TRADITIONAL MANUFACTURING PROCESSES HAVE EVOLVED OVER THE YEARS FROM
INDUSTRY 1.0
TO
INDUSTRY 4.0
IN WORLD OF DIGITIZATION AND CONNECTED SYSTEMS, CONVENTIONAL MANUFACTURING CAN MAKE USE OF TECHNOLOGIES LIKE
DATA, MACHINE LEARNING, CLOUD
TO MOVE TOWARDS A
SMART FACTORY STATE!
Smart Factory is a flexible system which embraces new digital technologies, Machine Learning, Predictive Algorithms and makes it possible to gather and analyze data across machines and business systems, enabling faster, more flexible and more efficient processes to produce best quality standard/customized products at reduced costs.
Self-optimization, self-adaptation and learning from new conditions in real or near-real time, autonomously run entire production processes are some of key highlights of Smart Factory.
Data of the Product is the most important constituent of Smart Factory which helps minimization of waste.
Sensors, data and analytics are deployed to make a Factory smart and creates a “Digital Twin” of the factory.
Smart Factory is a step ahead from traditional automation in factories as it is fully connected, and uses constant stream of data to learn and adapt to new demands.
Concept of Smart Factories goes beyond the boundaries of the Factories as it also connects to a global network of similar production systems ensuring full integration of Supply Chain.
Smart Factory continuously evolves and grows according to changing business needs:
Changing Customer Demand, so as to take into account adjustments in production scheduling/sequencing
Expansion in new markets, so as to factor increased capacity requirements / machines
New Products or services
More productive and responsive approaches to operations and maintenance, ensuring timely maintenance and preventing machine breakdown (Simulate far in advance Maintenance operations in Digital twin of the Factory to save time)
Incorporation of new Processes and technologies
Real or near real time integration with Production
Many of the manufacturing facilities are already using the components of smart factory in areas such as Advanced Planning and Scheduling using real time Production and Inventory data but a true Smart Factory is more than this, as it moves ahead of the shop floor system and influences the enterprise and broader ecosystem.
Characteristics of a Smart Factory
Blue Print to Smart Factory
Every Smart Factory initiative in a Company touches upon different aspects like Data, Technology, Process, People and Cybersecurity. On basis of specific objectives, Companies can prioritize which aspects are to be considered for investment.
Since there are many different possible configurations of a smart factory solution, there are number of alternatives for Companies to proceed on the journey that needs careful Definition, Planning and execution at a pace suitable to the organization.
Smart Factory initiatives should always start small, with testing concepts in a manageable environment, and then scale once lessons have been learned.
Important to involve all Supply Chain Partners and customers from start so that impacts anywhere in the chain could be assessed on time and necessary actions are taken accordingly. This helps minimize the risks for go live and Business impacts.
Example of an Offering available in market for Smart Factory
(Industrial 4.0)
Below are key products from SAP and it’s partners supporting Industrial 4.0 revolution and helping Companies achieve Smart Factory Initiatives.
Smart Factory Example – SAP’s Predictive Maintenance
Smart Factory – other examples
Thus there are immense opportunities to make use of Data and come out with smart solutions, not restricting to SAP as a product itself. These examples are :
Reduction in energy consumption in different assets in the factory
Reduction in Inventory levels
Minimization of waste
Quality checks and identification of defects for complex products (for e.g. microchips, circuit boards) using Machine vision equipped with AI and very high resolution cameras
Reduction in environmental emissions through AI controlled fuel valves
…
Capability of BCG
Bolders Consulting Group (BCG) can help Companies in shaping factories of tomorrow through Smart Factory initiatives. Smart Factory offering at BCG applies Industrial 4.0 technologies to achieve their Business objectives in ever changing technological and business processes.
BCG’s expertise spans across different technologies which in essence is core of Smart factory implementation:
Capability of BCG
Bolders Consulting Group (BCG) can help Companies in shaping factories of tomorrow through Smart Factory initiatives. Smart Factory offering at BCG applies Industrial 4.0 technologies to achieve their Business objectives in ever changing technological and business processes.
BCG’s expertise spans across different technologies which in essence is core of Smart factory implementation:
Consultants working at BCG have vast Functional and IT experience in different technologies which can help Companies embark on their Smart Factory Journey through well defined roadmaps.