NRTC AUTOMATION BLOG | INDUSTRIAL ROBOTS AND AUTOMATION
3 Steps to Transition into Industrial Automation
As industrial automation continues to revolutionize the manufacturing sector of the economy, what steps should you follow to automate your own company?
As industrial automation continues to revolutionize the manufacturing sector of the economy, what steps should you follow to automate your own company?
Industrial automation is a process of streamlining industrial systems by integrating smart tools and smart technologies to ease your production or fabrication process with very little human intervention. Automation reduces overall operating costs and the risk of human error through increased standardization, speed, and better adherence to the design specifications.
3 Steps to Transition into Industrial Automation
The key advantages of using industrial automation in your production line are an increase in efficiency, a reduction in human error and injury, minimal waste, and optimized lead time. NRTC Automation is making the entire process even easier with our automation services.
Where to begin with industrial automation
Sectors in need of automation to optimize the production process include manufacturing, processing, transportation, and warehousing.
There are three phases of automation, starting from the ground up:
BEGINNER PHASE
This is the first phase of automation. Starting with the basics helps companies understand the areas they can automate. Starting out with industrial automation includes these steps:
Identifying and evaluating areas for automation potential
Installation of sensing infrastructure (e.g. temperature, airflow, and pressure) and other simple task execution automation
Installation of single robots with basic programming to complete simple tasks
At this stage, most companies usually have limited infrastructure and resources for full industrial automation implementation. The general recommendation is to start automating smaller projects to test it properly.
And if it’s a success, it can be scaled further throughout the company.
INTERMEDIATE PHASE
Under this phase, a company is expected to have fully utilized its traditional automation processes so as to introduce some of the more complex automation processes. This phase involves:
Fully utilization of the basic sensing infrastructure installed in the previous phase so as to end up with a highly automated production process
Installation of more advanced sensing infrastructure such as vision systems
Installation of advanced programming that can take advantage of current optimization routines such as machine learning
Installation of industrial robot work cells to fully automate processes along the production line
This stage is where most small- to mid-sized companies find their comfort level and a balance between investment and productive output.
For larger corporations with heavily repetitive processes, such as automotive companies, the next stage of industrial automation may be better suited to their needs.
ADVANCED STAGE
This phase involves the introduction of more complex solutions such as Automated Mobile Robots and Automated Guided Vehicles (AGVs).
At this stage, most companies have mastered both traditional and cutting edge automation technologies that are crucial to industrial automation in all aspects of their operations by automating their manufacturing platforms, optimizing supply chains, and introducing complex data analytics to enhance their decision making.
This phase mainly involves:
Installation and utilization of advanced robotics such as automated guided vehicles
Utilization of the latest automation programming such as neural networks and artificial intelligence
Automation of the most significant indirect tasks such as engineering and management
Implementation of cybersecurity policies for industrial automation network
No matter what stage you’re at, industrial automation solutions can improve any aspect of your business and bring significant value.
Pillars of Industrial Automation
As Industry 4.0 introduces more automated systems along the production line to perform critical tasks, such as using programmable logic controllers (PLC) and automated infrastructure such as robots, Automated Mobile Robots, and Automated Guided Vehicles (AGVs).
The pillars of Industry 4.0 include:
Advanced data analytics
Data analytics is one of the largest contributors and drivers of industrial automation, which is based on the type of data you collect and how you process it. There are 4 types of data analytics.
Descriptive analytics: These analytics help you understand how effective your operations are, and what’s happening with your products and machinery, as it mainly relies on accurate and timely data that allows effective visualization of the company’s processes.
Diagnostic analytics: A diagnostic analysis is all about digging deeper into the root cause of a problem, by answering specific questions on why certain processes are less effective or why they have failed.
Predictive analytics: As the name suggests predictive analysis helps understand what’s likely to happen by reviewing and understanding certain patterns and tendencies. Predictive analytics do come in handy especially when forecasting demand and interpreting sales.
Perspective analytics: Perspective analytics is all about utilizing the information at hand and finding the best strategy to address a particular problem so that a business can optimize every process to its fullest potential.
Enterprise mobility
Enterprise mobility is the largest enabler of Industry automation as it combines several solutions such as enterprise mobility management, mobile app, and device management, together with client management. Some of the goals that intend to be achieved by these solutions include:
Data loss prevention
Compliance with security regulations
Bring your own device (BYOD) programs and other end-user accountability
Portability of the resources and adoption of the mobile applications.
Industrial Internet of Things (IoT)
Technology is key when it comes to automating field operations and integrating with business processes. It allows manufacturers to closely monitor the health and performance of their devices, perform remote troubleshooting, scheduled maintenance, and ensure the safety of operations for employees.
Types of IoT implementations for industrial manufacturing include:
Supervisory Control and Data Acquisition (SCADA) collects real-time data and processes it in real-time through direct integration with sensors, so as to provide insights for optimization.
Programmable logic controllers (PLC) are computers programmed for automatic operations using information from sensors.
Computer Vision
As more companies continue to adopt machine learning and AI, computer vision is providing better solutions to these companies by providing machines with the ability to open doors to new business opportunities on behalf of these companies.
For example, a vision guided robot can identify and analyze a company’s position in regard to the production of a certain item and react as programmed.
Artificial Intelligence and Machine Learning
27% of the largest companies globally have adopted some form of artificial intelligence and machine learning into their processes.
But as small- and mid-sized companies start to catch up with industry leaders through the adoption of advanced machine learning algorithms, these companies are reducing their manual work, optimizing costs, and enabling intelligent decision making.
