Smart Manufacturing Explored With Industrial IoT Part 4
In the previous parts of this series, we covered automation, Internet of Things (IoT) trends, Integration, Information processing, and specific components relevant for typical Industrial Internet of Things (IIoT) implementation.
In the current part of this series, we will explore the highest levels of smart manufacturing and how it is being used.
Highest Levels of Smart Manufacturing
Detailed plant operations are facilitated by ‘Level 2’ systems HMIs. Their varieties can range from PC-based softwares or a dedicated hardware type. Information required by HMIs is supplied to them by plant networks, either through from field devices or I/O and controllers.
HMIs can be flexibly located in control rooms, machines, management locations, maintenance locations or any suitable or relevant locations. Today, configuring industrial-grade or consumer-grade tablets as HMIs and portable and troubleshooting stations is a common practice.
Over the past decade, browser-based products have emerged as the real game changer in HMI space. This has reduced the user dependence on difficult software installations or specialized hardware.
On the lines of PCs and Ethernet successfully leveraging commercial technology into the industrial arena; browser-based products are successful flourish by offering the same end user experience as traditional software, but at a nominal price point. They also require near-zero configuration on the end user’s device.
These products provide an HMI interface via Internet, across facilities or different types of mobile devices, worldwide. Advanced features offered by these products include integration with Google Maps, MS-Excel, and video streams.
“Level 3” Manufacturing Execution System (MES) and “Level 4” Enterprise Resource Planning (ERP) systems reside above HMIs. These are software-based systems that are typically running on servers located at a given production plant, or sometimes, in a corporate office that is away from a production plant.
At each progressively higher level, usually, software systems operate at less “real time response” rate than they do at lower levels. At lower levels, response rate is higher.
A comprehensive smart manufacturing solution can power business management and operations only if has been built on an IIoT foundation. Combination of IIoT ingredients creates real-world applications to deliver specific benefits that they (applications) are meant to deliver.
How IIoT is being used today?
Corporate organizations can find ways to benefit from smart manufacturing. The key purpose of smart manufacturing is to improve product quality, track material usage reduce wastage and reduce costs.
Raw materials are received in bulk and are stored before keyed into a tracking system. Information to dispatch ingredients is used by MES to processing equipment as needed. Sometimes, logs on the weight of material are prepared at the time of receiving. Other logs are prepared when material is put to use.
Most of the production plants have one (or more than one) control room. However, today it is common to provide tablets to maintenance technicians and operators so that they can navigate through process areas. Right browser-based softwares operated on a tablet enables freedom of movement and extend the operator’s reach via video streaming that enables operator to monitor various areas in the plant.
Actual production equipment may consist of many interconnected packaged pieces of equipment or large site-built automation system. In either case, controllers (if more than one) interact with field devices in order to keep operators informed.
Finished products go through the packaging procedure. The machinery of packaging equipment is operated by its (equipment‘s) own controllers. Controllers also perform weight check or product inspection, and to label the goods. Packaging equipment is often a multi-step process. Equipment calculates, compiles and provides performance data in the form of speed or units per minute.
In process with multiple steps, steps limiting the throughput factor are difficult to identify. In the case of failure, operators need information to pinpoint the root cause. Smart manufacturing harvests all key performance indicators of production, and use them to identify bottlenecks that can be improved. It also facilitates troubleshooting.
At the highest level, smart manufacturing provides data that allows business operators to track, direct and optimize their raw material usage and productive output. They can analyze uptime and downtime in order to identify and wipe out inefficiencies.
Potential of IIoT
Today, a factory cannot prove itself as best just on the basis of looks. Smart factory always has room and opportunity for additional improvement. Obtaining more operational data and putting it to work results in improvement. Every process of improvement is based on quantitative analysis of measurements. IIoT also helps in providing quantifiable data.
Today, good connectivity is seen as a basic requirement rather than a luxury. Connected factory via intelligent machinery provides a platform for smart manufacturing. Now, technology has made great progress with regards to businesses leveraging IIoT in the most expedient way possible. Is this the limit? Only time will tell.
In a nutshell, the building blocks of smart manufacturing include smart devices, up gradation methods for legacy equipment, robust networking, and a variety of software that build into new facilities or integrate into existing operations. With user-friendly technologies easily available, users can focus less on data harvest and more on improving operations.
Which aspects of IIoT explored in the four parts of this series intrigue you most? How would you like to use IIoT today? Post your comments.
To discuss all aspects of IIoT, Android and other relevant technologies do visit and join our LinkedIn page.