SMART real-time data and technology when, where and in

SMART MANUFACTURNIG

ABSTRACT:

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Manufacturing
is now developed from past few years and become more automated, computerised
and complex. In this Report, the inception, current Situation and the future of
Smart manufacturing is analysed. Smart manufacturing is a result out form the
production integrating manufacturing assets of today and tomorrow with
communication technology, computing platforms, sensors , control, simulation,
data intensive modelling and predictive engineering. The core of smart
manufacturing is based on six parts, manufacturing technology and processes,
materials, data, predictive engineering, sustainability and resource sharing and
networking. Material handling and supply chains have been an integral part of
manufacturing. The anticipated developments in material handling and transportation
and their integration with manufacturing driven by sustainability, shared
services and service quality and are outlined. Smart
manufacturing is not a trend, it’s the future, and that future will be on display
throughout Atlantic Design & Manufacturing

INTRODUCTION:

If you haven’t noticed, everything today is “smart.” We have
our smartphones, smart TVs, and smart watches. It seems to make sense that we
also have “smart manufacturing.” Smart manufacturing, or SM, like everything
else that’s smart, utilizes connectivity and real-time access to data to
improve a process.
From the past few years, the conversation o a topic of Smart Manufacturing (SM)
has been focussed by industry experts and leaders. To state it simply, it is
the use of real-time data and technology when, where and in the forms that are
needed by people and machines. It is one of the most used term to describe
tomorrows Production. It is a “fully-integrated,
collaborative manufacturing systems that respond in real time to meet changing
demands and conditions in the factory, in the supply network, and in customer
needs.”(NIST, USA). Smart
Manufacturing enables all information about the manufacturing process to be
available when it is needed, where it is needed, and in the form that it is
needed across entire manufacturing supply chains, complete product lifecycles,
multiple industries, and small, medium and large enterprises.

Souls of Smart
Manufacturing:

Fig.1 Pillars of
smart manufacturing

Pillar 1.
Manufacturing technology and Processes:

The
Exposure of Manufacturing technology and Processes will be expected in several
years. new materials, components and product will emerge. Big and small area
additive manufacturing will expand its prominence in the factories. New
generation of low cost robots will enhance factory automation. Sensors and
software capabilities will make the new manufacturing equipment smarter and
amenable to factory and beyond communication.

Pillar 2. Materials:

 Smart
manufacturing won’t give a special treatment for development of Smart
Materials. It may well be that smart materials and smart products will follow
their own development paths. Some new materials will require novel processes
that must be developed and incorporated in smart manufacturing. Additive
manufacturing alone will be a great contributor to the search for new materials
and their mixes.

Pillar 3. Data:

The
data will be used to power any application to be envisioned, including building
predictive models. Moreover, it will be the best source for preserving and
extraction of past and new knowledge related to manufacturing.

Pillar 4. Predictive
engineering:

The
Predictive Engineering is development approach to design product that with help
design of Smart Systems. Traditionally, the manufacturing industry has focused
on using data for analysis, monitoring and control, e.g. productivity analysis,
process monitoring and quality control. Predictive engineering offers a new
paradigm of constructing high-fidelity models (digital representations) of the phenomena
of interest. Such models will allow exploring future spaces, some within the realm
of the existing technology and others that have not been seen previously. In
the future, today’s models will be enriched with both limited-scope models
(e.g. behaviour of a supply chain) and those that involve multiple systems
(e.g. models that integrate productivity, product quality, energy and
transport) to support decisions concerning future production and market
conditions. Such wide-scope models may contribute to restructuring the
manufacturing industry.

Pillar 5.
Sustainability:

Sustainability
is very important in manufacturing. The goals of sustainability efforts will be
materials, manufacturing processes, energy and pollutants attributed to
manufacturing. The entry points of any major sustainability effort are the
product and the market. Sustainability is not about what is manufactured but
how it is performed. It is the main force behind providing equal footing for
remanufacturing, reconditioning and reuse with manufacturing. Because of sustainability,
the line between manufacturing and service will remain blurry. For example,
reconditioning a used product is not a traditional manufacturing activity,
however, it may enter the new manufacturing dictionary.

Pillar 6. Resource
sharing and manufacturing:

As
manufacturing is becoming digital and virtual, much of the creative and
decision-making activities will take place in the digital space. While at some
level the digital space may be highly transparent, the physical manufacturing
assets with their know-how will be protected. This digital-physical separation
will allow for shared use of resources across businesses, including the ones
that compete.

     

The Essential Features of Smart Manufacturing, Applications and
State-of-art Survey:

Based on Bosch Group
experience in pilot projects in their own plants, it has been identified that
seven essential features that are necessary in Smart manufacturing for the
implementation of Industry 4.0.

1.      
People  As key Player:

Digital assistant
functions and intelligent workplace design support people with
production-related information and improved ergonomics, thereby increasing the
level of individualisation of the work environment. In the Bosch Rexroth they
provides numerous hardware and software solutions. This begins with assembly
areas that can automatically identify workers and create a work environment
that is tailored to them individually; show workers instructions that are
oriented to their knowledge; and provide them with smart assembly tools and
devices that are intuitive to operate.

