SMART few years, the conversation on a topic

SMART MANUFACTURNIG

ABSTRACT:

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Manufacturing
is now developed from past few years and become more automated, computerised
and complex. In this Report, the inception, current Situation and the future of
Smart manufacturing is analysed. Smart manufacturing is a result out form the
production integrating manufacturing assets of today and tomorrow with
communication technology, computing platforms, sensors , control, simulation,
data intensive modelling and predictive engineering. The core of smart
manufacturing is based on six parts, manufacturing technology and processes,
materials, data, predictive engineering, sustainability and resource sharing and
networking. Material handling and supply chains have been an integral part of
manufacturing. The anticipated developments in material handling and transportation
and their integration with manufacturing driven by sustainability, shared
services and service quality and are outlined. Smart
manufacturing is not a trend, it’s the future, and that future will be on display
throughout Atlantic Design & Manufacturing

INTRODUCTION:

If you haven’t noticed, everything today is “Smart.” We have
our smartphones, smart TVs, and smart watches. It seems to make sense that we
also have “Smart manufacturing.” Smart manufacturing, or SM, like everything
else that’s smart, utilizes connectivity and real-time access to data to
improve a process. From
the past few years, the conversation on a topic of Smart Manufacturing (SM) has
been focussed by leaders and industry experts. To state it simply, it is the
use of technology and real-time data used by People and Machines in the format
they want anytime, anywhere. It is one of the mostly used term to describe
tomorrows Manufacturing. It is a “fully-integrated,
collaborative manufacturing systems that respond in real time to meet changing
demands and conditions in the factory, in the supply network, and in customer
needs.”(NIST, USA). The information regarding manufacturing Processes is
provided by Smart manufacturing when it is needed, where it is needed in the
required format across the entire manufacturing firm.

Columns of Smart
Manufacturing:

Fig.1 Columns of
smart manufacturing

Column 1.
Manufacturing technology and Processes:

The
Exposure of Manufacturing technology and Processes will be expected in several
years. The innovations in new materials, components and product will emerge. Small
and somewhat big area additive manufacturing will expand its prominence in the factories.
Advance low cost robots will increase factory automation. Sensors will make the
new Equipment smarter and manageable to factory and beyond communication.

Column 2. Materials:

Smart
manufacturing won’t give a special treatment for development of Smart
Materials. It may well be that smart materials and smart products will follow
their own development paths. Novel processes will require for some new
materials which must be developed and incorporated in smart manufacturing.
Additive manufacturing alone will be a great contributor to the search for new
materials and their mixes.

Column 3. Data:

Data
is provided as power for envisioned of applications, including building
predictive models. Moreover, it will be the best source for preserving and
extraction of past and new knowledge related to manufacturing.

Column 4. Predictive
engineering:  

It
is a development approach to design product that with help design of Smart
Systems. Generally, manufacturing firms are focused on using the data for productivity
analysis, process monitoring and quality control. Predictive engineering offers
a different sample of building high-integrity models of the Context of
interest. In this models, some allow to Explore Future space such models will
allow exploring future spaces, some Stays with the existing technology and
others that have not been seen previously.in future we can expect that today’s
models will be enriched with both limited-scope models and the modules which involves
multiple systems to support decisions related to future production and market
conditions.

Column 5.
Sustainability:

Sustainability
is very important in manufacturing. Productivity,
production, energy and pollutants intended for sustainability efforts will be
product production. Product and the market are the entry points
of any major Sustainability efforts. Sustainability is about how it is
performed rather than what is manufactured. It is the main force behind
providing equal footing for remanufacturing, reconditioning and reuse with
manufacturing.

Column 6. Resource
sharing and manufacturing:

Manufacturing
is now more digital and virtual, and due to this the most of creative and
decision-making activities will take place in the digital space. The physical
manufacturing assets with their know-how will be protected Couse some level of
Digital Space is Transparent. This will allow to use of resources across
businesses, including the ones that compete.

                     

The Essential Features of Smart Manufacturing, Applications and
State-of-art Survey:

Based on Rexroth Bosch Group
experience in pilot projects in their own plants, it has been identified that
seven essential features that are necessary in Smart manufacturing for the
implementation of Industry 4.0.

1.      
People  As key Player:

People with Production related information improve
Ergonomics with digital assistant functions and intelligent workplace design support. In the Rexroth Bosch they provides different kinds of hardware and
software solutions. This starts in assembly areas where it can automatically
identify workers and create a work environment that is tailored to them
individually; show them instructions which are oriented to their knowledge; and
provide them with smart assembly tools and devices that are intuitive to
operate.

Fig. 2 The Essential
Features of Smart Manufacturing

2.      
Distributed intelligence:

The independent intelligent automation components with integrated
software perform their tasks better that the centralized automation, according
to the specifications of higher-level systems, and make autonomous decisions. Rexroth
Bosch is a pioneer of decentralised intelligence with intelligent electronic
drives and motion controls for hydraulic drives. Distributed intelligence is a
basic requirement for modular machines and flexible facilities that adjust
themselves to changing market and manufacturing conditions.

