INDUSTRY 4.0/IIOT
40th Anniversary 40yrasrevinnAht0 4 ARE YOU INDUSTRY 4.0 READY?
Neil Ballinger, head of EMEA sales at EU Automation, says manufacturers of any size can implement transformation
transformation a top priority. However, only 14 per cent believe their factories are ready to make the changes needed to realise Industry 4.0. So, what’s slowing this adoption, and how can more businesses put their digital transformation strategy into practice? For over a decade, manufacturers have seen the benefits of automation and how it can improve productivity in a variety of applications, with larger manufacturers, such as Siemens, Bosch and ABB, leading the way in digitalisation.
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Despite the success these companies have achieved and demonstrated to other businesses, small to medium enterprises (SMEs) have been slow to innovate. However, these businesses can experience similar success if they digitalise processes. As Jürgen Maier, former CEO of Siemens, explained when delivering the Made Smarter Review: “It is massively important for SMEs to engage with digital technologies. Many smaller companies think it is only for the likes of Siemens, but it is not. Technologies such as robots are now affordable and applicable to any manufacturer and can make significant improvements to productivity outputs.” It’s no longer a question of whether a manufacturer should digitalise, but how quickly. Manufacturers will continue implementing new digital technologies like AI, advanced robotics and cloud computing, but is it worth it if the employees are not fully trained? The reality is that with the
ecent Deloitte global surveys show that 94 per cent of executives in industrial companies consider digital
development of digital factories, the role of human workers will change and factories must ensure that they have the highly-skilled workers needed for efficient operation. According to The Manufacturer’s latest Annual Manufacturing Report, 59 per cent of respondents believe that the education system is failing and cannot keep up the pace of change in manufacturing technology. Schools are doing more to ensure young people improve technological skills and encourage more people to pursue careers in science, technology, engineering and maths (STEM) subjects. However, as technology advances rapidly, there is no guarantee that these skills will still be useful when the students enter the workplace. To ensure that manufacturers can find the skilled staff they need, they should work with trade associations to improve skills both in- house and in the education system. Local innovation hubs can train staff on new technologies, showing them how to operate new systems efficiently. Manufacturers can also collaborate with education programmes and schools to encourage more students to enhance their technological skills. Even if a plant manager hires the most qualified employees, cost remains one of the biggest obstacles for the full digitalisation of a factory. Smaller businesses might be reluctant to overhaul their entire facility because their current technology operates efficiently, and they cannot see the immediate return-on-investment. However, there are more cost-efficient ways for manufacturers to remain competitive and
24 DECEMBER 2020/JANUARY 2021 | PROCESS & CONTROL
Neil Ballinger: ‘By taking the time to choose the right adaptations for their facility, whether that’s replacing entire systems or modifying current infrastructure, every business can achieve its own version of Industry 4.0’
continue their own Industry 4.0 journey. While smaller manufacturers can continue to use legacy equipment if it still works, they should be aware of the risks of unplanned downtime. A lack of visibility and real-time data prevents manufacturers from accurately monitoring machine condition and detecting faults before they cause breakdowns. Instead of waiting for downtime to occur, these manufacturers should invest in devices that can help them to improve the productivity and maintenance of their existing systems.
Manufacturers can use affordable technology such as sensors to gather real- time data about a variety of parameters, such as temperature, pressure and flow. Accurately monitoring machine condition allows manufacturers to detect and anticipate issues, planning maintenance in advance to avoid expensive downtime. Engineers can fit smart sensors to existing equipment to immediately improve operations. Businesses should also consider adding connectivity capabilities to existing machines to allow devices to communicate over the internet and improve remote monitoring capabilities.
Access to real-time data about certain parameters can alert manufacturers to any issues with a machine, reducing the risk of breakdowns interrupting production. Gathering more information offers the long term benefits of increased visibility.
EU Automation
www.euautomation.com/uk/
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