The perception of tomorrow's industry manufacturing: Fourth Industrial revolution. It has been determined as the fully-integrated manufacturing systems that react in real time to developing demands in the factory.

1. HOW SMART IS YOUR
SHOP FLOOR?

2. INTRODUCTION
Ever visited a power plant in recent times? The number of
personnel on the floor is hardly 5.
A couple of people, operating a little away from the plant,
watching a number of displays and light bulbs would be
‘quietly’ monitoring the entire production process.
In fact, you would almost be greeted with an eerie silence,
except for the hum of the turbines. Now, contrast that with a
traditional manufacturing plant – the number of moving parts
(literally and figuratively) make the shop floor a beehive of
activity.
What if the traditional shop floor can also be managed and
monitored with quiet confidence and outstanding efficiency –
by connecting machines, systems and people seamlessly.

3. Deloitte Insights on The smart factory – says,

4. The smart factory represents a leap forward from more traditional automation to a
fully connected and flexible system – one that can use a constant stream of data
from connected operations and production systems to learn and adapt to new
demands.
… A true smart factory can integrate data from system-wide physical, operational,
and human assets to drive manufacturing, maintenance, inventory tracking,
digitization of operations through the digital twin, and other types of activities
across the entire manufacturing network.
The result can be a more efficient and agile system, less production downtime, and
a greater ability to predict and adjust to changes in the facility or broader network,
possibly leading to better positioning in the competitive marketplace.
“

5. The technologies driving this
revolution are of course Industrial IoT
(Internet of Things), Cloud, Artificial
Intelligence and Machine Learning.
According to a projection by Cisco,
manufacturing will account for 27% of
the projected $14.4 trillion IoT market
between 2013 and 2022, with smart
factories contributing $1.95 trillion of
the total value at stake in the same
timeframe.
… TECH
TRENDS
2018

6. SMART FLOOR.Let us look at how different areas of shop
floor by IOT and Cloud.

7. A publication of
Plant Data and
Data Driven
Decision Making

8. Use of computers in shop floor is not a new phenomenon.
IOT For Smart Data Collection
IoT, it is now far easier and faster to collect and manage large amounts of
manufacturing data not just in a single factory, but across multiple
production sites through the cloud.
And, when combined with analytics, companies will gain better insights,
allowing them to optimize plant operations, reduce defects and perform
preventative maintenance.

9. A publication of
Monitoring and
Managing Asset
Performance

10. Typically, in any shop floor, processes would be in place to divert
production in the case machinery failure.
Better Performance - IOT Analytics
Through the use of sensors, IoT and analytics it is possible to predict and
prevent catastrophic failure on large-scale plant floor equipment, like
boilers or compressors.
And, you can measure conditions like input flow and pressure settings, and
determine whether a piece of equipment is running at optimal
performance, including consumption of energy.

11. A publication of
Optimization and
Reliability

12. Having automated workflows, synchronization of assets, improved
tracking and scheduling, and optimized energy consumption means that
today, a smart shop floor / factory can increase yield, uptime, and quality,
as well as reduce costs and waste.
Reliability
The nominal manual intervention increases reliability.
Remote equipment management, including setting specific limits and
parameters, allows for significant savings in energy and costs.

13. A publication of
Business
Intelligence

14. By integrating shop floor decisions and insights with the rest of the supply
chain, sales & marketing and broader enterprise through the IoT
ecosystem, organizations can not only fundamentally change production
processes, but also enhance relationships with suppliers and customers.
Business Intellegence
If you are wondering, how come we have not touched Robotic Process
Automation (RPA) as we speak about the revolution that is taking place in
shop floor automation…
Well, that is a whole different area of discussion for another day.

15. “If you are interested in
taking advantage of IoT,
and would like to work
with an expert in digital
transformation – talk to
Hakuna Matata.”
HAKUNA MATATA
IOT Expert - Digital
Transformation