HARNESS THE POWER OF AUTOMATION WITH NRTC
NRTC Automation is an industry leader when it comes to industrial automation. With NRTC Automation, you can increase your company’s throughput and also maximize profitability.
Unlock your digital factory with NRTC, with automated data collection and product analysis to deliver data-driven insights.
Take action with NRTC Automation and improve your company’s bottom line.
How to Stay Ahead in Manufacturing in 2021
“The present is theirs; the future, for which I really worked, is mine.” ― Nikola Tesla
“The present is theirs; the future, for which I really worked, is mine.” ― Nikola Tesla
Although the manufacturing industry experienced setbacks due to the COVID-19 pandemic, there is still an opportunity for growth.
2021 will prove to be challenging because it will require manufacturers to think differently about their production processes. New technologies and techniques are needed to stay competitive in the post-pandemic world.
Read below about common errors that cause manufacturers to fall behind, and tips to get (and stay) ahead in 2021.
How to stay ahead in manufacturing in 2021
What causes manufacturers to fall behind?
Falling behind in manufacturing means losing revenue and potential customers to competitors due to avoidable errors.
What are some of these avoidable errors?
Not integrating new technologies: Manufacturers who keep up with technology and industry trends stay afloat in the competitive global market. Manufacturers who do not will miss out.
Being disorganized: Organization is key to productivity and overall company health. A disorganized manufacturing company is likely to have more errors that can potentially cost customer relationships.
Sleeping on data: If manufacturers aren’t using their data as the cornerstone to improving production, they are neglecting the full potential of their production lines.
Not utilizing talent: The people who work on the factory floor, as well as other staff in the company, are crucial to the success of the company. By not continuing their education, manufacturers run the risk of missing out on happier, more skillful, and more productive employees.
Not using lean manufacturing: Lean methodology gives manufacturers the chance to increase revenue while improving customer experience. When lean manufacturing isn’t prioritized, companies experience considerable losses.
What are the risks of falling behind competition?
It’s a jungle out there. If you don’t keep up with competition by making the errors listed above, you run the risk of seeing these effects in your production line and your bottom line:
Missing out on important data
Longer equipment downtime
Lower production efficiency
More wasted product
Less demand
We would venture to say that it’s simpler to stay ahead rather than stick with traditional manufacturing methods.
While implementing these new technologies and techniques may incur growing pains, the changes that are established will make it easier to track energy usage, spending, and productivity in the long run. With these measurements, you can effortlessly adjust production to meet your goals.
5 tips to stay ahead in manufacturing in 2021
To leave unnecessary risks in 2020 and continue growing your business this year, check out these five tips.
1. DIVE INTO IOT
The Internet of Things (IoT) has exploded over the past few years, providing manufacturers with the intercommunication necessary between industrial equipment for highly-refined production.
63 percent of manufacturers believe that using IoT technology will increase profitability because it allows industry professionals to develop strategies using real-time information from their production lines.
Innovation is the heart of manufacturing since the Industrial Revolution. By keeping up with technology, manufacturers can stay relevant and maintain satisfied customers.
2. KNOW MARKUP COSTS
Year after year, costs are driven up by inflation. These markup costs could detonate your manufacturing budget and reduce your bottom line significantly.
Aim to do strategic cost analyses regularly to stay informed about the latest developments in costs. This includes everything from raw materials to labor costs.
Also, consider analyzing your competitors’ prices to stay competitive.
As the saying goes, knowledge is power. Put yourself in a better position to make educated purchasing decisions and stay ahead of rivals with consistent cost analysis.
3. KEEP UP ON MAINTENANCE
Equipment breakdowns can result in massive downtime costs; for example, one minute of downtime can cost an average of $5,600 on the production floor.
Prevent costly unplanned downtime while also extending the life of your equipment by maintaining them on a regular basis. You can do this through a smart predictive maintenance program or simply by keeping a spreadsheet.
Whichever way you do it, as long as you stay on top of equipment repairs and part replacements, you are saving your facility from expensive human errors.
4. IMPROVE PRODUCTION WITH 3D PRINTING
Additive manufacturing isn’t new, but with new developments, it is bursting onto the manufacturing scene in a new way.
3D printing makes prototyping and production faster, easier, and less expensive. You can test products and troubleshoot products without the high costs of traditional manufacturing, supply products on demand, and keep fewer materials on hand which reduces your need for expensive warehouse space.
Adding a 3D printer doesn’t have to break the bank, either. You can purchase or finance a refurbished printer at a fraction of the cost of new equipment. If you’re in the market for additive manufacturing equipment, check out the iGAM Marketplace.
5. GET LEANER AND MEANER
Lean manufacturing is fundamental to manufacturing in 2021. Gone are the days where incurring material and energy waste wouldn’t heavily impact the bottom line.
Now, to stay competitive, you need to be aware of how much time, money, and resources you are using to produce your goods. Even minor setbacks can cause you to lag behind global competition.
Check out this article we wrote on Robotics and Automation News to learn more about sustainable and lean manufacturing methods, such as kaizen, 5S, and kanban. Plus, you can learn more about lean terminology and other industrial automation terms on our glossary page.
Act now and reap the benefits
A future of growth and prosperity is within reach, despite the struggles of 2020. With these five tips, you can get ahead of the competition.
SCHEDULE A FREE CONSULTATION WITH NRTC AUTOMATION
NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its 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.
Visit our website to schedule a free consultation today.
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.