Today, technology has a profound impact on how factories operate, from automated mobile robots, to cloud computing, to 3D printing. The application of technology is making the production process more and more intelligent and dynamic, allowing the Smart Factory concept to become a reality.
The emergence of smart factories has promoted innovation in the manufacturing industry, creating a driving force for businesses in particular and the economy in general to grow dramatically. So what is a smart factory? Find out with us now!
What is a smart factory?
A smart factory is a digitized manufacturing facility that uses connected production devices, machines, and systems to continuously collect and share data. This data is then used to inform process improvement decisions and resolve any issues that may arise.
Smart factory manufacturing operations are powered by a variety of technologies including artificial intelligence (AI), big data analytics, cloud computing, and the industrial Internet of Things (IoT).
Smart factory manufacturing operations are powered by a variety of technologies including artificial intelligence (AI), big data analytics, cloud computing, and the industrial Internet of Things (IoT).
a. Benefit
In fact, smart factories bring many benefits, specifically:
– Smart factory is more efficient than traditional manufacturing because all processes are optimally linked.
Lower production costs, partly due to reduced downtime and less waste.
– Underutilized production capacity can be identified and eliminated. On the contrary, this means that companies are making the best use of their resources.
– Smart manufacturing tools that use augmented reality (AR) to facilitate company work, improve planning and quality control. This also has a positive impact on product development and logistics.
b. The main principle of smart factory
The basis for a smart manufacturing process is the use of networked plants and equipment. The data collected here can be used to make data-driven decisions.
The basis for a smart manufacturing process is the use of networked plants and equipment. The data collected here can be used to make data-driven decisions.
4 levels of Smart Factory
The definition of smart manufacturing always refers to 4 levels of smart factory. They are the basis for targeted improvement and are not just necessary for the smart factory itself. Instead, they are also the basis for a targeted intelligent repository.
Level 1: Ensure data availability
Smart digital factory technologies require a comprehensive overview of current tasks. And of course, data is key. While collecting all relevant operational data does not make a factory smart, this step is absolutely necessary.
Level 2: Actively analyze data
The data collected at level 1 is used by smart factory solutions to perform comprehensive data analysis. The reason for this is that operational data at this level is available in a structured and understandable form. Central data storage also helps to visualize different states. However, companies should remember that a proactive data analysis is a very expensive undertaking.
Level 3: Operational Data
In the next step, the company’s data can be analyzed with the help of artificial intelligence (AI) and machine learning. No human interaction is required, instead, smart factory industrial systems 4.0 will take care of this on their own. Better automation at Level 2 also helps predict problems and anomalies that arise.
Level 4: Action-oriented data
At this level, the factory is intelligently connected, systems can independently find solutions to problems and take action. Therefore, human intervention is reduced to a minimum.
How to make a factory smart
In order for a simple factory to become a smart factory, it is necessary to first analyze the main areas in detail. This provides information on which process or device needs to be improved first. On the other hand, full implementation of tools such as smart glasses or sensors is inevitable. Finally, the introduction of new technologies requires intensive training in personnel.
Particularly important in the implementation of smart factory solutions is the collaboration between IT professionals and management. Both have to step by step implement the digitization plan.
Technologies used in smart factory
The Internet of Things (IoT) is one of the key technologies for the fourth industrial revolution. However, other approaches are also important for the smart factory to function properly:
- Big data analytics: Large amounts of data enable detailed analysis of the smart connected factory’s production process. Furthermore, the larger the data volume, the higher the accuracy and error detection rate.
- Cloud computing: with the help of this technology, the collected data can be stored and processed. This is essentially less expensive than traditional hosting and also increases flexibility in decision making.
– Digital copy: Companies that want to increase efficiency can use digital copy. This is a way to simulate physical processes or objects and their performance. This can be used to infer the effectiveness and profitability of individual methods.
Sensors: Installed on equipment and machines, sensors collect a lot of data during the manufacturing process. They can therefore be used for monitoring purposes, for example, to alert employees to impending problems.
– Augmented reality (AR): Smart manufacturing technology brings many modern approaches like smart glasses. Technologies like AR can also be used through smartphones to make production more efficient. At the same time, such approaches help to complete many production tasks faster and better.
Smart manufacturing tools and cybersecurity
Computer-based smart factory technology and digital systems require special cybersecurity. In particular, data protection and privacy are especially important.
Therefore, security should be a high priority when setting up a smart factory. This is quite possible, for example, by using tested software that implements basic and standardized security mechanisms.
CONCLUSION: Smart factory investments benefit manufacturers by creating safer, more efficient and more reliable operations. Companies will need to adopt digital technologies to meet the growing expectations of consumers. And Smart Factory is a direct way for manufacturers to disrupt a competitive and dynamic market as they use digital innovation to improve supply chain efficiency.
