Creating a Smart Factory plan involves integrating advanced technologies to optimize manufacturing processes. The foundation of a Smart Factory lies in the ability to harness a digitalized production process from end to end—business software and programming systems, machines, automation, and machine data to enhance efficiency and productivity. A successful plan begins with a clear understanding of the goals and challenges specific to the manufacturing environment. It is crucial to identify the strengths of the current processes and determine how smart technologies can augment them. The strategy should include a step-by-step implementation process, starting with the most critical areas that can deliver quick wins and significant ROI. As the plan unfolds, it is essential to involve all stakeholders, ensuring that the workers are trained and ready to adapt to the new technologies.
Defining the Business Model
Realizing your vision of a Smart Factory requires planning and defining the business model it will eventually serve. What are the goals and objectives? Do you want to be more efficient and productive, establish fully automated and autonomous production, reduce lead times, increase sales, and increase transparency? If your goals and objectives align with the above, you should consider what is needed to start a Smart Factory Plan.
Smart Factory Benefits
The proliferation of web-enabled and network-connected machines and devices can communicate in real time and provide fully automated production capabilities and real-time production data. Full end-to-end integration is possible today with automated quoting, production planning, material supply, machine programming, automated machine and material automation systems, predictive maintenance, interconnected logistics systems, and adaptive planning based on production requirements.
With software managing the data streams from individual machines and external sources, visualization and analysis of the production process in real-time are possible. Implementing front-end business software systems to process incoming orders more efficiently through the ERP system and generating the bill of materials (BOM), material requirements planning (MRP), and a manufacturing execution system (MES) that processes routing, programming, and scheduling.
Developing the Plan
Follow these steps to develop your Smart Factory plan:
- Determine the business model that you want to serve with the new Smart Factory vision.
- Take inventory of the software and machine systems that you have today.
- Create an information stream mapping (ISM) to determine which devices can communicate data in real time and which cannot. In addition, determine who in the company needs data and which data content they require. This step determines the data content derived from each device for tracking material flow, production efficiency, machine maintenance, machine availability, and status.
- Evaluate the data suppliers and integrators to visualize the data. If you are currently working with a preferred supplier, inquire which software systems are currently available to visualize machine production data and monitor the efficiency levels of each. If working with outside partners, how can they contribute to the overall vision of your Smart Factory with integrated logistics and supplies?
Taking Inventory of Current Systems
Based on your Smart Factory vision, what needs to change from your current processes, software, and machinery systems? While this may seem daunting, a step-by-step approach is best. Look for modularity for the greatest flexibility so the Smart Factory vision can be achieved at your pace. Choose equipment partner(s) that can provide modular systems for software, machines, and automation that will eventually fulfill your vision. If you have stand-alone lasers and brakes today that can communicate in real-time, can they be adapted to accept automated systems and software communication tools to fulfill your Smart Factory requirements? Once you have the Smart Factory vision plan for your company, then it’s a function of determining whether you can expand with what you have or do you need to replace what you have.
The Digitalized Smart Factory
Increased efficiency, productivity, revenues, production transparency, and customer satisfaction are all by-products of the Smart Factory and contribute to higher profit potentials for your company and competitiveness in the marketplace. Continuous evaluation and evolution of the strategy are necessary to keep pace with technological advancements and changing market demands. By methodically building a smart factory, manufacturers can achieve a more responsive, efficient, and competitive operation.
By Frank Arteaga, Regional Director Marketing – Americas
Bystronic Inc., Hoffman Estates, IL
Voice.bystronic@bystronic.com