A smart factory focus on digitized manufacturing as compared to traditional manufacturing, which heavily relies on manual process and operations. Having a smart factory over traditional factories grants you a whole bunch of new abilities along with some caveats, after all, nothing is perfect. But the benefits of smart factories far outweigh the caveats and most importantly save precious time and money. Building a smart factory model is not easy and requires a lot of software development. Let’s take the time to understand what a smart factory is in the first place and the technologies that play a key role.
What is a Smart Factory?
A smart factory can be aptly described as a fully connected, integrated, collaborative, and centralized manufacturing hub that can face the growing demands of customers in real-time. Things like faster and streamlined processes, improved machine utilization, reduced maintenance costs, machine automation, remote access to all operations, and reduced TCO, among many other things, do come in handy. Eternitech is one of the leading IT company in the USA and has helped countless companies make the switch to the smart factory model. A combination of various Industries and technologies contributes to the optimization of smart manufacturing. Here are the most important enabling technologies:
Industrial IoT
IoT refers to use of data between people and machines, and processes that are connected via data communication systems. These instruments typically feature sensors that gather useful data points on an offline or cloud database to track and find ways to enhance the manufacturing process. Operational effectiveness, control, and visibility into important critical parameters are made possible by IoT.
Cloud Computing
The ability to swiftly upload vast amounts of data that can be distilled to provide feedback and make decisions almost instantly benefits connected machines and devices on the shop floor. Smart factories can store, process, and share data more easily and affordably thanks to cloud computing.
Sensors
At specific moments in the manufacturing process, sensors attached to equipment and machinery help collect precise data points, giving quick visibility into the different shop floor layers. The environment in a lab can be tracked and detected by temperature sensors in a cleanroom, and the data can be shared through an IoT gateway. The data can then be used for AI (Artificial Intelligence) self-correction or to notify pertinent team members for review.
Big Data Analytics
Data collection over time can yield information about the effectiveness of the manufacturing process which key metrics to focus on, and the systems that need improvement. Big Data’s immense scale makes it possible to identify error trends and perform highly accurate predictive quality assurance. Shop floors may swiftly and effectively improve thanks to big data analytics’ presentation and timing, which delivers the correct information at the right moment.
Key Benefits of Smart Factories Over Traditional Factories
For a manufacturing hub to be called a smart factory, it has to provide the following basic benefits to the owner and the industry.
Adaptability
A smart factory can quickly adapt and rise to any demands of the client and their needs and requirements. Adaptability is one of the key benefits of smart factories when compared to traditional factories.
Performance and Efficiency
Smart factories have a network of sensors that are strategically placed to feed the system with important data. These data will then be analyzed in real-time to allow the operator to make any final changes or adjustments before the production begins. Such last minutes changes and corrections may save precious time during production. This leads to improved performance and efficiency.
Reliability
Reliability is the Achilles’ heel of traditional factories. Human errors combined with larger maintenance time can really wreak havoc on the product line, and even more so if it happens during peak hours. Smart factory’s automated process allows for greater reliability and minimizes human error. This leads to greater liability on the system and less burden on the operators. Eternitech has also partnered with a leading desktop application development company to ensure great service and reliability to its clients.
Quality
Using AI and machine learning algorithms, systems can quickly detect if there are quality control issues. If does detect any defects, the product will be discarded and sent for recycling and in the meantime, the system will figure out the source of errors and alert an administrator to fix the source. If the source is fixed, such defects will not happen with the next batch of production. This saves both time and money.
Security
Using data encryption and a secured tunnelling network, the systems at smart factories are less susceptible to vulnerabilities and external attacks. Security tools regularly monitor every process and take appropriate actions if necessary. Since these systems are always connected, it allows the IT teams to regularly update and patch any vulnerabilities.
Maintenance
Thanks to well-placed sensors, the systems get regular feeds of data about key processes, system reliability, and core functions. This allows IT administrators to quickly fix potential issues before it reaches a critical point.
Worker Safety
With automated processes, the possibility of a potential injury to workers is little to none. Additional safety precautions are also baked into the system to ensure minimum risk to workers’ health.
Conclusion
Making a switch to a smart factory model can be quite expensive, but it is also necessary. Eternitech, one of the leading software development companies, has helped many companies make the switch to smarter models and they were very satisfied with the result. Contact us at Eternitech to get additional information.
