You don’t have to replace your machines with the new ones to make your production “smarter” and more efficient. Your shop floor is a data mine, and digitization is the key to unlock its value. Technologies such as Industrial Internet of Things (IIoT), Artificial Intelligence (AI) or the public cloud are tools that allow you to collect and transform data into valuable insights, enabling you to improve production efficiency by identifying losses, minimizing production downtime or improving quality. Learn how technologies modernize manufacturing operations and maximize profits, turning even the most complex shop floor into a well-oiled… machine.
Manufacturers often face difficulties in achieving production goals, caused by the condition of machinery and equipment. Constantly improving shop floor, and expanding with modern robotic lines brings benefits…. Yes, this is true, but let’s consider whether a similar effect can be achieved in other ways, further reducing capital and operating expenses.
Effective utilization of the shop floor also includes the use of IT technology that allows precise tracking of production parameters, the quality of raw materials and input components, and the condition of machinery. On the basis of historical data correlated with current one, this allows to dynamically optimize and adjust the schedule or production parameters. This makes it possible to increase productivity, increase quality, and reduce material losses. The integration of machines with production management systems and process automation allows to increase in the resiliency and flexibility of plant operations, translating directly into its efficiency.
Consistent improvement, backed by smart technologies, allows manufacturers not only to avoid disruptions and achieve goals while minimizing resource consumption, but also to improve process efficiency. With flexible asset management, companies are countering production challenges by staying competitive.
According to Deloitte: Technology will play a significant role in helping manufacturers address the challenges they may face in 2024. With their continued search for efficiencies, many intend to continue to meet their digital transformation goals.
In this context, it is worth considering what will be the competitiveness and efficiency of organizations that invest in innovative solutions in difficult times relative to those that do not.
A Deloitte survey found that as many as 86% of manufacturing executives surveyed believe that smart factory solutions will be the main drivers of competitiveness over the next five years. This is because increased organizational efficiency is needed precisely in moments of complex economic circumstances. This can determine the “to be or not to be” of a given company. It is worth emphasizing, however, that this is only the case when innovations are introduced with specific goals and expectations of return on investment (in the form of improved efficiency, increased capacity, and others) in mind. Finding the right technology partner can be helpful.
Automated data collection, especially with the calculation of the key operational efficiency indicators (such as OEE) based on it, is an indispensable first step in the digitization of manufacturing companies. While these are important tools – their true potential is only revealed through the effective use of this data. The collected data provides the foundation for optimizing production processes, predicting potential failures, and increasing efficiency, all made possible by suggestions generated by artificial intelligence (AI) and machine learning (ML).
Management of production becomes more transparent, enabling rapid response to changing conditions and dynamic adjustment of processes. Additionally, equipment utilization can be optimized when OEE data is interpreted by artificial intelligence systems in the context of production. By correlating OEE with other production data and parameters, such a system finds and recommends areas of improvement for more effective production management (it can, for example, detect anomalies in machine operation to predict breakdowns or recognize patterns to predict product quality).
In the context of the production shop floor, access to data makes it possible not only to monitor its operation but also to understand precisely its performance and potential areas of improvement. It can also be used to “make realistic” production targets or standard times (previously usually estimated).
In addition, production flexibility becomes achievable through the use of collected data. Through AI/ML analysis, production plans and processes can be quickly adapted to changing market conditions. The combination of production machinery, data, and intelligent suggestions generated by digital technologies allows companies to achieve not only operational efficiency but also strategic flexibility in a dynamic industrial environment.
How does this work in practice? In the event of production disruptions (through equipment failure, unforeseen crew absence, or material delays), real-time monitoring allows you to immediately analyze the situation and propose solutions “on demand”, without waiting for the next shift or the next day. As a result, it can recommend dynamic changes to the production schedule, based on information about the efficiency of the line or shifts, the quality of delivered materials, or contractual requirements.
Production monitoring software is a fundamental part of the Industry 4.0 solution offering, defined as a system that enables managers, engineers (process, maintenance, or quality), and operators to analyze production in real-time. It provides comprehensive production data, such as the number of units produced, cycle time, time and reason for downtime, quality information, and energy consumption, which can be easily accessed at any time.
