Industry 4.0 arrives with Avanzate
What is Industry 4.0?
The concept of industry 4.0 consists of the introduction of digital technologies in factories. It is the name given to the phenomenon of digital transformation applied to the production industry.
The industrial revolution, also known as Industry 4.0, consists of the digitization of production processes in factories using sensors and information systems to transform workflows and make them more efficient.
How does Avanzate Industry 4.0 work?
In recent years we have made great efforts in the development of products oriented to Industry 4.0.
To improve the productivity of our customers’ production processes, we use various techniques:
– Big Data. Our systems collect countless production parameters from any PLC on the market and are stored in open databases.
– Smart Factory. The real-time analysis of this Big Data with our Science Analisys module allows us to provide Artificial Intelligence that helps to increase manufacturing in the production process of the industry.
– Our IoT (Internet of Things) modules allow us to collect data digitally from any sensor connected via Ethernet, without the need to go through a PLC.
– Total factory connectivity. You can consult your data anywhere in the world with connectivity and from any device, with maximum security. We are experts in providing solutions to our customers to improve their factory connectivity through Industry 4.0.
Production efficiency with Industry 4.0
We carry out studies on the industrial processes of our clients to improve them. With our industry 4.0 software we analyze standardized metrics of industrial efficiency, we give the conclusions to the client and we propose technological solutions to improve, if possible, the productivity of production cycles.
Years of experience behind us.
We study industrial production metrics to improve the productivity of machines and the optimization of available resources. Study of Availability, Performance and Quality.
Availability
Losses of productive time due to stoppages and adjustments
Performance
Yield losses due to minor shutdowns and production speed reductions
Quality
Loss of quality by producing poorly manufactured units and loss of production time
With these variables we calculate the OEE ratio which is a percentage value used to measure the production efficiency of industrial machinery.
Having an OEE of, for example, 40%, means that out of every 100 good parts the machine could have produced, it has only produced 40.
The OEE value helps to rank one or more production lines, or an entire plant, with respect to the best in class and which have already reached the level of excellence.
– OEE < 65% Unacceptable. Significant economic losses occur. Very low competitiveness.
– 65% < OEE < 75% Fair. Acceptable only if in the process of improvement. Economic losses. Low competitiveness.
– 75% < OEE < 85% Acceptable. Continue improvement to exceed 85% and move towards World Class. Slight economic losses. Slightly low competitiveness.
– 85% < OEE < 95% Good. Enter World Class Values. Good competitiveness.
– OEE > 95% Excellence. World Class values. Excellent competitiveness.
OEE is the best available metric for optimizing industry processes and is directly related to operating costs. The OEE metric reports on process losses and bottlenecks and the performance of plant operations.
OEE is the metric to complement the quality and continuous improvement requirements demanded by ISO 9000:2000 certification.
Industry 4.0 software Process control and supervision
We are specialists in the creation of SCADAs and modification of existing ones. We work with a multitude of SCADA environments.
If you want to automate a new phase of the production process or have modified an existing one, count on us. We are specialists in automating the production network and SCADA monitoring to take your business to Industry 4.0.
If you need to see this data in a remote environment, we also offer the possibility of monitoring your production process via web or mobile app.
Benefits of implementing Industry 4.0
Integrating Industry 4.0 into the production process can lead to a number of significant advantages in terms of productivity, quality and costs. These benefits are detailed below:
- Increased Efficiency and Productivity: Thanks to the automation of processes and the integration of intelligent systems, greater operational efficiency and an increase in manufacturing is achieved.
- Reduction of Operational Costs: The elimination of manual processes and the reduction of errors and downtime contribute to reducing the organizations’ operating costs and the optimization of available resources.
- Product and Service Customization: The ability to tailor the supply chain to meet specific consumer needs increases customer satisfaction and brand loyalty.
- Improving Product Quality: The integration of advanced technologies, such as artificial intelligence and data analytics, helps to improve the quality of manufactured products.
- Increased Flexibility and Adaptability: The implementation of intelligent and automated systems allows the factory to adapt more quickly and efficiently to the changing demands of the industry.
- Improved Data Security: The adoption of advanced cybersecurity technologies ensures greater protection of organizations’ sensitive data.
- Optimization of Strategic Decision Making: Real-time data integration and automated reporting facilitate strategic decision making and identification of improvement opportunities.
