Upgrading Machines for Industry 4.0 is Foolish!!

It all started with the Internet revolution, which enabled every computer in the network and in turn every soul on this planet to connect with one another. Since then, we got connected via PCs, Laptops, smart phones, TVs, watches, and even your shoes tie themselves up remotely. Internet Of Things’ (IOT) revolution is on the roll and Manufacturing Industry is not far off.

In recent years, automation has created an enormous impact on the manufacturing industries. Some governments are even concerned for the Job loss. Industry 3.0 is the harbinger of digital factories. Every machine, every robot, is connected with a small Programmable Logic Circuit (PLC), which is a computer collecting data from the production lines. But, is that enough information for the management to take a major manufacturing decision?

Catering to this problem, Industry 4.0 revolution has begun churning the wheels of Big Data generation inside the Manufacturing environments. It focuses on building a cyber physical ecosystem of machines and humans, where data is generated at every aspect of the production cycle. But hey, what would that mean for manufacturers and mass producers? Do they need to upgrade their machines and robots for the newer upgraded versions of Industry 4.0?

A simple thought of changing one machines is daunting, Industry 4.0 will be a nightmare to participate in. Again, if you don’t upgrade, you’re going to lose the tech race. What if I told you there’s a mid-way to upgrade your factory without changing a single machine? Yes, a widely accepted solution to this challenge is to externally place sensors on your production lines that generate data at key points. This doesn’t end here, big data generated by the sensors can be analysed to understand the efficiency of your production lines and hence help you take more informed decisions.

Your production line is heavily human dependent? No problem! You can still generated data at manually operated work stations. The efficiency here can be calculated by knowing the number of problems your workers face, how fast are these problems solved and what is the source of a repeated problem as well. This method of keeping track of your work stations is called an Andon System. A simple solution comprising of buttons and lights connected with Wi-Fi can help you operate your factory on your smart phone.

Conclusion

It is tough call to upgrade your production lines that are compatible with Industry 4.0 standards, and not upgrading could mean losing your edge over the manufacturing industry. Using a combination of sensors and Andon systems, is a smart way to upgrade your machines TODAY! However, it is important to know the best solution, tailored to your manufacturing facility.

About Compucare India Pvt. Ltd.

We are providing solutions since 1996. Our vertically integrated innovative automation solutions, keenly focused on Andon and Production Monitoring Systems (PMS), have earned us some of the biggest manufacturing tycoons of Indian market. Our solutions have helped increase efficiency of companies like Johnson Controls – Hitachi, Bata, IMI, Siemens and ABB to name a few. We take hubris in our exceptional services.