FEATURE Industry 4.0 & Smart Factories
Smart factory – turning the concept into reality
What is really needed to make smart factories optimally-functioning entities, asks Dr Myriam Jahn, Supervisory Board Member at SUESS MicroTec, and Head of Division of L. Possehl & Co
T
he Covid-19 pandemic has caused unprecedented disruption across the
manufacturing world. For many
business leaders, however, this hasn’t changed the drive toward the Fourth Industrial Revolution, or Industry 4.0, as manufacturers try to fi nd new ways of surviving in a changing world. Whilst the term Industry 4.0 is often used to convey a realm of possibilities, it comes with a number of challenges. The automation of information and data exchange in manufacturing technologies and the creation of smart factory is still a long way away from being realised for most businesses. Even though digital technology is changing the face of the industrial and manufacturing world, the march towards Industry 4.0 is rather slow. Advancements in the integration of physical objects and software are patchy across sectors, and whilst there are pioneers like Amazon, the rest of the sector is not there yet. Although there are no simple answers as to why progress is slow, there are three main obstacles that the industry is facing against fully realising Industry 4.0:
1. Connectivity
The goal of connectivity should be about data collection and data management. A truly-connected enterprise will eff ectively manage its data. Many PLCs are currently struggling with this, particularly because Industry 4.0 data comes from diff erent and diverse sources. To date, most data is either unused or used only for very specifi c, tactical purposes. Inadequate interoperability across incompatible technologies, systems and data types contributes to data not being strategically used. Without integration of machine and sensor data, businesses won’t be able to handle processes such as condition monitoring, predictive maintenance or traceability – the key components of smart factory. To overcome this, companies need cutting-edge platforms that can maximise the value of
18 September 2021 | Automation
manufacturing big data using machine learning, artifi cial intelligence and predictive analytics. Rockwell Automation has been pioneering IIoT connectivity and data analytics to enhance the industry’s productivity. Its FactoryTalk InnovationSuite software supports an ecosystem of advanced industrial applications, powered by PTC. “There is a digital necessity for companies to ensure they have the right infrastructure internally, providing the data insights necessary to achieve their goals. As customer demands increase, they realise having the right OT data context is critical to scale their digital transformation initiatives,” said Pierre Teszner, Vice President of Sales, Central Europe, at Rockwell Automation.
2. Implementation
Far too many conventional IT systems struggle to handle, manipulate and store the diverse data that Industry 4.0 demands. This not only leads to lost productivity, but additional technology headaches as more people are required
on the shop fl oor and unable to fulfi l their duties from remote settings. This is frustrating for many reasons: the integration of Industry 4.0 has not been as smooth as fi rst envisaged, and linking new equipment with the software required for a seamless integration is still proving elusive. There are also barriers due to lack of standardisation and lack of knowledge or understanding of the available technology. Open-source software solutions may be the best solution in the short and medium term, whereas in the long term, businesses will fi nd that structural changes are needed top to bottom.
3. Automation and IT hierarchy Industry 4.0 requires automation solutions to be highly cognitive. But when it comes to larger projects such as automation, organisations often follow a specifi c route or turn to an existing supplier, with the result that they can get “locked in” in a way that limits their access or mindset to alternative solutions in the Industry 4.0 environment. There is also a need for decision making to be done faster than before. While edge computing could be a viable solution, this technology is still in its infancy for many manufacturing companies. There are no easy solutions, but a better understanding between IT and OT (operational technology) must be prioritised if machines are going to ‘talk’ to each other eff ectively.
In addition, IT security is key to implementing a further layer of productivity software. Ideally, security assessments are the best way to analyse the legacy IT infrastructure, at the OT level especially, informing industrial manufacturers as to which areas to remediate before they embark on a full IT-OT convergence journey.
CONTACT:
Rockwell Automation
www.rockwell.com
automationmagazine.co.uk
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