INDUSTRY 4.0/SMART FACTORIES
A MODULAR APPROACH IN THE DIGITAL TRANSFORMATION QUEST WILL HELP INDUSTRIAL PLAYERS ACHIEVE OPERATIONAL BENEFITS, QUICKLY
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riving operational efficiencies that minimise disruption and downtime, improve productivity and facilitate growth is the Holy Grail for many industrial firms in an increasingly competitive landscape. The growing accessibility of data solutions is helping organisations in this space do just that, and digital transformation is a widely recognised concept no longer consigned to a futuristic outlook. But rather than a focus on extensive and expensive digital transformation projects, which look at the future vision, organisations should be exploring how to extract the right data that can help address the more urgent issues of the here and now. The ones that could bring the factory floor to a halt – today! Big data can feel overwhelming. It is overwhelming. But in focusing on the right data from small and manageable asset-based modules, operating cost savings can be realised much quicker. When a modular approach is established and built upon, these fast benefits just keep on growing and growing.
BEWARE OF THE RISE IN DATA SOLUTIONS PROVIDERS Data services have exploded in recent years as the realisation that data, and the right use of it, holds the key to business insights that can aid growth. With many new start-up data solutions businesses emerging, offering a plethora of data monitoring, measurement and analytic services, any industrial business looking to embark on or expand the digital journey are seemingly spoiled for choice. But deciding on a solutions provider should be a carefully considered decision.
An investment could be easily wasted if it were made with a firm lacking the industrial sector knowledge to know what to monitor and measure. Furthermore, the capability of the software to be effectively integrated with what is often a huge range of equipment brands and types – all of a variety of ages – is a key success factor. It is common in the industrial sphere for firms to be operating equipment that can be decades old, sitting alongside equipment that is just months old, and have many different brands installed. The very least a firm
Richard Jeffers is Managing Director of RS Industria, a cloud-based IIoT data- collection and reporting service that simplifies the connection of existing sources of manufacturing asset data.
should be stipulating is a brand-agnostic solution. And just as the seasons come and go, so do start-ups! With funding round phases often subject to delays or cessation, shiny new solutions can suffer hold-ups in development or even fall prey to an untimely demise. When making a significant investment in data services, taking into consideration the longevity of the provider is crucial.
EVOLVE YOUR DATA PLATFORM IN A MEANINFUL WAY As the Big Data agenda gathered pace, many industrial players rushed to invest in the installation of a range of sensors and monitoring equipment. This became more prevalent as the cost of such technology reduced over the years, making it much more accessible. The outcome of this is the collection of a myriad of data, to add to the magnitude of data that already exists in factories, with no one really knowing what to do with it or using it in a meaningful way to solve a pain point or inform decisions.
Even worse, the data often sits in silos rendering it almost useless. This is why taking a small steps approach can help: identify an issue to solve, find the most affordable and fast way to extract the data that will help provide the insights to solve it, and then move onto the next issue to solve. Using a modular, low-risk data platform to achieve this will help yield high returns. A modular solution approach means the most critical assets can be prioritised as a starting point, with the plan to expand as value is realised. Maximising the low-hanging fruit is a great way to start. Working with data services providers with industry-specific expertise and solutions will enable you to access the right data that already exists in various sources in an industrial plant, and augment this with new data sources to address any gaps. The final piece of the jigsaw is the extraction and analytics of the data that can provides the actionable insights for effective predictive maintenance, which holds the key to avoiding production downtime – a serious issue that can cost a plant around £10,000 per hour.
We worked with a logistics provider that was suffering frequent breakdowns of its main parcel sorter. The gearbox and conveyor bearings were showing excessive wear that required frequent replacement that were unusual and would usually be expected to have a longer service life. There were also high levels of metallic contamination in the lubricant which required more frequent oil changes. By implementing continuous monitoring of the drives and gearboxes, we were able to help the customer gather variable speed drive
10 MAY 2023 | FACTORY&HANDLINGSOLUTIONS
data to monitor the current, voltage and torque. Using cloud-based dashboards, we were able to process this data and establish and understand operating patterns. This informed the decision to re-programme drive profiles to reduce bearing wear. New lubricant specification led to a more cost effective solution and the continuous monitoring enables proactive replacement of parts, which significantly extends asset life. The real-time understanding of asset performance in this one factory process has led to an informed future maintenance strategy that will save time, money and eliminate downtime risk.
This is an example of why working with a provider that has a track record of effective integration of IT – underpinned by a strong knowledge of industrial assets and how to digitally connect them – should be high on the priority list when shortlisting providers. A sector-specific provider will be able to help a firm develop objectives that will achieve real value.
PUT YOUR HEAD FIRMLY IN THE CLOUD WITH ANY INVESTMENT It almost goes without saying, but we will anyway, that the only way to go when it comes to embracing Industry 4.0 is cloud-based solutions. As the industrial Internet of Things (IoT) gathers pace, the huge data processing and storage requirement makes on-premise options wildly expensive. And in a world where flexibility and agility are key to survival in a challenging and turbulent economic landscape, being able to scale up or down in accordance is key. Cloud services facilitate this perfectly, are maintenance free and you’ll always be running on the latest solution boasting the highest level of security. Negating maintenance, and hardware and IT infrastructure investment, is a huge saving for any business.
The information accessibility and shareability that cloud services facilitate is also unrivalled. Information across multiple departments and sites, collected via a multitude of sources and accessed via any device, creates infinite efficiencies.
Digital transformation is widely recognised as a must-have rather than a nice-to-have and barriers to adoption are slowing but surely being broken down. The case for digital connection of industrial assets is clear, but with a plentiful and growing array of solutions providers, the approach to selecting the right one must be carefully considered. The cost of doing nothing, or making the wrong choice, could be the make or break of any industrial operator.
RS Industria
www.rs-industria.com
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