The Perfect Smart Factory: 10 Steps to Establish a Perfect Smart Factory

In this article, you will learn about the perfect smart factory: 10 steps to creating It.

What Is The Perfect Smart Factory?

The Perfect Smart Factory: 10 Steps to Establish a Perfect Smart Factory
The Perfect Smart Factory: 10 Steps to Establish a Perfect Smart Factory

The Perfect Smart Factory is one in which “connected” monitors and sensors are utilized to collect data on various elements of your equipment operations. These monitors and sensors interact with each other and with your central data system via wireless connections.

The data is then examined, with technologies like Computerized Maintenance Management Systems (CMMS) being used to help with smart manufacturing. Increased efficiency, operational improvements, streamlined production, more focused maintenance, and other benefits result a result[1].

The phrase “Smart Factory,” which literally means “intelligent factory” in the Industry 4.0 context, refers to a highly digitalized and networked production structure that produces significant output and is backed by data and technologies.

The Perfect Smart Factory’s goal is to improve productivity and lower operating costs by focusing on all areas of the manufacturing process, from digital networks to virtual product definition, remote manufacturing and maintenance, and IT system integration and analysis. What measures do you need to take to create the ideal smart factory in this situation[2]?

The proliferation of “smart” machines, which can communicate with other machines as well as the environment, is hastening the transformation of manufacturing processes. It is vital to consider not only the technological elements, but also the human factors, such as worker training and the organising of personal skill building activities, in order to manage the transition to the Smart Factory.

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The Advantages/Benefits of a Smart Factory

The Advantages/Benefits of a Smart Factory
The Advantages/Benefits of a Smart Factory

The Perfect Smart Factory technology has various advantages, which begin as soon as you apply it. These advantages include[1]:

  1. Predictive maintenance is the norm in smart manufacturing, not preventative maintenance. Predictive maintenance identifies and addresses maintenance issues before they impact output. It permits maintenance to become a lot more valuable and efficient procedure.
  2. Better maintenance means less unplanned downtime and more focused, useful downtime when needed. Increased production yields result from increased equipment uptime.
  3. Increased production efficiency: Smart factories allow for real-time monitoring and fine-tuning, resulting in higher quality due to more efficient equipment.

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The Perfect Smart Factory: 10 Steps to Creating It

Let’s have a look at the steps you’ll need to take to develop the ideal The Perfect Smart Factory together!

1. Determine your requirements and goals

1. Determine your requirements and goals:
1. Determine your requirements and goals:

It is not enough to just determine that you want to build a The Perfect Smart Factory and then proceed. The “why,” as with any equipment or technology purchase, is essential to ensuring that you’re investing in the correct areas. The majority of smart factory installations take place in stages. It is critical to define your goals so that you can invest in the appropriate equipment at the appropriate time. Growing your maintenance efficiency will necessitate different technologies than increasing your output.

2. Get your team on board

2. Get your team on board:

More technology and automation might be scary to workers, who may fear they would lack the necessary skills or expertise to operate with new technologies. You can ensure that your most important resource – your people – will continue to develop and improve alongside you by explaining the rationale for the transition to The Perfect Smart Factory manufacturing technologies, collecting input, and educating them on these new procedures.

3. Create a transformation strategy

3. Create a transformation strategy:
3. Create a transformation strategy:

Using Industry 4.0, the path from the present state to the desired state must be planned systematically. We consider both the process and the technology in order to determine which problem is best handled with which technology. We conceive in terms of discrete milestones that, when combined, create the roadmap for the Industry 4.0 transformation landscape[3].

4. Make an investment in security

The Perfect Smart Factory: 10 Steps to Establish a Perfect Smart Factory
The Perfect Smart Factory: 10 Steps to Establish a Perfect Smart Factory

As demonstrated by the Cisco study on The Perfect Smart Factory, manufacturers today require very complex technology to handle the new industrial IoT scenario, which permits the connectivity of millions of machines across worldwide networks. The establishment of a secure link between the operational and IT networks is thus a critical component in being able to work with data in a secure manner. A secure network increases data accessibility while also allowing for greater cooperation among organisations, higher Overall Equipment Efficiency (OEE), and higher product quality. Not only that, but a secure and connected IT network may assist manufacturers in the process of resolving environmental, health, and security issues within their facilities, lowering all hazards.

