !
- Smart factories are digital systems capable of interpreting and analyzing data sets. This helps them to optimize themselves automatically. The benefits of these systems extend throughout the supply chain.
- They are decentralized, highly connected and adaptable. They improve efficiency and performance by analyzing production processes. They can also respond to unexpected changes. With their help, companies can minimize risks and increase production of higher quality products.
- In general, smart factories are expected to drive manufacturing competitiveness. To do so, you need to have a robust ERP system in place. And you need to invest in sensors and IoT devices. These are essential to the implementation of smart manufacturing.
- Plant operations can be intelligently coordinated from suppliers to end customers. Connected devices, including cell phones, tablets and laptops, will interact with each other.
- The factory of the future focuses on building a workforce with new skills, developing a strategy to connect the enterprise value chain, and implementing IT infrastructure to support connectivity across the value chain. To achieve these goals, manufacturers must rethink how they train and qualify workers.
- In addition, the factories of the future will be equipped with environmentally sustainable production methods. In addition, they will have a modular line configuration.
Industry 4.0 Automation in smart factories
Industry 4.0 is a term that refers to the new level of organization required for the future of manufacturing industry. The term encompasses several technologies, such as the Internet of Things, artificial intelligence, virtual and augmented reality, simulation, robotics, big data and cybersecurity.
Automation in smart factories, also known as Industry 4.0, is an important aspect of the fourth industrial revolution. It can increase productivity, reduce energy costs and improve sustainability. It also helps prevent errors and delays in production.
There are various definitions of Industry 4.0 and many industries and companies have their own goals when it comes to automation. The most common ones are to increase productivity and reduce waste.
Collaborative Robots in Smart Factory
Collaborative robots, or co-bots, are a key element of smart factories. They have several advantages over traditional industrial robots, including smaller footprints, ease of use and flexibility.
They also work with humans side-by-side, reducing the need for physical fences and increasing safety in manufacturing plants. In addition, they can be easily trained to perform new tasks and have a higher degree of agility than industrial robots.
Collaborative robots can be augmented by range extenders that enable them to move vertically and horizontally, enlarging the field of automation possibilities. The enlarged field of operation makes it possible to automate processes that previously required human assistance, such as picking up large pieces or attaching small parts to an unfinished assembly. This allows for greater flexibility, productivity and quality.
Palletizing is an example of a job where collaborative robots are extremely efficient. A box is picked up by an electric vacuum gripper and positioned on a pallet.
For example, Universal Robots’ UR+ cobot has the ability to scan and inspect objects using an onboard 3D scanner. This data is then analyzed and compared to reference images, dimensions, and tolerance values stored on its computer system.
The system can then make a pass or fail decision. If it finds a defect, it can send signals to the machine to change tool positions or speeds to correct the problem. This can reduce scrapped or reworked parts and ensure a smooth production process.
Internet of Things IOT in intelligent factories
When we talk about the Internet of Things (IoT) we refer to objects that have sensors and processing capabilities. Typically, these objects are connected to other technologies such as software and data in the internet cloud.
IoT in factories is not just about automation. The vast amount of data generated by connected devices will change the way manufacturing is done. It will also improve employee well-being, as smart production involves workers in every step of the process. Ultimately, IoT will affect manufacturing and employees alike, so it is important to take full advantage of this technology.
Smart factories connect to the Internet of Things system to detect and and with artificial intelligence generate a quick solution to correct errors in the production process.
The Internet of Things (IOT) is influencing production enterprises, creating smart factories and transforming business and operational processes. IIoT establishes connections between equipment manufacturers, employees involved in production and design development, and supply chain managers to create an environment where crucial data is shared easily in real-time.
La tecnología IoT está transformando los entornos de fábrica, permitiendo a los fabricantes obtener visibilidad de sus operaciones. Esto les permite monitorear el trabajo en progreso, maximizar la calidad del producto y evitar el tiempo de inactividad no planificado.
Augmented Reality in futuristic factories
The use of augmented reality in smart factories is gaining popularity. It provides employees with the information they need to do their jobs better.
Many companies are heavily dependent on a process that is based on a
ontinuous skills development for your workers. And using an AR device, staff can overlay text and video objects to create an interactive training experience.
While traditional methods, such as design and prototyping, are resource-intensive, the use of augmented reality in the manufacturing process can reduce time and cost. With the use of AR applications, employees can see and manipulate products in real time. This also helps improve training by providing a higher level of immersion and a sense of freedom. In addition, users can make changes to a product without worrying about making a mistake.
For example, AR technology can help workers in manufacturing processes navigate the production floor with ease. AR indoor navigation software will guide workers to specific equipment or machines. Users can also share their location with co-workers to keep their workforce coordinated. In addition, augmented reality also allows workers to communicate with their colleagues through digital displays. This will make it much easier to share information and work with other team members. With these benefits, it's easy to see why AR will play an important role in the future of manufacturing.
Analytics for smart manufacturing systems
Analytics are a critical component to any smart factory. They enable evidence-based decisions and optimise production processes, boosting productivity and reducing waste in manufacturing. Data is gathered and stored through connected equipment and devices to enable predictive maintenance, monitoring, and error-detection. This enables businesses to keep production lines running smoothly and reduce costs by avoiding costly downtime.
In the first phase of Industry 4.0 maturity, manufacturers collect and store a large amount of raw data that can be difficult to analyse. However, with this information, errors can be identified and faults fixed before they become a serious issue.
Real-Time Data Analytics for Smart Manufacturing Systems
Real-time data analytics for smart manufacturing systems can revolutionize the way manufacturers do business. It can improve production effectiveness, reduce energy and material waste, increase customer loyalty and enable faster product delivery cycles.
Manufacturers who rely on manual reporting are fooling themselves if they think real-time data won't make a difference to their customers and their business. Sales cycles continue to accelerate, buyer lead times shorten, and price volatility becomes the new normal. It's time to stop the over-reliance on manual reporting.
Putting the right data in the hands of manufacturing managers is critical to their ability to make smart, timely decisions. This is done by identifying patterns and anomalies in the data to determine the best course of action.
Cybersecurity in a smart factory (SF).
As the IIoT (Industrial Internet of Things) brings artificial intelligence, cloud computing and robotics to factories, cybersecurity risks increase. The smart factory is a highly connected environment that exposes people, technology, physical processes and intellectual property to cyber threats.
Forty-eight percent of manufacturers surveyed by Deloitte and MAPI identified operational risks, including cybersecurity, as the greatest danger to their smart factory initiatives.
Main objective of the intelligent factory
One of the most important goals of a smart factory is to improve production. This means not only reducing costs, but also improving quality and flexibility. A smart factory is able to realize these improvements through the use of information technology. To do this, it collects real-time data and optimizes its production processes.
Examples of smart factories
- Haier's factory in Qingdao.
- Haier Group Corporation , One of its major achievements is the commissioning of one of the world's first smart interconnected factories. This factory, located in Shenyang, enables the production of smart home appliances.
- Tesla's igafactory and its leadership in the automotive industry.
Benefits of Smart Factories
- Manufacturers can reduce the number of repetitive processes and streamline the entire process. This is especially beneficial in mass production.
- Saves money because production lines can be streamlined.
- They can be easily upgraded, are more efficient and generate less waste material.
- Relieves workers of dangerous tasks. Typically, robots are delegated to perform processes that can be dangerous for human workers. Helps protect workers' health and reduce accidents.
- A smart factory has the ability to make decisions without being closely monitored. For example, it can automatically correct the performance of a system in real time.
- Reduces the number of defective products produced.
- Essentially, this aims to create a completely decentralized production process.
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