Internet of Things


The idea of autonomous operations for manufacturing facilities has been on the agenda for several decades but, with the maturation of Industry 4.0 technologies, what was once an aspirational ideology has become very tangible, especially as companies form post-pandemic recovery strategies. Instrumentation Monthly recently caught up with Sachin Mathur, EMEA software and control director at Rockwell Automation, to find out how establishing a digital thread acts as a foundation for the autonomous factory.


Q Q&A what is the


ConneCtion between a digital thread and a digital twin?


when a physical asset – product, machine, component, or system – exists alongside its digital equivalent, they are digital twins. linked together so that operations and changes in one are reflected in the other, digital twins can be utilised at any stage throughout the lifecycle, baselining from machine building to the production process, and for maintenance and training. by uniting and continuously communicating


changes between various digital twin models, digital thread unlocks new possibilities in product development and lifecycle management, alongside real time manufacturing operations. these intelligent, data rich digital twin


simulations reduce the risk in testing operational changes and enhance the time needed to reach operational efficiency goals. digital thread is the key to accelerating innovation, maximising workforce productivity, optimising operations, and building agility and resiliency. the digital thread is parallelising automated


Q


updates on all the related applications when a physical update is made to a certain device or product.


how does a


manufaCturer go about establishing a digital thread?


we must approach the topic to digital thread like any new business initiative and strategic investment. digital (thread)


Instrumentation Monthly May 2022


transformation does not have to be the challenge we often perceive it to be. especially once you take a closer look and


realise that transformation is not just about deploying modern technology, but more importantly about putting the right plan in place based on outcomes, securing executive support, and developing the right talent. new digital technologies have transformed


the way enterprises engage with customers, gather intelligence, and do business. however, it is more than just becoming digital – it is about remodelling the business approach to improve efficiency, reshaping processes and remodeling a culture of continuous improvement. this is key to successful transformation. it is about keeping your strategy on track, being adaptable and leveraging the opportunities innate in the increasingly digitised world we live in. we have been long-term partners for our


Q


customers through their major journeys, from automation to machine safety, and are committed to supporting the digital enablement of an organisation. rockwell automation has been investing heavily to help our customers stay ahead of the curve in digital thread.


if an organisation is thinking of


establishing a digital thread, what sort of


projeCts Could they


identify where it Can be easily implemented and provide value?


start with the ethos “don’t boil the ocean.” every important upgrade in a production


line is something that an enterprise must plan and execute with a series of short and


mid-to-long term goals. there is no need to go from zero to 100 in a blink of an eye, albeit it is important to understand and appreciate that the “already” digital industrial organisations outperform their non digital counterparts in both revenue and profit. thus, start small, scale fast and iterate with results and learnings. thereby, it is important to focus on the


change of mindset prior to investing heavily in technology. we must remember that technology is an enablement piece and not the driver, your business outcomes and goals related to production, assets, compliance, sustainability, etc. should drive both business and technological decisions. breaking these down to highlight a few vital relevant process areas to improve with clear objectives and start with small projects that can show immediate returns. keep in mind that marathon runners do not


Q


get off the couch one day and run 26.2 miles without training; similarly, when it comes to bringing it and ot closer together, it pays to walk before you run.


Can you give an example of where


establishing a digital thread has helped a


Company move towards an autonomous faCtory?


pfizer, the well-known pharma company, produces more than 23 billion doses of medicine every year across its network of 42 global manufacturing sites. those global operations set out on a new


journey in 2016 and the goal was transforming operations into a seamless, data-driven insight engine that drives world-class performance.


Continued on page 40... 39


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