5. Establish wireless links
5. Establish wireless links

Wireless connectivity is critical for building a connected factory that can perform and respond quickly to customer requests and market changes. Industrial devices that employ wireless connections aid firms in their efforts to increase productivity, for example, by enabling real-time choices. The future of manufacturing is thus connected to wireless potential: a revolution that has dramatically transformed the technology we use every day and is now becoming a part of the industrial sector.

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6. Put Collaboration Technology to Use

6. Put Collaboration Technology to Use
6. Put Collaboration Technology to Use

Collaboration technology (software for video conferences, data sharing, and so on) can assist manufacturers in overcoming the day-to-day problems associated with process optimization, remote maintenance operations, and IoT. From the early conceptualization phase through the final manufacturing phase, a coordinated effort from many corporate divisions is necessary in today’s industry.

To create a more efficient productive process, the sales department, marketing department, all engineers, manufacturing department, and even supply chain reps must all collaborate. In a complicated setup like the one shown, engineers, for example, may access data and collaborate with the production department to act on production concerns in real time, even if the two teams are geographically distant. Machines can also be linked through remote access, allowing professionals to control the maintenance process from any location.

7. Ensure that the IT and OT departments are in sync

7. Ensure that the IT and OT departments are in sync.
7. Ensure that the IT and OT departments are in sync.

Historically, the IT and OT departments have operated independently in the industrial production process. However, in order to thrive in today’s business, it is important to create a better IT/OT partnership. Consider the plant maintenance procedure. Today, predictive maintenance governs the operative process of production: teams perform their responsibilities in accordance with the maintenance schedule, allowing for the improvement of the productive process from many perspectives, which was not previously possible in factories. When the IT and OT departments collaborate, their work becomes more efficient, and the whole production benefits.

8. Make an investment in data management

8. Make an investment in data management.
8. Make an investment in data management.

The Industry 4.0 revolution allows for the introduction of digital elements in manufacturing, dramatically altering the industry’s features. The Internet of Things (IoT), as well as the application of current technologies to industrial equipment, made it possible to monitor and receive data from the majority of the devices engaged in the manufacturing process. The ability to access this vital data provides for an improvement in productivity by decreasing maintenance time and enhancing overall OEE.

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A robust data management structure is necessary to achieve this: a solid architecture directed by competent employees to manage the efficiency of diverse production operations. Personal skills are also necessary in order to construct a successful The Perfect Smart Factory: the next two phases, in fact, focus on the human aspect of the process.

9. Soft skills and a digital attitude

9. Soft skills and a digital attitude
9. Soft skills and a digital attitude

Soft skills are critical for organisations to produce value. Consider issue solving, or the capacity to solve technical difficulties or find answers through lateral and strategic thinking, or knowledge networking, which helps you to locate important information in a network that can help you accomplish your company objectives. Workers must acquire a digital mentality to be able to meet the constantly-changing context as a result of the digital revolution, which is making factories smarter than ever.

10. Be flexible and adaptable

10. Be flexible and adaptable.
10. Be flexible and adaptable.

The Perfect Smart Factory works in a fast-changing environment that changes often and in significant ways in the disruptive setting generated by Smart Factories, where it is critical to be flexible and open to change in order to confront this type of scenario appropriately. New technologies are continuously developing, and innovation is changing the industrial landscape; as a result, it is important to be prepared and open-minded in order to take advantage of all market opportunities.

We’ve witnessed the first step toward realising the ideal The Perfect Smart Factory today. Security, wireless development, collaborative technologies, and many other current topics are all components to consider in the new industrial scenario established by 4.0 modern technologies.

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Bibliography

[1] “Step-By-Step Guide To Building A Smart Factory | ATS.” https://www.advancedtech.com/blog/step-by-step-guide-to-building-a-smart-factory/ (accessed Oct. 09, 2021).
[2] “7 Steps to Building a Better Content.” https://www.extrasys.it/en/redblog/7-steps-to-building-the-perfect-smart-factory (accessed Oct. 09, 2021).
[3] “Smart Factory: Digitization in 5 Steps.” https://www.t-systems.com/de/en/newsroom/expert-blogs/smart-factory-digitization-in-5-steps-204436 (accessed Oct. 09, 2021).

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