Digitalization Products or Digital transformation in every industrial sector made radical changes through accelerating the productivity and production of products by reboosting the effectiveness of machinery and efficiency in repairs and maintenance of machineries.
The fourth industrial revolution i.e, Industry 4.0 enabled the usage of cyber physical systems in reshaping the business models in a digital age.
Digital Transformation in manufacturing industries enables increased productivity and improved volume of production utilizing the essential features of industry 4.0 solutions.
a) Digitalization Products with Industry 4.0
- Industry 4.0 solution analyzes the current trends and tendencies to improvise the production.
- It facilitates the communication between machine to machine and human to machine in the form of human machine interaction such as touch interfaces and augmented reality systems.
- It collects huge amounts of data from the industrial Internet of Things.
- It combines both real world and digital world to swift global market to digitalization and automation.
- Digital work instruction for manufacturing will be provided by already recorded video to the worker as to follow the instruction and work according to it. Hence saves the cost and time of appointing a trainer to train the workers.
- Digital transformation leads to increased efficiency through streamline operation to maximize the efficiency.
- Improves productivity by avoiding overlapping operations saves time of employees and increases productivity.
Essential features of Industry 4.0 solution
To increase productivity in the industrial sector effectively with real time monitoring of the production system.
- Andon Board: Andon board software consists of display boards it allows supervisors and management executives for real time understanding about the performance of machines.
Benefits:
- Currently producing Product name is displayed
- Machine status can be tracked and displayed about the condition like running stopped or no plan
- Production count will be displayed on board
- Real time target and real time production achieved will be displayed on the board
- Timely escalation and alerts are provided to senior management.
- It maximizes the overall productivity
- Digital Work Instruction: Digital work Instruction are the instructions given to employees in a simpler form to make data driven decisions quickly and are accessible to operators with just a swipe of a tablet to increase production line and reduce downtime.
Benefits:
- Digital work instruction for manufacturing provides step by step visual process of pre recorded video or training material in order to complete the manufacturing task efficiently.
- Centralized database of product videos or training material
- Through a single click all station tasks are mapped
- Standard batch report and report summarizes the quality checks,material lot used, exceptions,signature,etc.. during the production process.
- Production monitoring System: Efficio Production Monitoring system is interfaced with machines and provides real time production updates of the shop floor.
Benefits:
- Real time monitoring facilitates production count
- The machine is integrated with an IoT system to determine the production count.
- OEE availability in production shop floor can be measured
- Calculation of production reports can be done.
- Production supervisor can focus on the targets that need to be achieved
- E-Preventive maintenance: Preventive maintenance enables to prevent the equipment falling down while working.it reduces the breakdown of the machine with a system of time based maintenance software which helps emergency repairs.
Benefits:
- e-preventive maintenance will reduce lost production cost and increases productivity
- Time based maintenance approach is a proactive measure to run task efficiently
- It prevents failure of equipment before happening through real time alerts.
- Kanban software: E kanban software eliminates paperwork, digitally analyzes the inventory of product lines, raises the material request by notifying kanban signals, examines the collected materials, and evaluates the arrangement of materials in the material bin properly.
Benefits:
- The Kanban system reduces the overproduction and leads to increased efficiency.
- Red kanban system raises the material demand in shortage of goods.Yellow and green notifies the materials available in real time.
- Quick view and management of inventory in the warehouse
- Real time SMS/Emails notification and simple material request
- Traceability: Traceability software enables to track and monitor the workflow in manufacturing industries like raw materials used, time spent to manufacture one product and overall productivity of the plant.
Benefits:
- Traceability tracks the PCB ,bessel assembly
- Online tracing is done by generating unique number to plant
- Order management tool helps in creating orders and viewing the orders
- It tracks on both online and offline systems.
b) Digitalization Products with AI in manufacturing operations:
The automated AI detective surveillance provides real time monitoring in all stages of the manufacturing process and always focuses on ensuring Environment Health and Safety of workers to improve efficiency in work and proactive measures to manage the warehouses arrangement and production count to increase productivity which leads to maximizing the profit and smooth functioning in workflow.
Artificial intelligence have evolved with the paramount significant attribute of attention by benefiting with
- Instant Object Recognition
- Reduced risk and cost
- Improved productivity
- Increased employees engagement
These benefits can be achieved by the intelligence inbuilt with augmented reality and artificial intelligence that develop the technology and lead to compete in a competitive world.
AI video analytics have exploded a widespread technological acceptance with specialized software system like
- AI PPE detection software
- People count
- Unsafe act detection
- Fall detection
- Face recognition
- Forklift collision detection
- Emergency response plan
- Invoice data processing
These AI specialized feature software tracks, detects the unsafe activity with proactive security system and real time monitoring system which engages the employees with the compliance of PPE all the time ensures safety reduces the risk and saves the insurance cost with increased productivity.
c) Digitalization Products with Environment Health and Safety Solution in reshaping Business Models:
The EHS Software solution tracks, monitors with real time safety alerts to the employees and contractors health status to ensure safety for proactive security. EHS software are accessible through internet in employees and contractor mobile or tablets thus this software enables the users to enter illness and injury information and tracks the incidents ensure to reduce the incident in future happening by implementing preventive measures.
EHS software solution System App consists of
- Incident management
- Safe permit to work
- Near miss software
- LOTO system
- Risk Assessment
- Visitor management, etc..
These EHS software enables the organization to Sustain environment, maintain health and ensure the safety of the workers and the workplace which enhance increased productivity and improved efficiency.
CONCLUSION
Digital transformation facilitates growth in a competitive environment automation reshapes the business models by reducing wasteful activities and focusing on improved productivity through proper maintenance of equipment.
