FEATURE IIOT & SMART MANUFACTURING


A standard way to create the factory of the future


David Messant, production manager at norelem, explores how standard


components can be used to implement digital,


supply chain and robotics


solutions, providing flexibility in line with the ‘factory of the future’


T


he traditional approach of engineering and manufacturing being dependant on human


and machine working side by side can create risk. If, for example, a machine goes into unplanned downtime, or the machinery operator is not available, the whole production line can come to a halt. For many manufacturers, increasing their resilience to these issues is crucial to survival, but can also be the key to unlocking even greater productivity potential. However, ‘Industry 4.0’ technologies such as


automation, AI and digitisation are already allowing businesses to stay on-line, helping to boost productivity and streamline production. But while sweeping technological changes in the


factory or plant is the ideal, this can take time to fully implement. This is where manufacturers can look to standard components instead, which have the ability to reduce costs, maximise efficiencies across production, and make plants more resistant to unforeseen circumstances. One such way that standard components


contribute to increased resilience is that they provide flexibility in line with the ‘factory of the future’. With advanced manufacturing technologies, these factories enable production to be shifted rapidly to meet demands by fast re-configuration of production lines. Rather than investing in bespoke,


complex machinery and costly bespoke components, engineers can use standard


32 JULY/AUGUST 2020 | DESIGN SOLUTIONS


components to change the set-up of the factory quickly and easily. Parts like gears, worm drives, guide rails,


motorised positioning systems and more are all available in a standardised range of sizes and materials from norelem. It is simply a case of having the knowledge, know-how and access to ensure that businesses assemble new machines. Of additional benefit, if any component needs


to be taken out of service, the part can be quickly sourced and replaced.


PUTTING AUTOMATION WITHIN REACH Automation is key to modern manufacturing – from large robotic arms to smaller collaborative robots working alongside humans. And while no one can predict the next steps, it stands to reason that manufacturers may start to explore how robotics and automation can help their business – both in terms of scaling production and enabling operations to continue in the event of staff shortages. Many small-to-medium manufacturers,


however, find that the initial outlay, maintenance and servicing of new machinery prevents them from deploying robotics. This is where standard components can put


automation within reach. With drives, controls, belts, pulleys, gears and more all available in various standardised sizes and materials, manufacturers can quickly and easily automate different parts of their processes, without the need for bespoke, costly, components and third- party engineers. Leading on from


automation is the need to embrace digitisation and remote working. Certainly, recent events have highlighted an obvious weakness in the


manufacturing sector, which is that without people at the side of machines to oversee operations, production grinds to a halt. To overcome this weakness, it is imperative that


the manufacturing sector is able to adapt to different working conditions, such as having the ability to manage robots remotely. However, although technology is starting to allow operators to control machines off-site, the maintenance side of manufacturing is a lot trickier because it is usually determined by visual inspections. If there is no process in place for remote maintenance alongside remote working, then this can introduce dangers such as components wearing away beyond repair, and unexpected machinery failure. To resolve this, elements of machinery can be digitised to allow maintenance engineers to diagnose problems and solve issues remotely. For example, by adding sensors to equipment,


engineers can monitor physical parameters such as heat and vibration. This eliminates the need for lengthy and tedious diagnosis testing, while increasing the likelihood of a first-time-fix versus multiple visits to the site. Having access to data also ensures that the right parts and standard components can be ordered, and the machine can be repaired as quickly as possible.


BE FLEXIBLE Turbulent times can rock any business, but with the typically hands-on nature of engineering and manufacturing, the effects are felt much more acutely. To ride out any storms in times ahead, manufacturers must be flexible in order to minimise downtime, increase productivity and ensure business continuity.


norelem www.norelem.co.uk


/ DESIGNSOLUTIONS


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