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Create A Smart Factory - Industry 4.0
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MIKE SHEW'S HOW TO CREATE A SMART FACTORY - INDUSTRY 4.0
The Value of Implementing Industry 4.0!
Companies that fail to optimize their plants for Industry 4.0 implementation will not survive in the near future. To move into Industry 4.0, companies must have Industry 3.0 fully implemented and optimized. Computer technology, electronic systems, and automation became the dominant force in the industrial market, which was the catalyst for Industry 3.0. Old factories became automated and shifted from analog and mechanical systems to electrical and digital strategies—industry 3.0 automated processes on the production line, replacing blue-collar jobs with white-collar jobs.
Leading the pack, companies capture all the benefits across the entire manufacturing value chain, increasing production capacity and reducing material losses, improving customer service and superior delivery lead times, achieving higher employee satisfaction, and reducing their environmental impact.
Across a wide range of industry sectors, it is common to see (30 to 50 percent) reductions in machine downtime, (10 to 30 percent) increases in throughput, (15 to 30 percent) improvements in labor productivity, and (80 to 85 percent) more accurate forecasting.
MIKE SHEW'S HOW TO CREATE A SMART FACTORY - INDUSTRY 4.0. CLICK THE PICTURE TO ENROLL IN THE COURSE!
Create a #Smart #Factory
How to create a Smart Factory
To create a #smart #factory, the company will face a surge of new digital traceability, compliance, and cost accounting requirements. To achieve this objective, you will need to replace many labor-intensive, paper-based, partially automated processes and systems. More production in any facility is not possible unless workers can be freed from expensive, non-value-added activities (time spent searching for misplaced inventory, handwritten documentation, incorrect customer requirements, and outdated methods from the beginning of the operation).
You will require a #Manufacturing #Execution #System (MES) team to help find and implement the best solution to manage your highly variable manufacturing process.
A Highly Variable Manufacturing Process
The number of variants to be accounted for and managed is excessive; the product could be manufactured in 500 different ways. Therefore, the goal is to build and deliver a digital solution, first and foremost, capable of managing the data and workflow of this complex process. In addition, the answer will provide #traceability and support to the shop floor operators who executed the complicated assembly process. How to Create a Smart Factory.
#Roadmap to #Industry #4.0
#Global #standardization is a critical element for the customer when taking on this enterprise Manufacturing Execution System MES program.
Your new team of Manufacturing Execution System (MES) program experts will help define the customer's long-term #Industry #4.0 roadmap. The maturity model ensures consistency in process, product, and business management across all of their plants and the different manufacturing divisions of their enterprise. This must be a true partnership showcasing a commitment to collaboration, innovation, and continuous improvement. It does not stop progress after implementation as technology and customer requirements constantly evolve.
Past #strategic moves often involved incremental, piecemeal, or stopgap approaches, although today's investments are much more substantial. #Businesses are creating #factories of the future, automating ever-larger bands of production activities and reimagining the role of their products once they are placed in the hands of customers.
Create a #Smart #Factory and How to Create a Smart Factory.
What are the #Main #Business #Drivers?
Control of data volume: hundreds of product family trees for each of the product family children lead to massive, unmanageable amounts of data. Improve data flexibility: a production environment deals with so many variations because production needs are extraordinarily flexible and can easily change in time according to customers' demands. A statically designed solution cannot cope with such requirements.
Ensure data maintenance: changes applied to any of these parts must be easily transmitted.
A Customized #MES #Solution
The design and implementation of a highly customized Manufacturing Execution System (MES) solution can cope with the complex assembly processes of product widgets, including handling various subassemblies and the traceability of their product family trees along the assembly line. An example: Leveraging Siemens Opcenter Execution (SIMATIC IT) Manufacturing Execution System (MES) software, the solution can be built with several innovative customizations for high automation and a set of customer-specific rules for product family tree management.
Create a #Smart #Factory andHow to Create a Smart Factory,
The #Evolution of the #Solution
Industries eXcellence experts can complete the integration of the new Manufacturing Execution System (MES) with the control layer and provide onsite technical training and support during and after each rollout. In addition, since the first implementation of a new (MES) system, your (MES) team should provide complete IT and governance support for #customer #requirements.
With new development and augmentation, this powerful solution with new versions considers the customer's evolving needs, adding new capabilities and features and applying advancements in technology to address the exact requirements in a better, more scalable, and more flexible way.
A new version based on Siemens Opcenter Execution (SIMATIC IT) Unified Architecture - with new technologies, faster capabilities, and better functionalities – is ready for the #customer this year. You can review the information at the link below.
Create a #Smart #Factory and How to Create a Smart Factory.
#Automated Vs. #Human #Production
Suppose you #automated machine tools within your manufacturing production lines. What would take 5-10 workers per production line now only requires one. What? One! How? The Smart Factory parts would now cost roughly 11 cents each (in labor) to produce. Depending on what your #OEM #manufacturers. This is approximately one cent of offshore competitors in comparison. Replace old #ERP software, spreadsheets, and manual processes with a new set of intelligent technologies.
New orders are now sent by customers' electronically, get quoted electronically, scheduled for production, and shipped without any errors or re-keying. Sales' impact is quite apparent as the MFG rarely needs direct salespeople to call on prospects physically. The new sales team is now one-half the old size and bookings' 3-4 times more business. In addition, sales are not focused on product warranty returns. Instead, they are focused on SALES!
As an #automated #manufacturer, you can deliver in days which takes offshore OEMs months. Once your labor costs are lowered to a competitive price, local manufacturers can focus on short delivery times, personal service, and co-innovation without the headaches. These lower-cost and rapid delivery capabilities have earned (OEMs) the right to recover their business from offshore (OEMs).
Create a #Smart #Factory and How to Create a Smart Factory.
#Survival of #Analog #Manufacturers
Surviving analog manufacturers responded by automating more and more of their production processes. The effect has been to dramatically lower labor costs and parts. And as a result, the global price of labor has effectively been equalized. As a result, labor arbitrage (simultaneous) or cost is losing out to or winning to increased productivity.
An Upward Trend
Through all of this, plants were designed decades ago, yet the business has tried to slip in robotic welding equipment, 3-D printers, and other modern machine tools into workspaces that never contemplated such gear. These new capital tools may be making a nominal difference in productivity and quality. However, the full potential of these solutions may be getting lost due to the workarounds needed to accommodate old building designs, process flows, etc.
Thankfully, manufacturers have been investing and are investing even more with renewed faith in the economy. According to a recent National Association of Manufacturers (NAM) survey, 21.3% of manufacturers surveyed plan to increase capital expenditures by more than 10%.
Create a #Smart #Factory and How to Create a Smart Factory.