The software assists in maintaining production continuity. With precise data on machine uptime, downtime, or efficiency, operators can plan machine maintenance and repairs, minimizing the risk of breakdowns and downtime. This in turn translates into increased production efficiency and reduced equipment maintenance costs.
1) Data from machines and systems
The first step is to verify the machines, controllers (PLCs) and production support systems for the data they provide. Usually, it is possible to integrate with them, but sometimes it is required to buy licenses or add-on modules from the vendor. If the right signals are missing, additional sensors may need to be installed to fill in the missing data.
2) IIoT connectivity
The Industrial Internet of Things allows integration with machines and systems via industrial protocols, as well as the collection and transmission of data to business applications, including those for monitoring, measuring, and interpreting the efficiency of production resources.
3) Visualization and conclusions
The data is presented in a convenient and easy-to-understand form. Statistics and diagrams presented in the form of reports or user screens can be accessed via desktop, tablet, or even phone. These screens are available both to office workers who need them and on the production floor, where operators can record the causes of downtime and get real-time feedback on production performance.
Typically, manufacturers proactively monitor several key performance indicators (KPIs) to understand how different functions are executing a specific process. Since each stage of production plays a specific role in a complex system, managers need to have quick access to information to understand how each part of the operation affects overall efficiency, where bottlenecks arise, and how they can be addressed.
KPIs, regularly monitored on the production panel, perfectly reflect this idea and represent best practices in managing production processes. Managers can keep track of key parameters in real-time, such as the number of units produced, cycle time, downtime, energy consumption, or productivity of individual machines.
In the context of modern manufacturing plants, specialized machinery, and innovative production, technologies play a key role in achieving set goals. Supported by advanced monitoring systems, modern machines allow precise control of production processes, which in turn translates into optimized efficiency. Common KPIs provide a unified view of the entire plant, integrating data from different sources and enabling managers to make good decisions.
The shop floor plays the role of the heart of any factory. However, optimizing production does not involve investing in new specialized machinery. The key to increasing process efficiency is the intelligent use of data and employee involvement.
The introduction of high-end machinery, tailored to the specifics of production, is one way to optimize the shop floor. Modern equipment with advanced functionalities makes it possible to obtain high-quality products while increasing productivity.
Digital transformation includes not only the introduction of new equipment but also a focus on the effective use of existing equipment, using available production data. Analysis of the collected information allows a better understanding of the production structure, identification of areas in need of optimization, and rapid response to changing market conditions. In this way, intelligent asset management becomes a key element of the strategy for achieving operational excellence.
We offer a full range of services for manufacturing companies, including:
– Advising on digitization roadmap and strategies to improve production efficiency.
– Return on investment (ROI) calculation
– Design, implementation, and integration of OEE applications with existing systems and infrastructure.
– Training, support, and service for OEE applications and production digitization.
Shop floor management involves the coordination and supervision of activities within the manufacturing environment to ensure efficient production and manufacturing processes. It encompasses various tasks such as production scheduling, quality control, inventory control and management, and workforce coordination. Effective shop floor management aims to optimize productivity, minimize waste, and enhance overall operational efficiency. All of these areas can leverage shop floor solutions to provide improved shop floor visibility, efficiency, and collaboration.
Shop floor digitization enhances manufacturing efficiency by providing real-time insights into production processes, enabling better decision-making, minimizing downtime, optimizing resource utilization, and streamlining workflows.
Implementing OEE (Overall Equipment Effectiveness) software on the shop floor enables manufacturers to monitor equipment performance, identify inefficiencies, reduce downtime, improve productivity, and enhance overall equipment utilization.
Manufacturers can leverage IIoT technologies on the shop floor to connect and monitor equipment, collect real-time data on performance and condition, enable predictive maintenance, optimize energy usage, improve inventory management, and enhance overall operational efficiency.
A client, a leader in the glass packaging manufacturing sector, identified the need to implement an integrated production data management system to replace outdated, manual reporting methods.
Introduction In the highly competitive food and beverage industry, achieving optimal Key Performance Indicators (KPIs) such as availability, performance, and quality is essential for maximizing operational efficiency and profitability. A client operating semi-automated production lines was experiencing persistent underperformance in these KPIs. To address this issue, the company required a robust and precise data-driven approach […]
In the aerospace and defense industry, which is characterized by particularly high requirements for precision and reliability, key performance indicators in maintenance, failure prediction or machine condition monitoring, are crucial.
