What is Smart Manufacturing Dev. Service - IBM Maximo Powered Mfg. System?
Since the implementation of IoT (internet of things), we are rapidly approaching the next Industrial Revolution. Industry 4.0 is a revolution in the high-tech strategy that promotes better computerization of the manufacturing system with its automation & data exchange. The goal is characterized by adaptability, resource efficiency, and ergonomics factory.
Smart Manufacturing enhance existing factory machines with new functions to prevent human errors and increase work efficiency. By adopting computer control and data processing, the system eliminates inefficiency and reduces production errors.
Basically Smart Manufacturing moved away,
from conventional semi-automatic production / standalone automatic machining; where every production machine & robotics are a standalone system working semi-together.
Into an Intelligent Automation powered by IoT; all available machines are connected by internet network with secured access for computer control-able adjustments through integration between your Smart Manufacturing Application to the machine's SCADA (Supervisory control and data acquisition).
How Smart Manufacturing Works?
Production data lifecycle will be collected from both Machine to Machine (M2M) & Machine to Person (M2P) generated by PLC (Programmable Logic Controller) and sensors. This data can be analyzed to help your company make future production plan decisions, for example:
- setting a benchmark for machine rotation,
- heatmap in your production process to determine bottleneck in your production process.
- and many more.
Collected data are also used to monitor the machine’s productivity, analyzes the process in every cycle, and makes alert for maintenance to prevent damage in the early stage.
In order to keep everything synchronized and work as needed, Smart Manufacturing usually comes with Cloud-based platform which can monitor and give orders under a single administration dashboard, therefore multiple production processes work together simultaneously.
What would you get by purchasing this product?
Better Manufacturing Decisions based on Data & Simulation
Information is important for business; with every production element connected to the network, a smart factory will provide easier access to important data for your management to analyze and make decisions.
Some application example:
- Daily production prediction based on current machine condition for the upcoming holiday season.
- Flexible scheduling for manufacturing based on urgency.
Enhanced Production Line Efficiency & Safety
Monitor your production process 24/7, to ensure:
- better safety in the factory
- direct prevention of human error (e.g. ensuring right production materials are used)
- or other risks in production lines.
Cost-Effective Preventive Maintenance
Besides the efficiency in the production process, Smart Manufacturing can set condition reminder for machine maintenance. Hence, your production will keep going, while failure is prevented, with a good saving on maintenance cost.
This maintenance reminder can be done by using various sensors or based on production cycle count, which also helps you in reducing the maintenance expense by directly informing your engineer on the machine's actual health.
Automate & Standardize Quality Control
Smart manufacturing implements machine vision, sensor, and other automation technology which has been widely adopted for automatic quality check & control.
With the help of automated physical check and standardized standard set in our software, industrial production quality will be improved.
Here are the detailed features you will get
If you have a conventional non-connected factory environment, for Smart Manufacturing solution to work we will need to implement
01. Data Extraction and Conversion
We will equip every machine with sensors, as well as other data extraction and conversion equipment, including extracting data from PLC whenever possible. This is done to enable your manufacturing plant to have better computer controls, in order to extract analytical data from all sensors, meter, and instruments.
This solution is also useful to handle inventory, and when facing equipment failure complexities. In the level of the massive manufacturing process, various factor needs to be decided upon supply chain parameters, such as safety stock levels, delivery schedule, logistic expenses, etc.
If you already have a connected factory environment, we can help you even further with:
02. IoT Gateway
IoT Gateway will receive data from every instrument, sensors, and meter, then distributes the analytics data to operational control facility, then operators can view operational status of the machines and oversee the production process, specific machines status, and judge required environmental parameters in real time.
03. Machine Condition Monitoring
This feature is an all-in-one package system which provides cost-effective solutions for monitoring machines. It works based on a real-time parameter, and if there are some factors that affect the quality and safety of your machines, an automated alert system will simultaneously issue and send a notification directly to the administration system. Hence, it also prevents further mis-operation and avoids fatal failure.
04. Vision Guidance Robotics
Vision guidance system utilizes compact size smart cameras with high resolution & frame rate for quality control inspection of industrial production. This will improve the production quality, stability, consistency, and efficiency over manual visual inspection by operators.
05. Automated Quality Check
Smart Manufacturing can help your company with hardware and software equipment for continuous production quality check with improved accuracy and result while reducing testing time and cost.
Few examples of automation testing implementation:
- Car navigation audio testing
- Mobile phone audio loop testing
- HiFi mobile phone audio testing
- Dynamic rotor balance analysis
06. Machine Automation
A complete motion control card, frame grabbers, and cloud-based IoT technology which provides the best performance for PC-based solution in automation and easily installed adjacent to machines, so it is individually responsible for control of each section. Distributed control is easily modified, repaired or upgraded without disturbing other networks.
07. Cloud-based IoT Technology
Cloud-based IoT integrates both hardware and software elements dedicated to enabling fast and high-performance industrial automation application with ready-to-use components to speed up the development, deployment, and expansion process of the modern smart factories system.