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Why Move Forward To The Concept of Smart & Modern Factory

Always think big, but start small and scale fast.

There are no two ways about how profoundly technology is impacting the way factories operate. It has made the manufacturing process intelligent and dynamic and the concept of the smart modern factory has become a reality now.

A modern smart factory is a fully connected and flexible system which a leap forward from the traditional system. A smart factory can use data from the connected operations and learns to adapt to the new demands. It integrates data from various physical, human, and operational asset for the driving processes like manufacturing, maintenance, inventory tracking etc.

Why Move Forward To The Concept Of Smart & Modern Factory
  1. Cost Optimization: The smart manufacturing processes in a modern factory lead to cost-effective processes in inventory and hiring as well. A higher degree of predictability helps in optimizing the processes and hence the cost. With better-optimized processes, better quality products can be delivered, which also leads to lower maintenance and warranty costs.
  2. Asset Efficiency: A massive amount of data is collected in the modern factory that is analyzed for trends and inefficiencies. This helps in understanding what will work and what won’t work, hence efficiency in terms of downtime, capacity, and change over time improve.
  3. Quality: Technology in the modern factory can quickly spot the defects and the defect trends. It helps in identifying the weak link in human and machine environment. This leads to faster rework identification, reduces the scrap rates, and improves the overall product lifecycle.
  4. Automated and Streamlined Data: The technologies used in smart and modern factories collect data and produce advanced analytics. This helps managers to make informed decisions. The key performance indicators can be measured against the business goals if the right data is available.
  5. Predictive Maintenance: The right data can help manufacturers to predict and resolve any maintenance issue on time so that the downtime can be avoided. The real-time condition monitoring can increase the overall efficiency of the plant.
  6. Cost Reductions: The accurate forecast can help in identifying waste and reduce the costs significantly. Data can guide to the supply chain issues, inventory issues, delivery issues, demand cycles.
  7. Reduction in Workforce Challenges: With automation, manufacturers can do the same job with the fewer workforce. Also, with the real time access to the accurate data, the workforce can focus on their core responsibilities, take quick and informed decisions.
Configuring The Smart Modern Factory

Each factory is different and unique. But, for a successful implementation of a smart and modern factory, the following factors are important and should be equally prioritized:

  1. Data: The most important aspect, lack of right data solutions make it difficult to track, analyze, and predict. Scalable data solutions are imperative along with the secure data storage options.
  2. Technology - Every aspect of the modern factory has to be connected and communicates with each other through a central control system.
  3. Process - The digital technologies break the walls of the factories. It creates interactions between suppliers, customers, and other various stakeholders. Hence, this processes in the modern factory should reflect these direct relationships and processes.
  4. People - The modern factory with the smart technology asks for the new cross-functional roles emerging from the application of the technology.
  5. Cyber Security - For a secure and smooth transaction and communication between various stakeholders, cybersecurity needs to be on the topmost priority, in order to maintain the safe factory operations.
The Way Forward

To start the journey of the smart factory and plunge in the industrial revolution, always think big, but start small and scale fast. This means that you should be aspirational in your vision but always stay realistic in your implementation. Think strategically and stay focused on your objective. “Value creation can begin with and scale from a single asset, and use an agile approach to iterate and grow,” says the Deloitte report.

Essentially, it is the communication and the ability to analyze the manufacturing data enables the ‘smart’ in the ‘smart factory’. As the new technology emerges, the next industrial revolution - Industry 4.0 converges and enables the concept of smart factories. It is the application of the intelligence that creates a dynamic environment of production and the desired results. Hence, reducing the costs, improving the overall quality, and creating a more reliable manufacturing process.

Keyur Bhalavat Founder and Director

A young entrepreneur full of intellectual energy and concern that transform into an untiring center of knowledge seeking, unafraid of exploring new and fresh ideas however challenging they may happen to be in the field of technology.