October, 2021 Continued from previous page
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Orchestrating Automation Across the Shop Floor As more workflows and resources are
added to the engine, the picture becomes increasingly intricate and interrelated. Although the possibilities may appear over- whelming, a successful automated factory workflow can be achieved by starting small — simply requesting the collection of material from point A, and confirming delivery to point B, for example. With an intuitive drag-and-drop inter-
face, additional steps or checks can be added as different scenarios emerge, thereby steadily reducing the amount of manual intervention needed over time and optimiz- ing production efficiency. For example, if an issue is flagged with
production, WIP materials may be automatically routed to a rework station. With full version control, any steps that turn out not to fit with operations can be easily rolled back. The use of smart analytics
further opens scenarios where the need for material, for exam- ple, could be predicted in advance, meaning resources can be prepared in advance, supply chains primed, and the risk of shortages further reduced. For an SMT line, the factory
workflow system would integrate with the pick-and-place machine so it knows when reels will finish and when to send refills. It could also communicate with the MES to know what will be required for subsequent work orders and trig- ger the filling of material buffer stations with the necessary materials, thereby reducing the distances AGVs need to travel and increasing the efficiency of the replenishment process.
Flexibility Every manufacturing setting
has its unique features, and a future-ready workflow engine needs to offer complete flexibility to the user. Workflows need to eas- ily be created and readily linked to events. The system must support hierarchical structures for long and short running jobs and enable efficient error handling to recover from the wide variety of possibili- ties in a factory setting. Even if the goal is lights out
manufacturing with no manual operations, an intelligent work- flow engine needs to accommodate fully automated, manual and hybrid scenarios to cover all aspects of shop floor operations as the system evolves. Over time and as processes mature, levels of automation can be steadily increased, facilitated by a growing library of reusable workflows. Using a factory-level work-
flow engine to create high automa- tion can deliver many benefits to high-tech manufacturers. The complexities of all events and pos- sibilities on a shop floor means a system must be intuitive, adapt- able and scalable but, correctly implemented, it will improve equipment utilization, reduce pro-
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using AGVs optimizes material workflows and protects the materials themselves from dam- age. Analyzing historical data and work order information from the MES, predictive algo- rithms can be used to create even further opti- mization and operational efficiency. A success- ful factory-level workflow solution, such as the Factory Automation module from Critical
Page 57
Manufacturing, must complement other sys- tems, including the MES and IoT data plat- form, and know how to organize everything. Based on the data and resources available, it must decide what needs to be done, request actions, coordinate and optimize shopfloor operations. The system will enable continuous workflow improvements and steady progres- sion to high automation. Ultimately, its suc- cess will lead to less and less need for human interaction, reduced labor costs, and smoother, more profitable operations. Contact: Critical Manufacturing, Inc.,
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