Fig. 2 The Essential
Features of Smart Manufacturing

2.      
Distributed intelligence:

Decentralised intelligent automation components with integrated software
perform their tasks independently, according to the specifications of
higher-level systems, and make autonomous decisions.Bosch Rexroth is a pioneer
of decentralised intelligence with intelligent electronic drives and motion
controls for hydraulic drives. Distributed intelligence is a basic requirement
for modular machines and flexible facilities that adjust themselves to changing
market and manufacturing conditions.

3.      
Fast integration and
flexible configuration:

        

With Plug and Produce, people, machines, processes and the flow of goods
are networked together on an ad hoc basis. Software tools simplify multiple
smart manufacturing machine steps: commissioning, integration and
(re)configuration, as well as preventive maintenance of all components, modules
and machines. Our Open Core Engineering includes
all the software tools, function toolkits and open standards for efficient
software engineering and rapid networking. Software wizards and tools support
commissioning engineers, operators and maintenance technicians in their tasks
and reduce complexity. Open Core Engineering enables users to work with their
preferred development environment and programming languages from the IT world
to maximise the efficiency and versatility of automation development.

4. Open standards:

Open Standards that extend across manufacturers and are platform-independent
form the basis for horizontal and vertical integration and thus for the
seamless exchange of information in value-creation networks. We have always
supported open standards such as Sercos, IEC 61131-3, PLCopen or OPC UA. With
multi-Ethernet interfaces and Open Core Engineering, Bosch Rexroth has
completely opened up automation to the IT world.

5. Virtual real-time
representation:

All components and objects are represented as virtual real-time
representations across the entire value creation process. These virtual
elements are closely linked to their physical counterparts and provide
in-context information for continuous process improvement in real-time. Bosch
Rexroth automation components and systems record all relevant data using their
own software functions and sensors and exchange these via multi-Ethernet
interfaces. Industry 4.0 solutions such as Active Cockpit evaluate the relevant
data and display it in real time. This provides operators and managers with a
solid base of information for rapid process improvements as production
proceeds.

6. Digital life-cycle management:

The comprehensive networking of all automation components, machines,
processes and product data — from development and production to recycling —
decreases development time and therefore development costs, for both completely
new smart manufacturing lines and upgrades to existing platforms. In addition,
this also ensures the application-oriented design of all components. Bosch
Rexroth supports digital lifecycle management with model-based simulations for
motion-logic systems. OEMs can validate and optimise the interaction between
hardware and software in a virtual system in parallel or before machine
assembly. They save time and can bring new designs to the market more quickly.

7. Secure value-creation
networks

Security and
safety for Industry 4.0 includes protecting people from machinery-related
hazards (safety) as well as the protection of production facilities and
corporate IT from attacks and faults from the surrounding environment
(security). This involves securing sensitive data as well as the prevention of
intentional and unintentional malfunctions. Bosch Rexroth works with all
relevant standardisation committees for security and is already implementing
the most up-to-date technology. More and more of Bosch Rexroth’s intelligent
components and solutions have a forgery-proof digital identity — an important
prerequisite for secure value creation networks.

The
benefits of smart manufacturing include:

Improved
productivity

Smart
manufacturing processes provide greater access to data across an entire supply
chain network. Real-time data outlines what the manufacturer needs and when,
which makes things more efficient for suppliers that can easily make
adjustments to orders. They supply what’s needed, not more or less, reducing
waste and any downtime associated with missing parts.

Innovation
and higher quality products

When
productivity is improved, it saves money, which can then be invested in product
development. Once analyzed, smart manufacturing data shows where customer needs
are and managers can find opportunities for new products or re-imagined
products of a higher quality.

More
manufacturing jobs

Adopting
smart manufacturing is a way to attract the younger, tech-savvy workforce since
more technology based manufacturing jobs will become available. Utilizing smart
manufacturing data and apps, employees can recognize new opportunities and
increase productivity. According to California Manufacturing Technology
Consulting®, smarter factories offer the opportunity to boost employment 2-4
times over the current national manufacturing workforce of 12 million.

Economic Impact:

Factor
Input                                     Mean Impact

                                                    K:
Capital                                               ?5%

                                                   
L: Labor                                                 ?12%

                                                   
E: Energy                                              ?13 %

                                                    M:
Materials                                          ?5%

Table 1.
Average Percent Change in Factor Inputs

Table 2.Economic Impact Summary,
Process versus Discrete

Table 3. Economic Impacts by
Capability Area

Shows that economic impacts are
estimated to be approximately $57.4
billion.

Conclusion:-

Smart manufacturing is not about
the degree of automation of the manufacturing floor; it is about autonomy,
evolution, simulation and optimisation of the manufacturing enterprise. The
scope and time horizon of the simulation and optimisation will depend on the
availability of data and tools. Financial issues were the most commonly cited
barriers to adoption of smart manufacturing technologies and processes. Concerns
about financial issues were followed by a lack of technical resources and
knowledgeable staff needed for implementation. The level of ‘smartness’ of a
manufacturing enterprise will be determined by the degree to which the physical
enterprise has been reflected in the cyber space.

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