NRTC AUTOMATION BLOG | INDUSTRIAL ROBOTS AND AUTOMATION
Industry 4.0: Simulations, IoT, and AR in Manufacturing
The fourth industrial revolution, popularly known as Industry 4.0, is powered by various technologies, including simulations, the Internet of Things, and augmented reality.
The fourth industrial revolution, popularly known as Industry 4.0, is powered by various technologies, including simulations, the Internet of Things, and augmented reality.
Industry 4.0 presents the world with applications meant to make life simpler. For manufacturing companies, simpler life can mean a whole lot of things. It could point towards easily identifying problems with your machines, predicting future problems, reducing accident rates, using analytics to identify the profitability of each machine, among others.
Incorporating simulations, IoT, and AR in manufacturing plays a crucial role in achieving industrial automation. To a great extent, one could argue that Industry 4.0 has helped unify operational technology (OT) with Information Technology (IT).
Read on to the end to learn more about the technologies fueling Industry 4.0 in the manufacturing sector.
Industry 4.0: Simulations, IoT, and AR in Manufacturing
FORCES BEHIND INDUSTRY 4.0
Industry 4.0 cannot become a reality on its own. Instead, it is powered by many forces such as autonomous robots, big data analytics, augmented reality, the Internet of Things, simulations, additive manufacturing, predictive demand, and bottlenecking production.
This section focuses only on three of these, which are the major players. That’s not to downplay the other elements that are helping make Industry 4.0.
SIMULATION FOR INDUSTRY 4.0 IN MANUFACTURING
Simulation refers to imitating the real-world system or process over time. Such imitations enable experts to closely evaluate real-world processes or systems in controlled environments.
Industrial organizations that are yet to explore this technology in their manufacturing process lose opportunities to study their systems before deployment. Using simulations can be beneficial, especially considering the high costs incurred in commissioning new manufacturing plants and processes.
Some of the benefits that you can anticipate from simulation in Industry 4.0 include:
· Revealing manufacturing bottlenecks and opportunities that can deliver more throughput
· Revealing opportunities to save costs, including direct and indirect labor
· Exploring the performance prediction of value streams or production facilities
· Enhances process quality through the emulation of realistic processes
Simulation is one of the important keys for unlocking the full potential of Industry 4.0. Simulation tools mostly work in a 3D environment to help verify the manufacturing process. They make it possible for manufacturing organizations to virtually validate manufacturing concepts for the lifecycle of a new product. That makes it possible to quickly launch high-quality products.
IOT FOR INDUSTRY 4.0 FOR MANUFACTURING
Achieving factory automation does not come on a silver platter. It requires ongoing innovations which set the industry on the right path to success.
The Internet of Things (IoT) is one such innovation that has proven highly beneficial to the manufacturing process. The IoT market size in manufacturing continues to grow and is projected to hit $994 million by 2023.
The use of IoT in the manufacturing process enables different outcomes like supply chain management, quality management, predictive maintenance, among others. Additionally, real-time monitoring of assets and connected operational intelligence boost the manufacturing process.
You can best understand the interaction between IoT and manufacturing by considering Porter’s Five Forces. In this model, IoT companies take the position of suppliers while manufacturing firms are consumers/buyers.
Suppliers (manufacturing companies) have higher bargaining power because they can take in low product differentiation and high product quality. The supply-demand is still low while the growth rate is skyrocketing. That implies the key IoT stakeholders for the manufacturing process will continue to face stiff competition.
Two major factors related to IoT in manufacturing are real-time asset monitoring and cloud-based deployment.
Real-time asset monitoring empowers manufacturing companies to monitor the changes taking place in their firms, thereby reducing defects and enhancing operational efficiency.
AUGMENTED REALITY (AR) IN MANUFACTURING
Simply called AR, augmented reality combines real and virtual worlds generated by the computer. It starts with capturing a real image that gets infused or augmented with different layers of digital information.
AR is not the same as virtual reality, an immersive experience that closes the real world. In the case of VR, a computer-generated video is superimposed on the real-world video to give the impression that the computer-generated objects have fixed locations in the real world.
Using VR in manufacturing would be limiting because of the obstruction of real-world interaction. Thanks to augmented reality, it becomes possible to have a seamless and natural perception of employee movement. The technology has proven useful in the manufacturing process in terms of measuring changes, envisioning the end product, and seeking out dangerous working conditions.
Manufacturing AR empowers manufacturers to get the minute details of the worker’s current environment. For instance, they can see a piece of equipment and the current operational temperature. The worker can determine from this information that the equipment is hot and should not be held with bare hands. Augmented reality in manufacturing is one of the most effective ways for factory workers to understand what is happening. They can tell which machines have broken down, restricted areas of the factory, and much more.
