Make the Move from Industrial Automation to the Smart Factory

This article takes readers through the basics of industrial automation, the smart factory, and Industry 4.0, while discussing the importance of power and connectivity in smart factories.

Automation does not a smart factory make. Though necessary to create a smart factory, automation isn’t sufficient. This distinction is important since a truly smart factory can dramatically improve your productivity, quality, and versatility.

Industrial automation is the control and monitoring of industrial machinery and processes with sensors, actuators, and control systems driven by computers. It’s safer and more efficient than hands-on human operation of machines, but is, by definition, repetitive. 

A smart factory infuses automation with intelligence. Automated processes are thoroughly interconnected, integrated, and choreographed by a range of cutting-edge technologies. Processes adapt to changing conditions rather than simply repeating themselves.

The entire factory environment is “thinking” and “deciding” with the help of data-driven algorithms and artificial intelligence. Machines communicate with one another over distributed control systems and intelligent automation networks, rarely waiting for humans to tell them what to do.

Smart factory ingredients include:

• The industrial Internet of Things (IIoT): Interconnecting industrial devices via the internet enables data collection, analysis, and control to enhance operational efficiency, productivity, and decision-making. In a smart factory, machines, sensors, and other connected devices communicate with one another, exchanging real-time data for predictive maintenance, maintaining asset health, and supply-chain visibility.
• Artificial intelligence (AI):  AI and machine learning (ML) help machines recognize patterns, optimize processes, and perform predictive analytics. 
• Digital twins: These interactive software models represent hardware environments and allow for simulations of alternative workflows, actions, and layouts to optimize performance.
• Robotics: In a smart factory, robots can work on an assembly line, collaborate with humans, or whiz autonomously around a factory floor and perform tasks like selecting components.
• Cloud computing: This on-demand infrastructure lets organizations focus on primary business competencies by providing on-demand access to a shared pool of computing resources, such as servers, storage, and applications over the internet. Users can consume resources as needed.
• Augmented reality (AR) and virtual reality (VR): AR technology overlays digital information, such as images, videos, or 3D models, onto the real world, while VR immerses users in a computer-generated simulated environment. AR and VR are used in training and maintenance, displaying schematics, fault codes, or maintenance logs directly in the technician’s field of view to facilitate diagnosing and fixing problems.

What About Connectivity in a Smart Factory?

Connectivity in a smart factory plays the crucial role of interconnecting automation system components of ever-increasing complexity. The most robust networking solution is industrial Ethernet (see figure). Unlike basic Ethernet in a typical business office, industrial Ethernet is designed to withstand harsh conditions, including extreme temperatures, humidity, electromagnetic interference, and physical stress in factories, power plants, and warehouses.

Industrial Ethernet is engineered for applications requiring precise timing and low latency where data-transmission times are predictable and consistent, e.g., robotic assembly lines, chemical processing, and packaging.

Consisting of four cable pairs to achieve multi-gigabit throughputs, industrial Ethernet is compatible with a wide range of industrial devices, including programmable logic controllers (PLCs), sensors, actuators, and human-machine interfaces (HMIs). For applications that don’t require multi-gigabit speeds, single-pair Ethernet (SPE) is a more compact, cost-effective solution.

Power Redundancy for Smart Factory Infrastructure

A smart factory requires much more computing than a conventional factory, including 24/7 availability of communication, control lines, and data centers. Therefore, operators must pay extra attention to reliable power. While data centers and critical computing units often have redundant backup systems, they still require power to carry out their functions after failover.

Power redundancy solutions include:

• Uninterruptible power supplies, which provide short-term power until backup generators come online.
• Dual power feeds, which, ideally, means the smart factory is connected to more than one grid and utility.
• Redundant distribution, including power lines and circuitry.
• Energy storage systems like batteries, which can release power during outages or peak demand.
• Smart monitoring with the ability to switch to redundant power sources before human operators detect a problem.
• A written disaster recovery plan and periodically testing power outage scenarios.

Bringing It All Together with Reliable Connections

Finally, for IoT-connected systems to operate a single entity, a smart factory requires reliable connections, and where there are connections, there are connectors. Durability and reliability are paramount to ensure they’re never the weakest link.

Component suppliers, such as Newark, offer a wide range of dependable connectors. These include easy-to-install factory-molded connectors with crush-resistant prewired cord sets for power distribution; DIN valve connectors for air tools in volume production like valve manufacturing; and I/O modules and sensor cables.

You can make your factory smart with intelligent applications, state-of-the-art equipment, and reliable power, all thoughtfully interconnected. Why just automate when your operation can outthink the competition?

Original article source: https://www.electronicdesign.com/technologies/industrial/article/55237630/newark-make-the-move-from-industrial-automation-to-the-smart-factory

FAQ

1. What is the Difference Between Industrial Automation and a Smart Factory?

Industrial Automation: Involves using machines and control systems to perform repetitive tasks with minimal human intervention, improving efficiency and consistency.

Smart Factory: Goes beyond basic automation by integrating advanced technologies like IoT, AI, and data analytics, allowing machines to communicate with each other, adapt to real-time conditions, and optimize production autonomously.

2. Why Should We Transition to a Smart Factory?

A smart factory offers greater flexibility, efficiency, and productivity. Real-time data collection and analytics enable predictive maintenance, reducing downtime and improving operational efficiency. Additionally, smart factories provide better resource management and faster decision-making, giving companies a competitive edge.

3. What Technologies Are Essential for a Smart Factory?

Key technologies include:

Internet of Things (IoT): Connects devices and sensors for real-time data sharing.

Artificial Intelligence (AI) and Machine Learning: Enables systems to analyze data, predict outcomes, and optimize processes.

Cloud Computing: Provides scalable storage and computing power for big data analysis.

Cyber-Physical Systems (CPS): Integrates physical production with digital models to enable self-optimization and real-time control.

4. How Can We Ensure Cybersecurity in a Smart Factory?

With increased connectivity, cybersecurity becomes critical. Implement strong encryption protocols, regularly update software, and establish a cybersecurity framework that includes monitoring, threat detection, and response plans. Partnering with cybersecurity experts and ensuring compliance with industry standards like ISO 27001 is vital.

5. What Role Does Data Play in a Smart Factory?

Data is the foundation of a smart factory. Sensors, devices, and machines generate massive amounts of data, which can be analyzed to identify patterns, predict equipment failures, and improve decision-making. Efficient data management and analytics are crucial to harnessing the full potential of the smart factory.

6. What Are the Challenges of Implementing a Smart Factory?

Cost: Initial setup costs can be high, especially when integrating legacy systems.

Skill Gap: Employees may need new skills to manage and operate smart systems. Investing in training is essential.

Integration: Combining existing infrastructure with new technologies can be complex. Careful planning and phased implementation can help mitigate challenges.

7. How Can We Start the Transition to a Smart Factory?

Start by evaluating your current systems and identifying areas that would benefit most from smart technologies. Begin with small, scalable pilot projects, focusing on a specific part of the operation, such as predictive maintenance or quality control. Gradually expand as you gain insights and see positive results, ensuring that you involve all key stakeholders throughout the process.