FEATURE SMART FACTORIES & AUTOMATION
A NEEDLE IN A DATA-STACK? HOW A ‘DIGITAL THREAD’ CAN OPTIMISE SMARTER MANUFACTURING PROCESSES
without involving the physical version in the process at all. Conventionally, commissioning a machine or system is done in the final stages of development. That is, immediately before it goes into use. But by this stage, the variables that can be
modified to optimise performance and debug behaviour are very limited. They include the data controlling the system’s functionality, the behaviour of the PLC-code (programme logic controller) and on-board software. With virtual commissioning, however, the process
of adapting current machines or developing new ones can start as soon as the manufacturer gets an inkling the market is changing. Production can carry on as usual. All the work
by Marc Booth, head of OEM and materials handling at Siemens I
n terms of modern machine building and the design of production lines, automation is now
widely adopted. However, despite the gains being made by moving products quicker through the manufacturing process at higher volumes through automated processes, the real efficiencies are achieved by the monitoring of equipment and the integration of the data being collected. This Total Integrated Automation (TIA)
approach, combined with a highly secure cloud- based data interface, is what unlocks the full potential of digitalised manufacturing. Once you have a joined up, data-driven view of the whole plant you can start to use predicative maintenance to help reduce downtime, cut energy costs through the smart monitoring of power usage, and increase throughput via the analysis of machine and production line capacity. These benefits are also the key drivers of
‘reliable ROI’, that is to say they demonstrate tangible financial savings which can be easier to get buy-in for at board level if you are looking for a technology investment to optimise productivity. For example, Siemens has saved itself and many of its clients up to 30 per cent on energy costs by embedding a TIA solution across their production lines, while gains of between 20 per cent -40 per cent can be achieved through other efficiencies driven by analytics. But despite such gains, one of the main
barriers to the adoption of a fully automated, IoT-based manufacturing system or plant is the fear of a cybersecurity breach. And while it’s true that the use of big data
comes with risks as well as rewards, Siemens own cloud-based operating system called Mindsphere (which has military grade encryption) is proving to be highly robust and yet still very flexible and responsive.
16 SEPTEMBER 2019 | FACTORY EQUIPMENT Further, our global Charter of Trust security
initiative – developed with our own suppliers and our global industry partners – is gaining real traction, offering manufacturers some peace of mind as they begin their digitalisation journey.” It’s also worth noting that Siemens’ own research suggests that less than ten per cent of the world’s machines are currently monitored. That means we still need to get a lot of firms to Industry 3.0 before they even contemplate stepping up to Industry 4.0. But once factories and production lines are
geared up for digitalisation a whole world of opportunities open up – with digital twin one of the most significant and transformational, especially as it can de-risk capital investments before any physical kit is built and components purchased. A digital twin is a virtual mirror image of a
physical product, machine, production process and its performance. There’s no limit to the number or variety of digital twins that can be created. In fact, you can have a twin for every machine on your factory floor. You can even have a twin for your entire plant. What drives the digital twin process is data from
sensors installed on physical assets to determine real-time performance and operating conditions. Data is analysed and fed back into a closed-
loop, virtual environment. OEMs in particular can see how a machine performs under various conditions and gain the knowledge to drive future optimisation or modification. In this way, manufacturers can improve not
only the performance of individual products but also their product development and production processes. And, crucially, they can do it all continuously and at minimal cost. A digital twin can also validate a device
involved in ideation, development, design and commissioning is taking place in a virtual environment, running in parallel with the live manufacturing system. There’s no need to wait until the physical machine even exists. There’s also far more scope for modifications to multi- disciplinary properties of a system such as mechanics, electrics and automation. And, not only is virtual commissioning faster
and more cost-effective, it has the added advantage of avoiding potential damage to the real machine during commissioning and run-in. Now machines are no longer simply ‘machines’,
they’re software platforms. And nor do they exist in isolation, they’re part of the wider digital enterprise. They’re connected to customers, OEMs, channel partners and experts alike. The value chain is transforming together. Siemens call the process ‘the digital thread’ -
the framework that allows for a connected flow of data. It provides an integrated view of a machine’s data, both through its lifecycle and across functional perspectives which are traditionally siloed. The digital thread captures data flows created
at every stage from ideation to service. It continues through every decision and step in the manufacturing process, until the product leaves the factory and reaches the warehouse. Manufacturers move closer to partners and
experts, who can help them explore new options in product development, new machines and factory configurations. And they do so more cost-effectively, faster and with far less risk than previously possible. What’s more, in industries where accountability
is a significant issue, notably retail, pharmaceuticals and chemicals, the digital thread provides the added assurance of a clear audit trail detailing every aspect of a product’s development. Altogether, digitalisation provides the key to
developing machines and entire factories to meet the changing needs of the market – and boost the bottom line.
Siemens Digital Industries
https://sie.ag/2wUqutv
/ FACTORYEQUIPMENT
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