NRTC IS CHAMPIONING AUTOMATION, A KEY ELEMENT IN INDUSTRY 4.0
At NRTC, we have made it our mission to deliver automation in the manufacturing sector. Simulation, the Internet of Things, and augmented reality foster the growth of Industry 4.0 as we make key steps that ensure automation becomes part and parcel of your process.
Contact us to learn more about our engineering services. We would be glad to walk with you every step of your journey towards embracing Industry 4.0.
What is Digital Manufacturing?
Digital manufacturing is the future of production and automation.
Digital manufacturing is the future of production and automation.
Manufacturing has traditionally been a numbers game: giant assembly lines mass producing products in vast quantities. Mass production is no longer the predominant model.
Manufacturing is trending towards a different future—one in which products can be produced on a dime and respond to changes in customer demand. Consumers are demanding higher-quality, customizable products, and on-demand products.
The result of demands placed on manufacturing is two-fold:
Lifecycle Churn: Consumers replace their products more often. In fact, one-third of home appliances and 60 percent of TVs are replaced with a better product, even when they continue to function. If companies want to keep up with consumer demand, they’ll need to constantly innovate and launch new SKUs.
Greater Customization: Mass production strategies cannot efficiently produce customized products. For example, a line of drones may be produced for a variety of applications. Each SKU will require different hardware, software, and systems which leads to multiple short production runs for each model.
The digital revolution in manufacturing is essential for satisfying these emerging demands.
What is Digital Manufacturing?
With the emergence and refinement of new and traditional technologies, manufacturing is becoming a multi-disciplinary field. Digital manufacturing, in particular, is becoming more prevalent across industries.
Digital manufacturing is an interdisciplinary approach, combining elements of design for manufacturability (DFM), computer-integrated manufacturing (CIM), flexible manufacturing, and lean manufacturing.
Digital manufacturing is the co-creation of product and manufacturing processes using a computer system. By linking systems and processes across production, the computer system is able to model and iterate on manufacturing designs and processes before creating the final product or assembly line layout.
An automotive original equipment manufacturer (OEM), for example, can model its manufacturing process (including tooling, assembly, and factory layout) while designers iterate on the next car lineup. Product and manufacturing designers can collaborate throughout the product life cycle, catching mistakes and identifying constraints early.
Types of Digital Manufacturing
DIGITAL MANUFACTURING LIFECYCLE
The digital manufacturing lifecycle is composed of three main parts: product, factory, and value chain management. Each aspect of the lifecycle is tied to manufacturing execution.
First, the product lifecycle includes engineering design, sourcing production, and service life. Digital data is utilized and necessary revisions to the design are subsequently made during that stage.
The smart factory leg uses automation and industrial internet of things (IIoT) technologies such as smart machines, sensors, and tooling. IoT provides instant feedback during operation, allowing greater visibility, control, and optimization. Enhanced business intelligence systems perform in-depth analysis, leading to insights into areas of performance or process improvement.
Value chain management aspects refer to optimizing for process and inventory while assuring quality. The result is decreased inventories, optimal process integration, and better customer satisfaction.
Benefits of Digital Manufacturing
Digital manufacturing strategies help companies recognize the benefits of product lifecycle management (PLM) in a number of ways. At its core, the main benefits are related to producing more, faster, and at a lower cost.
The benefits of digital manufacturing include:
Reduction in manufacturing waste: It’s estimated that 68 percent of manufacturers have reduced their bottom line as a result of excess materials, labor, packaging, and shipping. Through design modeling and optimization, predictive analytics, as well as an efficient response to demand. For example, digital data may be shared with contracted manufacturers to order just the right number of items, avoiding waste.
Mass customization: The use of computer-assisted control (CAD) and automation allows customization of product SKUs, without iterating on the production line. The result is the ability to continuously iterate on designs and manufacture products in smaller batches. Additionally, companies can utilize software to manage production, rendering low volume production runs more economical.
Avoidance of costly errors as a result of missed or misinterpreted data
Facilitation of more efficient factory lineups and models, with optimum layout
Enablement of quality data sharing through CAD-based machine inspections for industrial robots and machine tools
Improved visibility: IIoT sensors allow real-time visibility into the process, equipment, and systems. Technicians can optimize machine use and perform preventative maintenance using remote monitoring technology. Additionally, machine data can also be integrated with other data sets to optimize production—including the entire supply chain.
More rapid pace of innovation and enablement of six-sigma and lean initiatives by analyzing dimensions with a graphical environment. For example, digital manufacturing can help automate time consuming processes, such as front-end engineering.
Take Advantage of Digital Manufacturing
Capitalizing on digital manufacturing is essential for companies of the future. Consumers will come to expect higher-quality products delivered on faster time frames for a lower cost.
