The Science and Art of Machining Productivity was written by F.W. Taylor in 1907. He followed it by the science of operator productivity in Scientific Management in 1911.
The Productivity Benefit of Industry 4.0 - Visualization by Consultants
Capturing the true value of Industry 4.0
April 13, 2022
Companies at the front of using industry 4.0 technology set are capturing benefits across the entire manufacturing value chain—increasing production capacity and reducing material losses, improving customer service and delivery lead times, achieving higher employee satisfaction, and reducing their environmental impact. Scaled across networks, these gains can fundamentally transform a company’s competitive position.
Implemented successfully, the industry 4.0 solutions deliver irresistible returns. Across a wide range of sectors, it is not uncommon to see 30 to 50 percent reductions in machine downtime, 10 to 30 percent increases in throughput, 15 to 30 percent improvements in labor productivity, and 85 percent more accurate forecasting.
Digital transformations are revolutionizing all aspects of manufacturing, touching not just processes and productivity but also people.
At a global industrial company faced a considerable ramp-up in demand—volume more than doubled over just three years, which translated to producing more than 50 million additional parts. The business embarked on an ambitious digital transformation at one factory. The goal was to increase overall equipment effectiveness (OEE) by ten percentage points and reduce product unit costs by more than 30 percent.
The project delivered: the factory was admitted to the Global Lighthouse Network, that recognizes leadership in the Fourth Industrial Revolution. The site is open to external visitors to observe its transformation. But despite this achievement, it was unclear to the company how to take this local success story and replicate it across other sites. The science and art of machine and operator productivity is to be developed for industry 4.0 production or engineering systems.
A technology-first rollout (buying available technologies on basis of benefits highlighted by vendors) means that solutions are deployed without a clear link to real value opportunities across the company, business challenges, or capability requirements.
https://www.se.com/ww/en/work/campaign/articles/a-beginners-guide-to-understanding-industry-4.0.jsp
Industry 4.0: Explained
Transforming how the manufacturing sector operates, Industry 4.0 includes integrating innovative technologies like cloud computing, the Internet of Things (IoT), artificial intelligence, machine learning, and analytics to construct what is known as smart factories.
Adopting Industry 4.0 empower enterprises to be a part of the next industrial revolution and ensure manufacturing industries with the right tools to execute predictive maintenance and alleviate the scope of downtime. Deploying technically advanced equipment in smart factories results in higher productivity levels and an evident improvement in quality. Leveraging machine learning algorithms can allow industries to seamlessly diagnose any form of concern, minimize manufacturing errors, and save a considerable amount of time and money.
Industry 4.0: The impact
Digital 4.0 has a multi-dimensional impact on various industrial processes. The advantages that the technologies offer present significant ROI opportunities through effective communication and improved decisions. The following are some ways that Industry 4.0 is impacting the manufacturing sector.
Enhanced productivity: The technologies associated with Industry 4.0 enable manufacturers to significantly improve their production output by putting in less effort. All the available resources can be used in a cost-effective manner without sacrificing efficiency.
Improved efficiency: Integrating the multiple innovative technologies of Industry 4.0 increases efficiency levels across the entire production line. Industry 4.0 alleviates the scope of downtime and decreases the time utilized to complete the production process.
Seamless compliance: Industries such as pharmaceutical and medical equipment manufacturing have a specific set of regulations that have to be met during the manufacturing process. Automated and integrated systems make it seamless for manufacturers to comply with any form of regulation with the help of automation.
Cost-effective: While the initial transition to a smart factory involves upfront expenses, the industry witnesses an evident reduction in costs with the effective integration of all connected equipment and data management.
What is Industry 4.0?
Learn about industry 4.0 technologies, benefits, and transformation challenges.
https://www.microsoft.com/en-us/industry/manufacturing/resources/industry-4-0-technologies
What is industry 4.0?