- Exploring New Business Models and Markets: The implementation of Industry 4.0 provides the opportunity to create new business models and expand into new markets more efficiently.
- Reducing Environmental Impact: The adoption of more sustainable and efficient technologies contributes to reducing the environmental impact of the plant’s operations.
Industry 4.0 innovations
Industry 4.0 innovations connect the physical and digital worlds, making it possible to create intelligent and autonomous systems thanks to the different technologies involved in Industry 4.0. Among some of them we find:
Big Data and AI analytics
Big Data is responsible for collecting data from a wide range of sources, including data capture from IoT (Internet of Things) enabled assets, equipment and devices. These data sources extend beyond the factory floor, encompassing other areas of the business. This data can include everything from customer reviews and market trends to weather forecasts.
In addition, these analytics are powered by AI and machine learning, which in real time leverage information to improve decision making and automation in all areas of manufacturing and supply chain management.
Cloud computing
Cloud computing is the foundation for the most advanced technologies, from IoT to IoT integration, and provides the means for innovation. Because all the data that powers Industry 4.0 technologies resides in the cloud.
Internet of things
The Internet of Things (IoT) is essential to Industry 4.0, such that most physical devices, such as robots, machinery and equipment, use sensors to provide real-time data on their status and performance. This technology enables companies to operate smoother supply chains, design and modify products quickly, avoid downtime, and efficiently track products and inventory.
Additive manufacturing/3D printing
At the time of its inception, 3D printing was used as a tool for rapid prototyping, but it now offers a wide range of applications. Thanks to 3D printing, parts and products can be stored as virtual inventory files and printed on demand, reducing both costs and the need for larger stock.
Autonomous robots
With Industry 4.0, autonomous robots are becoming more and more common. These robots are programmed to perform tasks without the need for human intervention. Being equipped with AI, sensors and machine vision, these robots are capable of performing increasingly complex and delicate tasks.
What is the impact of Industry 4.0?
The implementation of Industry 4.0 in your company can have a significant impact thanks to the incorporation of new technologies. However, the extent of this impact will depend on the size, sector and specific characteristics of your company. Some of the most common effects include:
Efficiency and Productivity
Industry 4.0 achieves process automation through the use of robots and Artificial Intelligence (AI) systems. To improve efficiency and productivity, robots can perform repetitive tasks with constant precision, freeing employees to focus on other activities. In addition, technologies such as IoT allow real-time monitoring of machinery and processes, enabling predictive maintenance.
Improved Decision Making
Industry 4.0 technology is capable of collecting and analyzing large volumes of data, providing valuable information for strategic decision making. Through the use of big data and advanced tools, companies can identify patterns and trends that would not otherwise be evident, such as product demand over time. In addition, with the help of this information, AI can provide informed recommendations based on the data and help managers make decisions more quickly and effectively.
Innovation and Product Development
Technologies such as 3D printing enable rapid prototyping and product customization. This reduces the development times and costs associated with creating new products, allowing companies to experiment with new ideas and bring innovative products to market faster. In addition, these technologies provide companies with the flexibility to manufacture customized products on a large scale, which can significantly improve customer satisfaction by better matching their needs and preferences.
Frequently Asked Questions
What is Industry 4.0?
The Internet, smartphones and connectivity have completely changed our personal lives in the last decade. However, they are not fully integrated in our businesses and factories. That is why Industry 4.0 is positioned as a new industrial model that integrates IoT (Internet of Things) technologies into the production chain.
What is the goal of the 4.0 revolution?
Industry 4.0 digitally merges various disciplines to ensure customer satisfaction and service customization. One of the objectives of this revolution is the union between digital technologies that allow cost reduction and greater efficiency in the company.
How does Industry 4.0 influence companies?
Industry 4.0 can mean different changes in the work and production of factory products. Industry 4.0 directly influences the way workers work, making more customized products for customers thanks to this industry.
How does Industry 4.0 affect the human factor?
Industry 4.0 is not here to replace people in their jobs. On the contrary, its aim is to facilitate tasks and free workers from monotonous tasks. In this way, they will be able to devote themselves to others that are more enriching for the industry itself, as well as for themselves.
How does Industry 4.0 affect my manufacturing process?
Industry 4.0 transforms your manufacturing process by automating and optimizing production, creating smart factories. This improves quality standards and reduces errors, while the workforce focuses on more strategic and creative tasks. By manufacturing a product, you gain greater efficiency and adaptability to market demands.