Industry 4.0 integrates digital technologies and continuous improvement methods to create a connected, intelligent manufacturing ecosystem that optimizes efficiency, reduces waste, and lowers costs throughout the product development lifecycle.
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What are the 5 pillars of Industry 4.0,
and how can they help you achieve your product development goals.
Industry 4.0 refers to a system of connected digital technologies and
methods. The principle is to integrate the entire manufacturing ecosystem.
From incoming raw materials to final inspection and shipping.
We do this to reduce waste and defects, allocate resources efficiently,
lower production lead times, and reduce production costs.
To do this, continuous improvement methods are combined with advanced software, automation,
wireless sensors and machine learning. To enable smart decision making with rapid response times.
Here is a closer look at the 5 pillars of industry 4.0.
No. 1. Kaizen and 6S
Kaizen is Japanese for “improvement” or “continuous change for the better.”
Based on Kaizen logic, 6S is used to Sort, Shine, Sustain, Safeguard, Set in Order and Standardize.
6S is used to establish and maintain an orderly workplace, clearly labeled and rationally laid
out, without clutter or waste. From this, it follows that each employee takes responsibility
to consistently apply habits of orderliness and discipline in their daily work. And as
orderliness becomes habitual, it inspires the workforce to constantly improve, even in small
and incremental steps. Kaizen sets the groundwork on which intelligent manufacturing is built.
No. 2 Connected Systems
Smart manufacturing places a premium on the collection of large amounts of data in real time.
This data is shared between manufacturing cells, processing equipment and operators by being linked
to a central computerized database, either via physical cables or wirelessly.
On the shop floor, the Industrial Internet of Things (IIOT) uses various wireless sensors on
products to follow individual parts or whole assemblies through their journey
in the factory, all the while updating their status to a central database. This
creates a cloud of data which provides valuable insights on raw material usage,
machine downtime and maintenance, production bottlenecks and more.
So the next step in intelligent manufacturing is
to make sure that all relevant devices and products are talking to each other
and that this information is available to operators so they can make smart decisions.
No.3 Data Transparency
Once there is an ecosystem of connected devices sharing data, operators can access this
information via a variety of terminals, displays or other digital interfaces. They can see at a
glance the status of the task they are working on, and its relationship to the entire product flow.
Operator input at any point in the production cycle will immediately register throughout the
system, updating metrics like inventory in stock, machine status and load, product lead
time , and any other criteria that management has defined as essential to company performance.
With this wild field of view, problems become easier to spot and hence easier to correct,
for example if parts are spending too long at a given workstation.
No. 4 Automation
Automated systems will be used wherever possible to perform routine jobs. Since
automation is repeatable, reliable and tireless, this is the ideal way to free
human workers from tasks that would otherwise exhaust them or expose them to potential injury.
Not all automation is of the heavy-lifting variety. Some 3D scanners for example,
can be used for rapid, in-line measurements of fabricated parts and instantly identify
non-conformities much quicker than a human operator could do.
Automation frees workers to perform other jobs for which humans are uniquely suited,
jobs requiring creative thinking, problem solving, planning and analysis.
No.5 Machine Learning
Once a lean system has become digitally integrated, machine learning and artificial
intelligence will be combined to anticipate – and respond to – emergent conditions on the
shop floor without needing human intervention. For example, CNC milling machines will know
how long a given tool has been used to cut metal, and will schedule sharpening
or replacement before the tool is allowed to go dull and thereby impact production.
In fact, proactively planning routine maintenance is one of the best ways that companies can
prevent costly unscheduled downtime and this system is rapidly being introduced at Star.
Over time, machines will get smarter by using larger data sets to allocate
resources efficiently and alert human planners to conditions that may require their input.
There you have the 5 main pillars of industry 4.0. Star Rapid is
fully committed to implementing them and creating a lean and intelligent
manufacturing solution to support your product development goals.
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