Industry 4.0 is the transformation occurring in manufacturing to integrate digital technologies such as cloud computing and analytics, AI and machine learning, and the Internet of Things (IoT) into production facilities and operations. Also called the fourth industrial revolution or manufacturing 4.0, industry 4.0 is characterized by improved efficiencies such as increased automation, predictive (proactive) maintenance, and self-optimized process improvements.
Industry 4.0’s greatest impact is likely to be on the supply chain—bringing smart manufacturing to factories and smart warehousing to logistics. But the transformation doesn’t stop there since industry 4.0 also connects with back-end systems—allowing software to ensure products get to the right customers at the right time.
The benefits of industry 4.0 technologies
There are many benefits of industry 4.0 technologies, including:
Productivity. Productivity improves because AI and autonomous systems augment factory workers to increase production efficiency and quality and reduce downtime.
Asset utilization. Greater flexibility across the entire manufacturing operation from industry 4.0 technologies means improved asset utilization and the potential for increased revenue.
Optimized processes. All industry 4.0 technologies are deployed for one purpose—to optimize manufacturing processes for greater efficiency and improved customer service.
Operation continuity. Ensuring business and operational continuity is critical since downtime is especially costly in manufacturing and production.
Improved quality. Agile factories and smart manufacturing processes improve overall throughput and quality while reducing costs.
Streamlined logistics. With visibility into the entire supply chain because of AI and data analytics, manufacturers can optimize production and delivery.
The Science and Art of Machine Productivity in Industry 4.0
1. Use Smart Machines in Processes and Operations
What is a Smart Machine?
It is self-aware, reacts autonomously and provides information about the product being produced, production parameters utilized, production time taken production quantity in unit time periods, production history, configuration, condition, quality and Overall Equipment Efficiency (OEE) to other machines.
"We define smart machines as digitized (or cyber-physical) machines that consist of physical components (e.g., machine frame, engine, and tools), intelligent components (e.g., sensors or software that enable sensing, collecting, and storing of data), connectivity components (allowing for the interaction with the environment and the processing of data outside the machine; e.g., in the cloud), and are extended by machine-related services (e.g., services focused on optimizing manufacturing processes). - Philipp Scharfe and Martin Wiener, Technische Universität Dresden.
https://www.researchgate.net/publication/352538995_Smartification_in_the_Mechanical_Engineering_Industry_A_Typology_of_Smart_Machines
Productivity Improvement Through Smart Machines
https://nraoiekc.blogspot.com/2017/07/productivity-improvement-through-smart.html
2. Promote the Setting up of Smart Factories
The full factory is made smart by connected machines and connected workforce.
High Productivity Through Smart Factories - Industry 4.0 - Bulletin Board
https://nraoiekc.blogspot.com/2017/07/high-productivity-through-smart.html
Operator Productivity in Industry 4.0
The Connected Worker in Industry 4.0
What is connected worker?
The Connected Worker embraces changes, solves problems, and improves continuously by engaging the full potential of the connection to the Digital Twins. AVEVA’s solutions addresses the needs and expectations of the human behind the working asset when learning, preparing and executing work. AVEVA provides the connected worker with seamless collaboration, access to timely information, and enhanced visualization and insights.
___________________________________
https://www.youtube.com/watch?v=A51kqJeLAH4
_________________________________
TCS Connected Worker - ENERGY, RESOURCES, AND UTILITIES Sector SOLUTION
Digitization to enhance safety and operational efficiency of Operators
The industry still grapples with challenges like ensuring worker safety, reducing risk of errors, managing skill-performance gap and creating visibility of work status.
TCS SOLUTION
TCS Connected worker solution is designed for field workers to accelerate field force digitization, enhance real-time operational visibility, enable in-field data-driven decision making by providing real time contextual information from various OT and IT systems and enabling real time information interaction.
TCS Connected Worker Solution aims to bring digital transformation in the field by addressing the requirements of the industrial worker and offering a comprehensive and scalable ecosystem to deliver end-to-end solutions for real-world use cases in the areas like:
Health & safety
Operational efficiency
Productivity improvement
Skill enhancement
No comments:
Post a Comment