The best way to get started with digital manufacturing is through small projects that impact safety, efficiency, or quality. Projects may be value-driven based on customer journeys to maximize ROI. Consider collaborating with manufacturing floor technicians who can identify the best projects and increase adoption.
Plan to scale only after completing a series of successful projects. First, deploy to a manufacturing line, and the plant level next. Finally, develop a strategic plan to overcome roadblocks and embed technologies into future plants. It’s also important to continuously develop and invest in new roles and capabilities through upskilling programs.
Ultimately, a successful strategy to scale digital manufacturing is focused on business value. According to Mckinsey, aspirations should be linked to real and specific business needs.
Industry 4.0
The digitization of manufacturing has been nicknamed “Industry 4.0” because it represents the fourth revolution to occur in manufacturing. Industry 4.0 builds on Industry 3.0, which is when computers were first introduced to manufacturing.
According to Mckinsey, pioneers of Industry 4.0 have recorded 30-50 percent reductions in downtime, up to 3 percent improvements in productivity, and 20 percent declines in quality cost. Manufacturers aren’t deploying technologies at the same rate: many organizations are stuck in “purgatory”: they have no strategy to scale across their network.
Failure to implement digital manufacturing technologies will render businesses stagnant in the near future. Digital manufacturing will someday become essential to remain competitive. Businesses that stay ahead of the curve will continue to have an edge.
GET AHEAD WITH NRTC AUTOMATION
NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.
From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services.
Contact us today to learn more about how we can help you meet your production goals.
How Can You Adapt to Rapidly Changing Industrial Automation?
Manufacturing is changing. Industry 4.0 is advancing manufacturing with limitless opportunities for growth.
If you’ve been paying attention to the news, you’ve probably noticed two trends: COVID-19 and Industry 4.0.
Today, we’re passing up an analysis on the pandemic’s impact on the industry to discuss the Fourth Industrial Revolution. If you are a small- to mid-sized manufacturer, you may feel left behind in all this innovation. Thankfully, NRTC Automation is here to help!
Learn more about the digital revolution and how to keep up below.
Adapting to changes in industrial automation
Shifting from traditional to digital manufacturing
In the last 100 years, manufacturing has made some impressive leaps.
Innovations in the production line have improved productivity drastically, enabling manufacturing to put out more product and reduce waste.
When industrial robots hit the scene in the mid-20th century, the industry changed forever. Now, manufacturers could create uniform products in minimal time with fewer (costly) mistakes.
Today, the digital manufacturing revolution, or Industry 4.0, is revolutionizing the way manufacturers view data and production. With the help of AI and IoT, seeing the intricacies of the manufacturing process is easier than ever before.
What it means for manufacturing
Industry 4.0 is changing the face of manufacturing.
Digital information allows manufacturers and operators to enhance their production lines with limitless data. For example, if productivity drops slightly, an alert from IoT connected devices will notify the operator. Depending on the cause, the operator may choose to tweak the equipment to enhance performance. Better operational efficiency means a greater bottom line for your company and a more competitive stance in your industry.
Plus, digital manufacturing allows machines to communicate with each other, reducing the amount of labor needed from employees on the production line. Your staff can work more fulfilling and engaging jobs rather than working the line, which can be dangerous for their health. Less workers on the line means increased cost savings for you as well: a production line operated by one person saved an average of $120,000 every month.
Prototyping and 3D printing are also improved due to Industry 4.0. Now, because of additive manufacturing, manufacturers can design and create a prototype in a fraction of the time compared to traditional prototyping methods. Product development is sped up, getting your product to your customers sooner.
How to adapt to Industry 4.0
No matter where you are in your journey to automation, we suggest the following to stay up-to-date with the latest developments in digital manufacturing.
INCREASE CYBERSECURITY PRACTICES
Manufacturing is one of the most targeted industries for cyber attacks. With one fell swoop, hackers can destroy your internal systems and leak confidential information.
Can your company withstand a day, or even a week, without power to run your manufacturing facility? If not (and most companies cannot), then you need to strengthen your firewalls and other cybersecurity practices before you become a victim.
Check out our blog post here for ways in which you can protect your company and employees from malicious cyber threats.
ADD SMART DEVICES
Now is the time to invest in IoT.
Adding smart devices to your facility will put you in line with even the biggest competitors in your industry. Using the latest technology in IoT will enhance supply chain management so you can continue to optimize your production line for the best results.
USE YOUR DATA
Finally, use the data that digital manufacturing offers you.
Data is an extremely valuable tool that allows you to shift from a confusing and mismanaged warehouse to an efficient, streamlined production line.
