• Category
  • >Internet of Things

Learn about Smart Factory and Factory 4.0

  • Siddhika Prajapati
  • Nov 05, 2021
Learn about Smart Factory and Factory 4.0 title banner

Seeing the increasing economic effect of IIoT around the world, many experts and investors have been questioning themselves if the business is on the verge of a technical revolution. 


But hearing from the numbers and forecasts, there is substantial and concrete proof that the concept of smart manufacture has now split into corporate awareness.  There is no uncertainty that a large part of the expenditure shall be devoted to the elements of IoT in all kinds of industry, particularly including construction.


But there are not just the forecasts and data to show us that the concept of Manufacturing the Internet of Things is obtaining traction across practically all business areas. 


Related blog - What is IoT?


Having previously proven to be the shortage show in manufacturing, IIoT carries the authenticity of these machine to machine connections, the security of preventative maintenance and the understanding of big data analysis. In other terms, the IIoT change has already started.


What is a Smart Factory?


Before we concentrate on the complexities of the smart factory, by means of introduction, some words must be told about its fundamental idea, the Industrial Internet of Things. Although the idea has been about for quite a course now, it isn’t, but obvious to only what precisely it contains and what all its features are. 


Just as IoT strives to enable our daily life by interconnecting things and making them interact and cooperate to bring us easier and quicker solutions for our daily struggles (remember smart coffee makers?) The IIoT is the identical concept but used to whole enterprises, such as the manufacturing, and few other services or local businesses.  


Recommended blog - IoT applications in daily life


Therefore, what we require to have to be about a true IIot deployment, is not just a machine-to-machine interface, but also connecting the gap between real and digital finance within a company and decreasing man-to-machine participation by advancing smart industrialisation and machine learning.


A Smart Factory is a notion deriving from IIoT that contemplates a production background as a fully automated and intelligent system that enables abilities, machines and logistic chains within the production plant to be run without human interference. 


Furthermore, a smart factory is a point where all those things fall thanks to the transfer of data not just between production devices and machines, but also between each element in the product technology sequence. 


This is a shift in machine learning, which implies that services can be sent out more effectively and bring more profits than would be reasonable if the production rules remained only under human guidance.

The image depicts the key elements of Smart factories and Industry 4.0 namely HMI, Sensor, Monitoring Tools, Instrument, Control System and Mobile Robots

Smart factories and Industry 4.0 - key elements


Implementation of Factory 4.0


It is very true that the real implementation of the smart factory mainly depends on the specific feature and the individual elements of the production setting in question. But there are several reliable software remedies out there that are capable of handling many special kinds of hardware and are flexible to a large number of different stationing scenarios. 


Suggested Read - Software documentation


Being the solid basis for each smart factory, the sensor remains necessary throughout the production plant to control the situation of assets, gather and interpret data and apply the resulting shrewdness to optimize reproduction. 


Yet for the sensors to do all those kinds of services, there must be a program to provide and maintain them, allowing them to collect data and to impersonate it in a perceptive and user-congenial way.


The true potential of the smart factory rests in its capacity to evolve and develop along with the growing needs of the business—whether they be changing customer need, expansion into brand-new markets, the addition of new goods or services, more ominous and responsive access to operations and preservation, incorporation of new methods or technologies, innovations to production. 


Considering more powerful computation and analytical skills—along with more comprehensive ecosystems of intelligent, connected resources—smart factories can allow organizations to adjust to changes in plans that would be difficult, if not improbable, to prepare so early.


What is the influence of the smart factory on companies?

The image depicts the Fourth Industrial Manufacturing Revolution - Analytics, Sensors and the Smart Factory 4.0

Fourth Industrial Manufacturing Revolution

There would be zero hype or even won't be double-digit increase estimates regarding the idea of Factory 4.0 if that weren’t for the advantages that the installation of smart manufacturing methods can deliver to any business. 


Building a dynamic composition environment by using both mechanisation and intelligence advances reliability, efficiency and security while reducing maintenance and downtime losses. Let’s have a more imminent peek at how that is achieved within the notion of a smart factory. 