Industry 4.0, also referred to as the fourth industrial revolution, is a concept encompassing a complex process of technological and organizational transformation of companies, which began in 2013.
If you think OEE has no secrets to you and your plant maintain highest OEE results… think again. Harsh truth is that most manufacturing plants’ OEE land somewhere between 35 and 43%. They just don’t know about that.
Whether you're a seasoned user or new to ThingWorx, overcoming these hurdles is crucial for IoT success. In this blog, we'll uncover the top challenges, offer tips for newcomers, discuss strategies to enhance your ThingWorx experience, and explore the importance of upgrading your ThingWorx solution.
Very often overlooked or accepted as-is due to being an integral part of the production – in times of crisis and cost-cutting, it can become a major factor that improves the bottom line of your organization. Where to look for significant energy savings to reduce energy costs? How manufacturers should focus on these goals to make an impact?
According to the German Federal Statistical Office, energy consumption by the industry for the production of goods hardly changed between 1995 and 2019. In 2019, it amounted to 3,874 petajoules. This means that it remains at the same level as in previous years. Germany plans to halve its primary consumption of energy by 2050, with the industry having to take part. In the era of the energy crisis, the drive to improve corporate energy efficiency is entering a new level.
In the manufacturing industry, efficiency is key to staying competitive and profitable. One way to improve efficiency is through data visibility. By having access to real-time visibility of the operational data throughout the manufacturing process, companies can identify bottlenecks, monitor production lines, and make data-driven decisions. In this article, we'll explore how data visibility can help manufacturing companies improve their efficiency and ultimately their bottom line.
Energy consumption bills have been a major focus in virtually all areas of industry for many years, and the current global situation is a factor driving up demand for solutions that make it easier to monitor energy consumption or save energy. In an industrial environment, where the cost of utilities has always been one of the main business drivers, the latest twists and turns in the global economy: inflation, natural resources supply challenges and the threat of fluctuating and unpredictable increases in energy costs – are arguably the most important economic factors these days.
The new opportunities associated with Industry 4.0 require companies to adapt to the new environment. In this article, we take a closer look at the current situation in the automotive industry, discuss the challenges it faces and the opportunities offered by digital transformation.
Digital transformation is reshaping the way how people, products, assets, data, and operations are connected to create an outcome for the customers and switch digital data into the customer experience. Digital technologies create new business opportunities across the globe and enable the evolution of enterprise, products and processes for valuable capabilities. The article describes the Internet of Things concept and shows how to use cloud infrastructure to take advantage of the digital transformation in business.
Internet of Things systems have one huge advantage – they can collect lots of data. Temperature, items produced, amount of remaining liquids, humidity, machine uptime, damaged products, vehicle routes, electricity used. Based on this, we can get even more value by calculating KPIs to indicate how close to perfect our system is. Going manually through an endless stream of numbers changing every couple of hours is impossible and inefficient. The simple solution is to visualize the data by using a carefully selected chart type, that will exponentially increase its value. In this article, I want to show you the benefits of good data visualization and explain how it can be applied in your solution.
The sudden epidemic of SARS-CoV-2 coronavirus and the COVID-19 disease has affected every sphere of the modern world. Caused by an epidemiological threat, the restriction of the flow of people, goods and services has already negatively affected the continuity of production processes in many industries, and each day this situation persists, without credible forecasts of a return to normality, will pull others into the spiral of detention threats.
Scalability in web applications has become crucial in the past years. An ever-growing number of devices and clients, connected to the Internet, makes it difficult to handle the traffic by a single server. Scalability is a characteristic of a system that tells if expanding the resources of a server(s) will make it run faster (or handle more load).
Modern web applications that serve data and content to millions of users run in clustered environments. Dealing with a huge amount of connections at the same time requires many resources. That resources are CPU time and RAM. Each and every connection produces an additional load on the server. Having just one server would require a vast amount of resources and we already know that Moore's Law is no longer valid. That said we need multiple servers ready to respond to users’ requests. Web applications use HTTP(S) protocol which works in the request-response communication method. Upon user's request, the server will prepare the response and send it back. Every response needs to be processed by the server and that's the key factor in provisioning resources for the server - requests may be different, starting from simple static data like CSS or images to more demanding like requesting data from database, filtering or calculating certain data.
