Smart factory is a transition between traditional manual production where humans have to participate as much as possible in all stages of AZ production to use machines and apply the power of science and technology 4.0 such as Internet of Things, Big Data, Artificial Intelligence, Cloud Computing, so machines can produce, collect , and communicate the information itself, humans only manage remote monitoring.
BENEFITS OF IMPLEMENTATION OF THE SMART FACTORY MODEL
Using the IoT technology platform, implementing the digitalization of the Smart factory management model in the factory has the following benefits:
Reduced production costs:
If the process is optimized to change the traditional way of production, it will create efficiencies in terms of reducing time and labor costs, avoiding machine wear and tear, and saving maintenance costs, asset wastage, operational reduction of process variability. A good quality process from a Smart factory should be a good quality process that produces better quality products thereby reducing warranty and maintenance costs.
Increase operational productivity:
Smart factories rely on automation to complete processes, thereby speeding up production processes and becoming more automated, requiring less human intervention. In fact, automatic machines can be programmed to operate 24/7. It makes the process faster and cheaper.
Remote Monitoring:
Visibility of machine component operating status (both historical and real-time) allows plant managers to quickly monitor and diagnose systems remotely and identify and resolve problems before they affect machine availability and produce compounds.
Pre-Maintenance:
Predictive analytics enables more accurate machine maintenance planning, can help reduce machine downtime, increase average time between failures, and reduce unnecessary preventive maintenance and spare parts inventory costs. With predictive maintenance, most of the guesswork is eliminated as maintenance decisions can be made based on real-time and historical data from the machine, helping to detect and resolve problems ahead of time, when they become too serious.
Process Optimization:
The interoperability provided by IIoT technology enables seamless communication between machines, materials and people. This connectivity enables optimization of data processing, increasing efficiency and productivity. By using a wireless network of connected devices to streamline communication. Managers, technicians and employees can use their time more efficiently and effectively. Likewise, wireless solutions can be used in lighting selection and call department applications.
Safe and sustainable production:
Smart factories offer tangible benefits for worker health and environmental sustainability. The operational efficiencies provided by Smart factories can have less environmental impact than conventional manufacturing processes. Automating machine-operated processes reduces human error, including work-related injuries. The relative automation of Smart factories can replace certain roles that require repetitive manual operations.
Product quality control:
Product quality control seems to be a relatively difficult problem for many businesses. With the smart factory, IoT technology and sensor devices are applied to monitor and control the product manufacturing process. As soon as abnormal conditions affecting product quality are detected, the system will automatically give an early warning. As a result, businesses can determine where problems are coming from to provide timely solutions, proactively control product quality, and avoid end-of-cycle risks.
Gain a competitive advantage:
Another benefit of intelligent manufacturing is gaining a competitive edge in a crowded market. When you can work faster, smarter, and more cost-effectively than your competitors, you get more customers. Your competitive advantage allows you to stand out while everyone else struggles to get ready-to-use and cost-effective items on time.
Improve customer satisfaction: Detecting mechanical faults and problems also helps businesses to be proactive about equipment and production time, ensuring to fulfill all customer orders without worrying about slow progress. Product quality, guaranteed delivery time will definitely increase the level of customer satisfaction. This may be the goal that the manufacturing company is aiming for.
A factory can be called a smart factory when the factory applies one or more digital technologies in the company’s operations. But in addition to using digital technology, the application of that technology must meet several principles. The principles of the smart factory are:
How to reduce the number of human errors. With the use of digital technology, it is hoped that production errors and management processes handled by humans can be reduced. Reducing human error can increase factory productivity and efficiency.
How to get the job done faster. In the business world there is a saying “time is money”, and when a process or job can be done more quickly, this will increase the company’s profit potential.
How to use resources as efficiently as possible. Efficient use of resources means a decrease in the cost of production so that it can increase the room for the company’s profit margin.
How to reduce work accidents. This will make employees/workers feel safer at work and reduce the company’s burden to bear compensation or liability in the event of a work accident.
Well, when a digital technology is applied in a factory and meets one or more of the above principles, then the factory can be referred to as a “smart factory”.
Some examples of the application of digital technology in smart factories include:
Internet of Things, the use of the internet in various aspects to support work in factories.
The use of software, for example a factory implements a digital-based accounting management system using accounting software, so that the process of recording and accounting for the company’s financial activities becomes faster and more precise.
Utilizing cloud technology, for example a factory uses cloud storage to store company data and documents so that data becomes more secure and does not take up much physical space.
Supply chain, raw material management and management, and inventory management in factories assisted by various digital technologies will encourage resource efficiency.
Automatic maintenance, a management system to periodically check various machines and production equipment in the factory so that it will reduce downtime due to production machine disruptions. This not only boosts productivity, but also makes it easier for companies to manage and maintain their assets.
We can see that the majority of factories today, especially for middle to upper scale companies, have started to implement this digital technology. It’s just that, there are companies that apply it in large numbers and there are also those that only use one or two technologies. In the ideal concept of a smart factory, a factory can really be called a smart factory when all aspects of the factory are already utilizing digital technology. The more digital technology is used, “the smarter the factory is”.
Examples of Smart Factory Application Cases
Examples of factories that can be called smart factories for example Hirotec. This automotive spare part company implements Internet of Thing technology combined with machine learning algorithms to monitor all production machines used. The reason is to reduce the occurrence of downtime. Yes, previously, Hirotec could also incur a loss of $361 per second during downtime. Downtime is a common thing in the world of mechanics and machines, but in a factory it must be attempted to occur to a minimum to reduce potential losses.
By applying machine learning technology, there is a special software and application that checks all machines regularly. So, a machine will be maintained or cared for when the machine is about to break down, not when the machine breaks down. This reduces the company’s downtime significantly and ultimately increases Hirotec’s profitability.
