From Volume 3 Issue 3 of Connected.
Industry 4.0 is a comprehensive overhaul that spans the entire value chain, touching every aspect of how we design, procure, manufacture, deliver, service, maintain and sell our products. The main theme of the Fourth Industrial Revolution is connectivity. Manufacturers should examine how new-age technology can transform their manufacturing and production processes. New cutting-edge technology such as robotic automation, cloud-based solutions, AI and digital twins gives manufacturers the ability to become more efficient, streamlined and flexible, according to an article from Indeed.
Industry 4.0 is a term commonly used for the goals of the Fourth Industrial Revolution that focus on automated decision-making, interconnected machinery, improved data analytics and increasing productivity across the value chain, according to Industry 4.0 Influencer Jeff Winter. This allows for an efficient production of goods.
INDUSTRY 4.0 AND MANUFACTURING
The biggest benefit to incorporating new technologies is the ability to be more adaptable. There are several effective methods to adapt production to meet the needs of end users.
Resource Management: Many companies operate in an environment where they have plenty of data, but this data is fragmented by who possesses the information and where it is located. You can think of this as having the necessary data, but the information is stranded on different islands that aren’t connected. To make the best use of the information that a company has, the data needs to be connected and easily available to individuals who need it. Another important factor is ensuring that the data shared and uploaded is secure to avoid cybersecurity concerns.
Data Optimization/Contextualization: Having the correct systems and software in place to share data throughout a company allows for the opportunity to see the overall picture of a manufacturer’s operations, but it can also result in an overload of information for someone to analyze. Data contextualization is the association of all relevant data that needs to be present to make the data meaningful and easier to understand. For example, a process temperature being out of range is not very informative without the association of the work cell, operator, shift, time and product being run. With improvements in software and AI, it is possible to get help with consolidating, contextualizing and analyzing information to pinpoint where issues are occurring and the source of these problems.
Increased Productivity: Downtime is something that all manufacturers would like to reduce, but there are many reasons why companies may experience more downtime than they would like. Examples include not having enough material or the need to shut down production lines for repairs. Manual planning for materials or maintenance is tedious and causes inefficiencies. Modern technologies like Manufacturing Executions Systems (MES), Computer Maintenance Management Systems (CMMS) and Enterprise Resource Planning (ERP) Systems can aid in planning for materials and maintenance, leading to decreased downtime when production lines are not operating.
While all the benefits of new technologies can appeal to companies, implementing these technologies isn’t always straightforward. Digital modernization requires planning and the necessary conditions to be in place to reap all the benefits. For example, an MES can assist an organization by analyzing production data and providing in-depth information about the manufacturing process. If a manufacturer does not have a network that supports the transmission of data, then the benefits of MES are not being fully utilized.
THE ROAD TO DIGITAL MODERNIZATION
Kirby Risk has a team of consultants that can help match solutions to business and manufacturing problems, no matter where you are on your digital journey. Our team can help you with:
- Manufacturing Execution – Moving from spreadsheets to modern digital MES with ERP integration.
- Decreasing Downtime – Using modern tools to track asset performance and conditional maintenance.
- Improving Preventative Maintenance – Building organization and accountability for maintenance organizations with modern CMMS technology.
- Data for Continuous Improvement – Collecting and contextualizing industrial data for decision-making.
- Improving OEE – Improving by reducing downtime, enhancing quality and collecting data throughout the process.
- Networks and Cybersecurity – Safely bringing data off the shop floor and connecting today’s automated world.