The ThingWorx IoT Hub Connector is the bridge that connects the ThingWorx platform to the Azure cloud (more specifically to Azure IoT Hub). It provides secure (certificate-based) communication, thanks to which we can use the enormous possibilities of cloud computing. It is also a very extensive, but generic solution.
Synergy, this is how you can define this natural combination of technologies that will significantly affect the appearance of the future of production. Recently, in addition to the Internet of Things (IoT), artificial intelligence (AI) is gaining more and more popularity. The connection of these two technological trends heralds a real revolution in industry 4.0.
This year's Liveworx, due to the global situation caused by the COVID-19 pandemic, has exceptionally been held only online. On the very first day it was announced that a new version of ThingWorx - the most popular platform maximizing the potential of the industrial Internet of Things - will be released for commercial use. According to the announcements of Joe Biron, CTO responsible for IoT technology at PTC, it is supposed to be faster, cheaper and more effective.
The evolution of artificial intelligence, as well as machine learning has gained momentum in the last few years. The constant drive to increase the computing power of computers has given the opportunity to use algorithms and mathematical apparatus created in the second half of the 20th century on an unprecedented scale. With the imminent arrival of a commercial quantum computer, we can slowly become afraid of scenes from the movies with Arnold Schwarzenegger as Terminator. However, without going too far into the future, and focusing on the present, I decided to check the possibilities offered by the technology available today and whether it can be used to predict the spread of COVID-19 disease.
The Industrial Internet of Things changes our view on the classic concept of production today. The largest manufacturing companies are eager to reach for technological solutions that streamline and increase the efficiency of production processes. With the development of subsequent technologies, interest in the concept of industry 4.0 increases, and thus, the number of connected devices. To meet the demand for infrastructure with adequate capacity and speed it was necessary to evolve towards the next generation of networks - 5G. How will 5G affect the development of Factories of the future and why is this crucial from the perspective of the Internet of Things? You will learn everything from the article.
The Internet of Things is being used more and more, and even global giants are already using the optimization or information gathering solutions. All this to improve existing processes, acquire, process and report more data, or even introduce new services for their clients, thereby increasing sales revenue. How is the Internet of Things changing the reality of the aviation industry?
Following up our partnership with Rockwell Automation, our team of business and technical experts found their way to Munich, Germany to participate in TechED EMEA. It is a unique event during which you can listen, talk and test the latest news in the field of industrial automation and directly participate in the next industrial revolution.
Nobody would be surprised by a statement that the Automotive industry is innovative in its nature. Cars are machines that historically revolutionized many areas of industry themselves, and today we can’t help but notice that the industry has not slowed down even for a moment and has always been focused on technological growth that serves both the business and its customers.
It might seem that the Internet of Things is dedicated only to industry. However, transport and logistics are closely connected to it, and they can also take advantage of the ongoing revolution. In the end, every industry uses transport services or logistic processes to some extent.
As every time for the last couple of years, our strong team of representatives was present in Boston to attend one of the most important IoT events of the year – LiveWorx, 2019 edition. Get the ball rollin’ And even with 10 participants from various business areas, actively seeking new information and presentations, […]
Industry 4.0 and its foundation, the Internet of Things (IoT – especially in industrial version: IIoT), in the last years have dominated the way of thinking of advanced management concerning manufacturing business resources.
PTC is phasing out its Axeda platform. Although they look similar at first sight, Axeda and ThingWorx differ very much in capabilities.
While ago, PTC announced a new release of ThingWorx Platform (8.4). Among other exciting features, this release has OOTB support for integration with InfluxDB.
The approach that has been underestimated for a long time is nowadays spreading its wings and becoming a crucial set of solutions for global corporations. However, not only for them as medium and small companies are following the biggest ones as well. Thus, the advantages of the Internet of Things have been recognized by everyone. […]
Recent years were hyped about the Internet of Things (IoT) and how it was supposed to re-shape the whole industry. However, so far we’ve seen many more people talking about it than actually implementing it enterprise-wide. Is IoT mature enough to be “the real deal” and bring measurable value to businesses? The term IoT […]
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