Whether it’s only manual or fully automatic, every production procedure must be controlled in order to be under control, efficient and safe. Consequently, the applications of the IoT projects in this business sector have to focus on tracking the progress at each level and collecting appropriate data from devices or resources that would be unless only isolated parts of gear with no capability to coordinate and manage their own process.


But what the information and communication between the product, process tools bring to the procedure is more than simply enhanced surveillance and monitoring skills. Premised on the smart factory making strategies, developments can be acquainted, in real-time, instantly leading to product cycle maximization. 


Speaking of product, check out our blog on Product Positioning


Furthermore, the more automatic and controllable a method is, the more stunted it is likely to be to human mistakes, which not solely boosts productivity through decreasing downtime or preservation costs, but additionally improves closing product quality.


What makes Smart Factory different?


  1. Smart factories can likewise be effective in factory floor logisticians. Thanks to wireless sensor networks linking the machines, equipment, materials or each production surface, such as the conveyor belts, in which all the assets included in the production processes can be tracked in real-time, giving their full distinctness to the workers throughout the entire product series. 


For this reason, property usage and intra-factory logistics can be the best possible to maximum potential. Decision making can also be changed thanks to the accumulated knowledge about all of the assets’ abilities.


  1. Gathering and examining data is a central notion in the idea of Factory 4.0 because it enables the release of the potential concealed in the tools, resources and population. 


Related blog - What is a Smart City?


In this smart factory, data can transfer to the right point in the production string at the correct time without the necessity of intervention on the part of a human overseer. This allows a more direct model of communication, wherein devices and tools easily share data between them to attain higher levels of performance.


  1. But to accomplish this, information from different product contexts requires not just to be received, but also combined and interpreted to bring significant penetrations. 


A factory 4.0 robust data analysis environment is competent in doing this, which ultimately may point to originating a fully-fledged preventive preservation mechanism that shall keep the rules up and going despite the deficiencies recounted to tear and wear occurring from regular material exploitation and development. 


Also, data manufacturing can help in planning strategies for reducing the loss of materials and power as well as the best possible asset utilization.


Also Read - AI in IoT - Benefits and Applications


  1. Despite the lots of techniques that a Factory 4.0 might be crowded with, it can stay to be human-orientated. Even more further than that: it can be added to be employee-friendly precisely because it is also intelligent and personality-driven. 


Why is this? Since the more monitored and predictable the manufacturing environment is, the smaller threats it acts to the workers who control, manage and maintain its elements. 


Equipped with direct and important insight from the information analytics operations, employees are ready to detect the most vulnerable links in the product chain and act proactively in a state of detecting deviations.


Thanks to this mechanic which has been brought in by the smart factory, also the mechanics themselves can be traced by the operation and warned of any possible risks if they appear to enter any predefined danger zones.  


  1. Customization in the field of production is unquestionably one of the methods in which the business is heading now. Growing customer demands continue to spur the aim in the industrial sector against more versatility in return.


Suggested Read - Cost of Production


The measures to introduce product flexibility, before-mentioned as the utilization of new materials or innovative manufacturing methods, should be executed easier with the proficiency and awareness taken from the large data collected in the process of production workflow overseeing. 


Thanks to that, smart manufacturing plants can attain new levels of flexibility and provide for the growing needs of the consumer market.


  1. Additionally, owing to reducing the timeout that it needs for the material to be reengineered and reconfigured, companies are able to advance their product, process performance while adhering to be more flexible and available for new business challenges.


The smart factory is dedicated to companies who would want to leverage the capability of their devices, staff facilities and time to obtain competitive benefits. It is reliable that bringing up the concept of factory 4.0 and bringing it to life needs investment, training and strategy. 


But in the continued run, granted all the benefits that a fully automatic and intelligent factory may possess, the impact of a considerably implemented smart factory should invest in investment paybacks plus put its pioneering adopters at the lead of the Factory 4.0 changes.


Latest Comments