Intelligent manufacturing has become an important trend in global manufacturing.With the gradual disappearance of the demographic dividend, factories and enterprises need to find a new production model to alleviate expensive labor costs and respond to the demand for rapidly updated products.The emergence of the Industry 4.0 model provides new ideas for the manufacturing industry.Connecting all stages of the product life cycle through the Internet of Things, from raw material procurement to production to delivery and entering the customer's home, the entire process can be visually managed.
This is also the scene of the fourth industrial revolution. The Internet of Things has built a bridge for the entire manufacturing process and created a cohesive manufacturing environment.The raw material supplier knows when to ship the goods, the manufacturer knows how to ensure the quality of the product, the information feedback from each customer allows the manufacturer to gain a new understanding of the product and the market, and the Internet of Things solves the information isolation between suppliers, manufacturers and customers. The smart factory raises the manufacturing service capabilities to a whole new level.
In the future, the Internet of Things will bring huge value to the manufacturing industry, and the potential value may reach tens of trillions of dollars.It is estimated that with an annual growth rate of 6% in the next five years, the market will be close to 2020 billion U.S. dollars by 700.Huge application scenarios include automotive and transportation, mining, electronics, chemical, pharmaceutical, oil and gas industries.So, how will the new manufacturing scene change, and how will factories and enterprises meet the trend?
Changes in the manufacturing supply chain
The demand in the consumer market changes so quickly, which is undoubtedly a big problem for the traditional manufacturing industry.The real-time expectations of customers continue to rise, and the supply chain is becoming more and more complex. It is difficult to meet the current market needs to manage and control the manufacturing process through manpower analysis or backward tools.The smart factory uses a large amount of real-time data collected by smart sensors and the Internet of Things, and then based on the analysis of the cloud high computing power server, and creates a more flexible production process to keep up with the pace of customer needs.
The model of intelligent manufacturing is completely different from traditional manufacturing. Relying on advanced digital manufacturing technology, factories can produce on demand, purchase raw materials from suppliers all over the world, avoid the risk of large inventory, and manage customer feedback through social media to achieve individuality In order to achieve a faster, more flexible and more efficient product delivery level.
Thanks to the development of the Internet of Things and digital technology, smart manufacturing has brought new capabilities to factories. Although upgrading smart factories is not necessary, it is a very valuable thing.Using an optimized supply chain can not only reduce delivery time and costs, but also reduce the number of defective products in the production process based on market information.
Maintain consistency in product quality
In the past manufacturing industry, when the factory received workshop information or surveyed data from customers, the product had already entered the customer group, that is, damage had already occurred, leaving the user with a low-quality impression.The new manufacturing model, with the help of the Internet of Things technology, allows factories and enterprises to collect and transmit data in real time, which can provide timely insight into the problem and make changes before the product causes serious problems.
Future products will be equipped with smart sensors. These sensing parts will be able to ensure the consistent quality level of each product. Whether it is consumer electronics, household appliances or industrial equipment, the sensor can report abnormal data of the product to the manufacturer, and then the factory will provide more information. On-time after-sales service.In addition, the factory can analyze product deficiencies from the data, optimize the next product, and ultimately ensure more product quality.
This approach avoids customer complaints and damage to the company's brand, and at the same time may save the company huge costs.In the past, after the occurrence of major problems in automobile products, a large number of recalls were not uncommon, which not only led to the decline of the company's brand influence, but also incurred heavy monetary costs.
The advantage of the IoT connection manufacturing process is that once a problem or defect is discovered, it can be repaired in time before the error has serious consequences.Especially in today's artificial intelligence breakthrough, it can quickly analyze the hidden dangers, complete the control of production quality at a near real-time speed, and bring better products and fewer losses.
The important value of predictive maintenance
Unplanned downtime of the factory production line and unplanned maintenance will bring huge losses to the company. It is impossible for every piece of equipment and machinery to be kept without problems, but the downtime occurs outside of the plan, which not only causes the company to suffer from production losses, but also At the same time, it also slows down production efficiency.Today, when the cost is getting more and more expensive, this kind of unexpected shutdown may take a long time to check and repair, and to pay a huge amount of money, which is even more unbearable for small and medium-sized enterprises.
In the industry 4.0 model, there is a predictive maintenance method. By placing various sensors on the production equipment in the smart factory, it can automatically monitor the wear and tear of the machine in real time.Borrowing machine learning algorithms can accurately track the replacement time of parts and machines.
Predictive maintenance helps to arrange the replacement of equipment parts before the error occurs, and can arrange a reasonable replacement time, for example, when the machine is idle, it will not take up production time.This not only ensures the efficiency of the production line, but also improves the overall agility of the factory.
How to build a smart factory?
Smart factories are an inevitable trend in the development of manufacturing in the future. There are already some excellent cases. For example, large global manufacturers include General Electric, Siemens, Honeywell, Mitsubishi Electric, Rockwell Automation, Schneider Electric, General Dynamics, etc. All are trying new manufacturing models.However, upgrading a smart factory must combine its own needs and environmental characteristics, and different companies should adopt different methods in order to achieve their desired results.
There are usually several target directions for enterprise transformation, such as slowing down labor costs and reducing the overall cost of the factory; improving the efficiency of the production line and shortening the delivery time of products; increasing the flexibility of the factory so that it can quickly respond to market needs and so on.Companies can create a complete upgrade program according to their own needs.
The first thing is to build the Internet of Things to connect sensors, motors, switches and other various gadgets. The smart factory in the Industry 4.0 era includes production lines, robots, the Internet of Things, remote automation and so on.In addition, it also involves production networks and customized production systems, virtual product planning, production and remote maintenance.
In addition, smart factories need new types of workers, and the introduction of professionals with IT knowledge and OT operation technology.Repetitive tasks in factories will be handed over to robots, and people will pay more attention to product design, process optimization and monitoring.
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