3.      
Fast integration and
flexible configuration:

          

With Plug and Produce, people, machines, processes and the flow of goods
are networked together on an ad hoc basis. Software tools simplify multiple
smart manufacturing machine steps: commissioning, integration and
(re)configuration, as well as preventive maintenance of all components, modules
and machines. Rexroth Bosch Open Core Engineering includes all the
software tools, function toolkits and open standards for efficient software
engineering and rapid networking. Software wizards and tools support
commissioning engineers, operators and maintenance technicians in their tasks
and reduce complexity. Open Core Engineering enables users to work with their
preferred development environment and programming languages from the IT world
to maximise the efficiency and versatility of automation development.

4. Open standards:

 

Open Standards that extend across manufacturers and are platform-independent
form the basis for horizontal and vertical integration and thus for the seamless
exchange of information in value-creation networks. Rexroth have always
supported open standards such as Sercos, IEC 61131-3, PLCopen or OPC UA. With
multi-Ethernet interfaces and Open Core Engineering, Bosch Rexroth has
completely opened up automation to the IT world.

5. Virtual real-time
representation:

All components and objects are represented as virtual real-time
representations across the entire value creation process. These virtual
elements are closely linked to their physical counterparts and provide
in-context information for continuous process improvement in real-time. Bosch
Rexroth automation components and systems record all relevant data using their
own software functions and sensors and exchange these via multi-Ethernet
interfaces. Industry 4.0 solutions such as Active Cockpit evaluate the relevant
data and display it in real time. This provides operators and managers with a
solid base of information for rapid process improvements as production
proceeds.

6. Digital life-cycle
management:

The comprehensive networking of all automation components, machines,
processes and product data — from development and production to recycling —
decreases development time and therefore development costs, for both completely
new smart manufacturing lines and upgrades to existing platforms. In addition,
this also ensures the application-oriented design of all components. Bosch
Rexroth supports digital lifecycle management with model-based simulations for
motion-logic systems. OEMs can validate and optimise the interaction between
hardware and software in a virtual system in parallel or before machine
assembly. They save time and can bring new designs to the market more quickly.

7. Secure value-creation
networks:

Security
and safety for Industry 4.0 includes protecting people from machinery-related
hazards (safety) as well as the protection of production facilities and
corporate IT from attacks and faults from the surrounding environment
(security). This involves securing sensitive data as well as the prevention of
intentional and unintentional malfunctions. Bosch Rexroth works with all
relevant standardisation committees for security and is already implementing
the most up-to-date technology. More and more of Bosch Rexroth’s intelligent
components and solutions have a forgery-proof digital identity — an important
prerequisite for secure value creation networks.

The Benefits and Impacts of smart manufacturing:

Improved productivity

Smart
manufacturing processes provide greater access to data across an entire supply
chain network. Real-time data outlines what the manufacturer needs and when,
which makes things more efficient for suppliers that can easily make
adjustments to orders. They supply what’s needed, not more or less, reducing
waste and any downtime associated with missing parts.

Innovation and higher quality products

When
productivity is improved, it saves money, which can then be invested in product
development. Once analysed, smart manufacturing data shows where customer needs
are and managers can find opportunities for new products or re-imagined
products of a higher quality.

More manufacturing jobs

Adopting
smart manufacturing is a way to attract the younger, tech-savvy workforce since
more technology based manufacturing jobs will become available. Utilizing smart
manufacturing data and apps, employees can recognize new opportunities and
increase productivity. According to California Manufacturing Technology
Consulting, smarter factories offer the opportunity to boost employment 2-4
times over the current national manufacturing workforce of 12 million.

Cost Analysis:

             Factor Input                                     Mean
Impact

                                                   
K: Capital                                              
?5%

                                                   
L: Labor                                                 ?12%

                                                   
E: Energy                                               ?13
%

                                                   
M: Materials                                           ?5%

Table 1.
Average Percent Change in Factor Inputs

Table 2.Economic Impact Summary,
Process versus Discrete

Table 3. Economic Impacts by
Capability Area

Shows that economic impacts are
estimated to be approximately $57.4 billion.

Conclusion:-

Smart manufacturing is not about
the degree of automation of the manufacturing floor; it is about autonomy,
evolution, simulation and optimisation of the manufacturing enterprise. The
scope and time horizon of the simulation and optimisation will depend on the availability
of data and tools. Financial issues were the most commonly cited barriers to
adoption of smart manufacturing technologies and processes. Concerns about
financial issues were followed by a lack of technical resources and
knowledgeable staff needed for implementation. The level of ‘smartness’ of a
manufacturing enterprise will be determined by the degree to which the physical
enterprise has been reflected in the cyber space.

 

References:

1.      
article:
Andrew Kusiak (2017): Smart manufacturing, International Journal of Production
Research, DOI: 10.1080/00207543.2017.1351644

2.      
Gallaher
M.P.  Et al. 2016. Economic Analysis of
Technology Infrastructure Needs for Advanced Manufacturing, 11-2.

3.      
Features
of Smart manufacturing, Retrieved from

https://www.boschrexroth.com/en/gb/trends-and-topics/industry-4-0/features-of-smart-manufacturing/features-of-smart-manufacturing#
, accessed on 10 Dec. 2017.

4.      
Benefits
of Smart manufacturing, Retrieved from http://www.fishmancorp.com/benefits-smart-manufacturing/
accessed on 11 Dec. 2017.