15/02/2016

SmartManufacturingisReadytoTakeOffForbes

http://onforb.es/1TQJpd2

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KevinO'MarahContributor
OpinionsexpressedbyForbesContributorsaretheirown.

LOGISTICS&TRANSPORTATION

7/22/2015@1:16PM 1.906views

SmartManufacturingisReadytoTake
Off
Industrie4.0isathinlyveiledmarketing
campaignledbytheGermangovernmentandbig
alliesinbusinesslikeRobertBoschGmbHand
Siemens.Atfirstblushtheconceptsoundscool,
ifabitforcedasthoughitsbackershave
somethingtosell.Newfielddatacollectedby
SCMWorldhoweversuggeststhatrealizingthe
visionofsmartmanufacturingisimminentand
thatitsimpactscouldbeenormous.
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FourthIndustrialRevolution
AsconceivedbyitsoriginatorsIndustrie4.0
pitchesrobotics,networkeddatacollectionand
analyticsasthenextwaveofefficiencytofollow
thefirstthreeindustrialrevolutions,namely:
1)steamandwaterpower,
2)massproductionandelectricpower,and
mostrecently

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3)informationtechnologyandelectronic
controlsforfurtherautomation
Thegrandiosityoftheterm4thIndustrial
Revolutionissomehowillsuitedtoastoryline
inwhichtheprecedingrevolutionsarereally
incrementalstepsinabiggersweepofhistory
fromafeudal,agriculturalworldtoasocially
fluid,informationdrivenworld.Andyet,the
conceptreallyisasbigasitismeanttosound,if
onlybecauseitmaybethefinalchapterinthe
storyofhowmanufacturingischangingthe
humanexperience.

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SCMWorldhasjustfinishedanextensivefield
study,initiallyfocusedonhowtheInternetof
Things(IOT)impactsmanufacturing.For
startersitsessentialtorecognizethatIOTin
manufacturingisreallyjustaplatformforbetter
managementofproduction.Bycollectingdata
fromeverymaterialconversionstepwithsensors
alloverthefactoryandthewidersupplychain
IOTenablesqualitychecking,customized
executionandcontinuousprocessimprovement
atthelevelofeachunit,ratherthaninbatches.

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Tomakeuseofthisplatformhowever,thereare
atleastthreeadditionalpiecesthatmustbein
place.Theseincludeanetworkwithmessaging
standardstocollectandconnecttheinformation,
ananalyticaltoolkittomakesenseofit,and
flexibleautomationtotakeaction.Progresson
alloftheseissuddenlyhurtlingforward.
MassCraftsmanship
HarleyDavidsonforexamplehastappedsmart
manufacturingtogainanedge.HarleysYork
Pennsylvaniamotorcyclefactorywasuntil
recentlyavintageassemblylineplantwith
minimalflexibilityinamaketostock
environment.Bydigitizingthecontrolsystems
andusingautomatedguidedvehiclestomove
piecesaroundthefacilityitshiftedfrommaking
batchestomakingeaches.Toenablethe
workforcetohandleallthisnewvarietyit
deployedawirelessnetworkwithextensive
digitalsignageandconstantvisualtrackingby
supervisors.
Theproductioncyclewentfroma21dayfixed
plantoasixhourhorizon.Thisnotonlycutcosts
andinventory,butalloweddramaticallybetter
responsivenesstocustomerdemand.
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CiscoSystemsmeanwhileisusingacloudbased
virtualMESsystemtocollectdatafrom
productionstepsacrossitsoutsourced
manufacturingnetworkinordertoenable
predictivequalitytesting,traceunitproduction
ataserialnumberlevelandburninsoftwareto
finishindividualproducts.
AndjustlastmonthFoxconnannouncedan
ambitiousstrategytodeploysimilartechnologies
initsmassivenetworkofplantstoimprove
efficiencyortargetcustomers.Networked
machinesreportwhatsreallyhappeningbythe
secondandallowdecisionstobemadeattheunit
level.
Meanwhile,advancesinrobotics,includingin
particularsmaller,safer,cheapercollaborative
robotsofferanotherlevelofprecision.General
Electricisinvestingheavilyinsuchcobotsfor
applicationinitsHealthcare,Power&Waterand
Energydivisionsbecauseoftheirextreme
flexibility,easeofprogrammingandrelatively
lowcost.Unitsareinusetodayatcompanies
includingJohnson&Johnson,ZugandNordic
Sugarforprocessesthatrequirehumanlike
sensitivityincludingsoftpackingboxesand
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testingfinishedwashingmachines.
TheMachinethatChangedtheWorld
100yearsagoHenryFordrevolutionized
manufacturingandintheprocessconsumerism,
workandsociety.Todayweareonthecuspa
newera.Workersarebecomingtechnology
empoweredcraftsmenratherthanreplaceable
cogs.Consumerproductsarepersonalized
insteadofstandardized.
Asforsociety,thepiecesareallinplaceforatime
ofmaterialefficiencyandcreativeexplosion.

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