The term Industry 4.0 refers to the 4th Industrial Revolution, which aims to meet the modern needs of Industry and introduce radical technologies in industrial processes that will establish the ‘Smart Factory’. Industry 4.0 adopts a well-balanced set of technologies to integrate the terms: interconnectivity, digitization, intelligence, and automation. In Pragma-IoT, we apply our deep experience to offer solutions that will make it possible for our customers to gain complete control over the production line and factory management.
Main Concepts of Industry 4.0:
Internet of Things (IoT)
In the journey to digitally transformed manufacturing processes, one of the most important keys to adopt “Industry 4.0” is leveraging the power of Internet of Things (IoT). The various factory devices are designed to connect to the internet via the IoT and coordinate multiple industrial processes and tasks. Furthermore, by installing appropriate sensors in the factory machines, it’s given the opportunity of collecting real-time data on their performance and condition. Based on the above, the industrial processes are optimized, factory control is better gained and every-day problems that arise are easily solved.
Big Data Analytics
Inside a factory, there are dozens of interconnected devices from which we have to collect a huge amount of data. All this kind of data come from different environments such as computers, sensors, cameras, electronic applications, etc., and through the use of advanced analysis systems must be able to be collected, stored and then analyzed. Big Data Analytics is a digital strategy of managing data that will help to facilitate factory processes and allow factory owners to analyze the related data for evolving the production procedures.
The amount of data collected in the process of optimizing the construction process is huge and it becomes impossible to manage it manually. The rise of Cloud Computing technology provides a platform where data can be stored in the so-called “cloud” and processed to remote servers. Cloud Computing is a technology with sophisticated use cases emerging across industries, which offers solutions that transform industrialization and allow manufacturers to gain insights throughout the product lifecycle.
The rise of Augmented Reality technology is building the promise of advanced computing and processing power to set the stage for the establishment of “Industry 4.0”. The world’s manufacturing organizations invest in this intelligent technology, and profit from many enhancements in the field of staff training, tool assembly processes, and decision-making procedures. Augmented Reality can play a key role in creating a sustainable way of managing difficult situations, improving working conditions for employees, and developing new processes of directing activities.
As the global manufacturing industry enters in “Industry 4.0”, innovations such as robotics and automation are set to take over. Robotics are the use of computers, control systems and information technology to handle industrial processes and machinery, improving efficiency, speed, quality and performance. Robots are designed to effectively complete tasks, 24/7, in large manufacturing operations in a similar manner to humans, thereby boosting production output without any additional labor costs. Robots have the ability to perform repetitive tasks and allow human workers to focus on more intensive duties.
System Integration belongs to the “Industry 4.0” pack as it involves the combination of various computing systems and software packages in order to create a larger system. An example of System Integration is when machines are allowed to “talk to each other”. The adoption of System Integration methods in industrial processes presents many benefits such as improved productivity, faster manufacturing processes and greater efficiency.
Simulation is described as “the imitation of the operation of a real-world process or system over time”. Nowadays, Simulation is well-established in the industrial manufacturing processes, since it poses many advantages and opportunities. Simulation methods can help manufacturers visualize the relevant parameters, since it can provide insight and understanding not easily achievable by testing. Simulation enables manufacturers to optimize decision-making as well as the design and operations of complex and smart production systems.
The Machine-to-Machine communication is accomplished by integrating any machine to any machine that shares a common data exchange service. For this, sensors, actuators, and identifiers are coupled on these machines, thus representing communication through the IoT. Machines Integration in Industry 4.0 introduces unprecedented levels of automation, enhanced flexibility and agility, and operational efficiency into production procedures.
Machines to ERP Integration
Enterprise Resource Planning (ERP) systems are able to assemble together a variety of business processes and enable the collection, storage, flow and sharing of data between the processes. ERP integration to industrial machines ensures that the data within the ERP system is much more accurate, allowing you to have control over your entire business. The advantages of using Machines to ERP Integrations are immediately visible and have long-term benefits such as automated processes, real-time data, supply chain optimization and faster return on investment.
Smart Buildings use Internet of Things (IoT) devices – sensors, software, online connectivity – to control nearly everything: energy and water utilization, lighting, shading, room temperatures, waste/recycle without the need for the intervention of its users. In the midst of a significant industrial transformation, Smart Building technology is being applied in a variety of systems to improve operational efficiency, increase productivity, and reduce operating costs.
Production OEE & TEEP
- OEE stands for Overall Equipment Effectiveness
- TEEP stands for Total Effective Equipment Performance
OEE and TEEP are different tools of measuring the availability and effectiveness of your production line. These useful methods provide you indications on where you can make improvements to increase capacity without spending any money in new machinery or production facilities. It is undoubtable that these calculations offer a more effective, reliable, and efficient monitoring of machine utilization.
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Adding value, not complication
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What are the benefits of Smart Industry?
- Increased productivity and improved efficiency. The technologies that are being used reduce machine downtime and enhance the ability to make more products and make them faster.
- Less operational costs. The Industry 4.0 technologies i.e., automation, systems integration and more provide faster manufacturing, less product waste and fewer quality product problems.
- Higher customer experience. With Smart Industry, problems are being solved quickly, quality of the products is improved, and the profitability is increased.
- Improved reliability and quality. Smart factories are able to detect production failures faster, identify the cause behind them and make corrective changes.
- Higher profit margins and revenues. The collection of real-time information across the entire supply chain can enable manufacturers to offer more customized, high-margin and high-quality products, while reducing operational costs.