IT in Manufacturing


Towards the Smart Factory

February 2019 IT in Manufacturing

With much of the reported paradigm of Industry 4.0 resting on self-configuration of machinery and production lines, Omron’s Victor Marquess looks at what can already be achieved to get on the path to an Industry 4.0 future and the promise of the Smart Factory.

Mass production is giving way to shorter batch runs, just-in-time production and increasing levels of customisation, which demand the flexibility of the Smart Factory. Not only does this require more intelligent and sophisticated production processes, but also the ability to reconfigure everything from individual machines to complete production lines, without incurring delays between batches. And, as batch sizes become smaller, so the need for shorter changeover times becomes more acute.

Production line changeovers have moved from mechanical readjustments to a button push on an HMI, dramatically reducing reconfiguration times. But as the requirement for more frequent changeovers has grown, so has a need for greater intelligence in the self-configuration process. There is now increasing pressure on machine builders to deliver machines that are ‘Smart Factory ready’, and which can configure themselves quickly and with less operator interaction.

With the advanced integrated functionality of components such as PLCs, drives, servos, sensors, HMIs and robotics, plants already have the means to implement a Smart Factory production environment as everything required for self-configuration is already available.

Software is the key

For machine builders, programming self-configuration capabilities within the machine cannot be an afterthought. “Addressing self-configuration late in the machine design process always results in a less capable system, compromising competitive advantage and increasing development costs,” explains Marques.

Traditionally, programming this added level of functionality into the machine has been a challenging and time-consuming process, adding cost. And if there is little commonality from one machine design to the next, the economics of increased programming time might not add up. However, help is at hand.

Omron has focused on making the software side of development quicker and easier for those machine builders and end-users committed to the Industry 4.0 paradigm. The company provides a complete library of pre-written, pre-configured and pre-tested function blocks that dramatically speed up the programming of advanced functions at every stage in the machine development – not just at the end of the project. Modular and reusable, the function blocks can be dropped into the design as needed, and then simply embellished to meet the needs of the specific Smart Factory application.

There are currently more than 40 function blocks, to choose from, with more being written, tested and added all the time. Examples include motion control, path control, tension control, temperature control, servo settings, sensor set-up, vibration suppression and device operation.

While today’s requirement may be for shorter batch runs as a minimum requirement, the mass customisation envisaged by Industry 4.0 might be the base requirement in just a few years’ time. Indeed, many industries are already looking at so called ‘batch size one’ requirements, where every product coming off the line might be subtly different to meet the needs of individual customers.

“Omron’s function blocks mean that even the most sophisticated machine applications no longer need to be last minute considerations as an afterthought value add proposition,” concludes Marques. “Machine builders can begin to add advanced functionality such as self-configuration as part of the standard machine development process, helping to deliver all the competitive advantage that the Smart Factory concept promises.”



Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Transforming battery manufacturing processes
IT in Manufacturing
Siemens and Hirano Tecseed, a Japanese machine builder, are partnering to transform battery manufacturing processes.

Read more...
From Trojan takeovers to ransomware roulette
IT in Manufacturing
Cisco’s Cyber Threat Trends Report offers a comprehensive and overview of the evolving cybersecurity landscape, leveraging its vast global reach through the analysis of DNS traffic.

Read more...
The road to decarbonisation in mining
IT in Manufacturing
The mining industry is a key player in global carbon emissions, and ABB’s eMine is at the forefront of efforts to drive the sector’s decarbonisation.

Read more...
Siemens democratises AI-driven PCB design for small and medium electronics teams
Siemens South Africa IT in Manufacturing
Siemens Digital Industries Software is making its AI-enhanced electronic systems design technology more accessible to small and mid-sized businesses with PADS Pro Essentials software and Xpedition Standard software.

Read more...
Siemens’ PAVE360 to support new Arm Zena Compute Subsystems
IT in Manufacturing
Siemens Digital Industries Software is expanding its longstanding relationship with Arm and adding support for the newly launched Arm Zena Compute Subsystems in its PAVE360 software, designed for software-defined vehicles

Read more...
Empowering OEMs in industrial automation
Schneider Electric South Africa IT in Manufacturing
Organisations are increasingly focusing on empowering OEMs within the industrial automation sector

Read more...
Fortifying the state in a time of cyber siege
IT in Manufacturing
In an era where borders are no longer physical, South Africa is being drawn into a new kind of conflict, one fought not with tanks and missiles, but with lines of code and silent intrusions. The digital battlefield is here, and cyber space has become the next frontier of conflict.

Read more...
Levelling up workplace safety - how gamification is changing the rules of training
IT in Manufacturing
Despite the best intentions, traditional safety training often falls short, with curricula either being too generic, too passive, or ultimately unmemorable. Enter gamification, a shift in training that is redefining how businesses train for safety and live by those principles.

Read more...
Reinventing data centre design: critical changes to meet surging
Schneider Electric South Africa IT in Manufacturing
AI technologies are pushing the boundaries of what is possible which, in turn, is presenting data centres with a whole new set of challenges. Fortunately, several options are emerging which include optimising design and infrastructure for efficiency, cooling and management systems

Read more...
Watts next - can IT save the planet
IT in Manufacturing
The digital age’s insatiable demand for computing power has collided with an urgent and pressing need for sustainability. As data centres and AI workloads consume unprecedented energy, IT providers are pivotal in redefining how technology intersects with environmental stewardship.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved