Data acquisition
More data, less waste
digitalisation’s potential extends far beyond its perceived applications. Data collated by the Association of Swedish Engineering Industries (Teknikföretagen) emphasises the importance of digital tools to reaching sustainability goals - leveraging IT technology in other sectors, like manufacturing, has the potential to reduce total
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CO2 emissions by as much as 20 per cent. Increasing digital tool use is vital to aligning
manufacturing activity with the Paris Agreement, increasing resource efficiency and, crucially, reducing waste. Globally, industrial waste generation is almost 18 times greater than municipal solid waste, according to the most recent data from the World Bank. Every manufacturing facility generates waste, a lot of which could be avoided. Overproduction and defect output are two of
the most common contributors to waste generation. Facilities running on legacy technologies that lack the sophistication to deal with the challenges of modern-day manufacturing are far too common. However, this does not mean that manufacturers should accept vast waste generation as an unavoidable consequence of production. Industrial waste must be reduced, and data can play a key role in achieving this, if manufacturers know what to do with it.
IMpROVInG OpERATIOnAl EffICIEnCy Every manufacturing facility, no matter its size, complexity or age, generates a significant amount of data every day. In a smart factory, this data includes everything from equipment performance to product quality and is collected via sensors installed on each machine. Starting small, with each individual machine’s data, is the first method of reducing waste on a large scale. Small changes to individual processes
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espite uptake of digital tools, only 59 per cent of manufacturers cite improved sustainability as a reason to digitalise their operations. However,
In reshaping the world towards a new normal post pandemic, industry must leverage digital transformation at an accelerated pace. This is already happening - according to IBM, 67 per cent of manufacturers have accelerated digital projects since COVID-19. While improved operational efficiency is typically the reason for these changes, industry should capitalise on the convergence of Industry 4.0 and environmental, social and governance (ESG) goals to improve their sustainability credentials. Here, V R Vijay Anand, head of Digital Machining at global leader in metal cutting Sandvik Coromant, explains why data holds the key to reducing manufacturing’s waste problem.
accumulate and together have a huge impact on operational efficiency. Collecting data from machinery on the shop floor and analysing it allows manufacturers to monitor and act on machine data. Manufacturers can then use this data to optimise individual machine processes that significantly contribute to overall energy use by detecting inefficient processes, streamlining production and logistics planning and predicting upcoming maintenance needs. By making several smaller processes more energy efficient, data can be used to control - and reduce - overall energy consumption. Energy inefficiencies can be identified in real time,
giving manufacturers the opportunity to identify potential reasons and solutions. For example, when looking at energy consumption data, manufacturers may discover one piece of equipment that uses significantly more energy than others. Using this information, manufacturers can then identify the cause of increased power consumption and implement improvements to streamline machine efficiency and reduce energy waste. Analysing data in real time, continuously, can also help streamline machine maintenance.
Data analytics can identify upcoming problems before they happen. If a machine experiences a problem, or change in performance, it may start to produce parts that are not fit for purpose that would ultimately end up as waste. Data on machine performance can help to identify minute changes in machine behaviour as soon as they occur, so that engineers can conduct predictive maintenance before multiple defect products are produced. The CoroPlus suite of products in the Data
Driven Machining offer area, from Sandvik Coromant, help manufacturing organisations improve efficiency, reduce waste and increase productivity. The CoroPlus Process Control, which monitors machines in real time and triggers actions in accordance with programmed protocols. If specific, predetermined issues occur, the solution automatically triggers a correctional action - like stopping the machine or replacing a worn cutting tool. Conducting maintenance in this way improves operational efficiency by as much as 89 per cent and reduces waste by allowing manufacturers to assess data, monitor machine performance, and identify faults before they occur.
March 2022 Instrumentation Monthly
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