Minimize downtime and increase productivity by making informed decisions on what changes to apply to your production line. The opportunity for improvement is limitless, so take advantage of data to enhance your manufacturing processes.
Start slow and get industrial automation support with NRTC
If you are a small- to mid-sized manufacturer who wants to grow, but you’re new to automation, then you’ve come to the right place.
We will help you meet your production goals and rise above the competition by adopting comprehensive and sustainable automation practices.
NRTC Automation offers full-service solutions to assist you from start to finish:
With NRTC, you can keep up with changes in the industry and improve your business in the process. We work with top auto manufacturers such as Toyota, Mercedes, and Ford, so you know you can trust us. Head over to our site to learn more about our decade of experience in the industry.
Plus, check out our YouTube video below to see more of our warehouse!
VISIT NRTC AUTOMATION TODAY
NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.
From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services.
Schedule a free consultation with us today to get personalized automation strategies for your company.
Industry 4.0: The Next Big Thing in Industrial Automation
Industry 4.0 is the next generation of automation, allowing manufacturers to optimize their factories and enhance their production process with data analysis.
Industry 4.0 is the next generation of automation, allowing manufacturers to optimize their factories and enhance their production process with data analysis.
Manufacturing has seen immense progress since the first Industrial Revolution. Electricity and telephones marked the Second Industrial Revolution, followed by the Third Industrial Revolution with the invention of industrial robots and automation.
Now, manufacturers are experiencing the Fourth Industrial Revolution. What new technologies and innovations have spurred this new era of industry? Read below to find out!
What is Industry 4.0?
Industry 4.0, or the Fourth Industrial Revolution, is the next revolution in industrial manufacturing, focusing on the interconnectivity of industrial equipment and increasing computerization of manufacturing processes.
The main feature of Industry 4.0 is that autonomous systems like robots and computers are enhanced through data and machine learning, making automation more self-sufficient and efficient.
Rise of IoT
The Internet of Things (IoT) has been around longer than computers. In fact, the first electromagnetic telegraph from the early 1830s can be considered the first variation of IoT because it enabled long-distance communication.
As technology progressed over the past two centuries, communication and data became more intricate with greater capabilities for connection and analysis.
In 1999, the term “Internet of Things” was born and became increasingly popular in the 2000s as wireless technology gained a greater presence in both the home and in factories.
Today, the IoT is progressing rapidly as more devices are created and used worldwide. In 2017, there were a recorded 8 billion IoT devices connected to the internet, and it is projected that there will be 75 billion IoT devices in 2025.
What makes up IoT?
There are four essential components that make up IoT:
Industrial equipment with internet capabilities (PLC, HMI, etc.)
Connectivity (router, etc.)
Cloud platform for data
Dashboards for action and analytics
Industrial robots and equipment are connected to an internet-enabled router and create data as they perform, which is sent to the cloud via a router or other form of connectivity. Manufacturers and operations can use dashboards to view the data and make decisions based on their analytics.
Importance of Connectivity
With connectivity, manufacturers have a greater ability to optimize their production lines using the data culled from the IoT.
The power of IoT is that it allows manufacturers to connect multiple sites from different locations, and IoT is not dependent on hardware or restrained by the limitations of software. That means manufacturers of all sizes and industries can enjoy the benefits of Industry 4.0.
With IoT, there is full visibility throughout the entire supply chain, giving manufacturers the advantage to create the best possible product for their customers.
Cybersecurity in Smart Manufacturing Factories
With greater connectivity comes greater risk.
Manufacturers should be diligent about having increased cybersecurity protection against hackers in their smart factories. A successful cyberattack could devastate a factory’s production and cause increased downtime as operators scramble to fix the error and secure the connection.
Because of the dangers of cyberattacks, manufacturers should pursue cybersecurity with the same determination as smart manufacturing processes.
A great place to start is with the National Institute of Standards and Technology’s (NIST) Cybersecurity for IoT Program. The program has articles, published papers, videos, events, and more for manufacturers to learn the best practices for securing their systems against hackers.
Reap the benefits of increased connectivity without fearing the downfall of an attack. Secure your networks and systems and check your security levels frequently to ensure that you are on the defensive against hackers.
Be a part of Industry 4.0.
With increasing connectivity, manufacturers can easily create more efficient production lines and improve their products. Industry 4.0 provides data that can be used to cut down on waste, save money with enhanced economical processes, and reduce downtime in factories.
Connect your factory today and be a part of the Fourth Industrial Revolution.
AUTOMATE WITH US.
If you still need to work on automation before you can leap into IoT, then partner with NRTC Automation. We can design, build, and engineer a customized work cell for your facility. We used affordable refurbished robots so small- to mid-sized manufacturers can benefit from automation in their facilities.
Contact us today to learn more about how we can help you improve your production line.