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UPGRADE TO INDUSTRY 4.0 - Part 1

What is Industrial Revolution 4.0

Industry 4.0 is the fourth industrial revolution which made changes in the technology industry. These changes include a more sophisticated data exchange and automation system changes, and involve IoT or Internet of Things, Cyber ​​Physical Security, and Cloud Computing. In generally, Industry 4.0 creates what is called Smart Manufacturing Factory.



| Image Source : Wikipedia.org - Credit to "Christoph Roser at [AllAboutLean.com]" |


Internet of Things (IoT)

The use of communication media connected such as laptops, tablets, mobile phones to control or supervise the production process.IoT in this world can be seen almost all machine data via the communication device or computer browser. Data can be viewed production process, or system diagnostic machine.This feature is able to provide real time information to stakeholders through the medium of its smartphones such as the alarm to a supervisor.


Cyber ​​Physical System

Cyber ​​physical system is the production process controlled engine wear or controlled by the controller (PLC / DCS / microcontroller / CPU) and can be connected through cyber communication media such as intranet, internet, wifi, or other media that can be connected in realtime.This system is use PLC or HMI or both of it that can be controlled and monitored via the intranet and can be connected to the Internet when needed.


Cloud Computing

A data storage system is made for resource sharing and random enabling a balanced distribution of the resource and hardware performance.Generally cloud computing in industry means the machine data storage is done in real time in both the server's internal network server or network server on the Internet.


SMART MANUFACTURING

Smart Manufacturing is a manufacturing system that uses a computer either in controlling the production process from raw materials to the warehouse level to the last process of storage of finished products.The goal is to provide real-time information to the production process so that it can more flexibly and quickly to changes in the market.Examples of these systems is the use of MES - Manufacturing Execution System as a bridge between the factory floor to ERP - Enterprise Resource Planning ERP systems such as SAP.


INDONESIA - MOVING TO SMART MANUFACTURING

In my experiences, has doing automation project in many manufacturing factory in Jakarta, Bekasi, Riau, Surabaya, Gresik, Pasuruan, Malang, Pandaan, and other region (Balikpapan, Samarinda, Makassar, North Sulawesi, Ambon), Indonesia manufacturer are moving to industrial 4.0, with their demand that all production reporting can be achieved in real time. Today the small factory want to use a central control room that can overview all production. 

The use of operators are moving from controlling to supervision. The operator supervise the machine and take action if something happen. With the industrial 4.0 revolution, the management want to know the real data, this is for taking better decision in overcome market changing.


I had experiences when I was young and become a production supervisor for a high speed spinning fiber yarn manufacturing, operator need to record all production result, take a weight  and formula the input and output. The software in supervisor room are connected to company IT - ERP system. As a supervisor, I have to  walk from supervisor office to a plant site (300m - 4 times a day) to take data from operator handwritten logbook and then back to office and enter it to company IT - ERP system. And then I must check to warehouse (another division) about the real weight of the products and compare it with operator log. If there any mismatch, I must investigate it.
The process can take 2-3days only to know real value of product output (fiber yarn weight). And this is will calculate by production administration to know the efficiency of that day. Once, marketing ask for 3000kg type A and need to prepare it in a week. In the same week, we got order 6000kg type B. So our production manager order raw material type A &  each with their respective order weight. 
The operator wrongly set the parameter and the result was 6000Kg type A and 3000kg type B. And it happens so often so we have "waiting list product" in our warehouse waiting for sale seasons. And sometimes the machince down and repair need 2 day, while our marketing so confidence that we can produce 5000kg in a week. Our production manager get warning because of this.
If the system are integrated, we can easily communicate between department and the logic inside ERP system can limit and acknowledge the management for better decisions. In my cases, it will stop the production of type A when the set parameter are wrong and acknowledge the management and also log it to database for future references.


Let peek the current technology that will support the industrial 4.0 & Smart Manufacturing by some of the well known automation manufacturer in Indonesia:

1. Schneider Harmony Wireless Button

Schneider Harmony Wireless Button are a mechanical generating signal (No Battery) that send the signal when someone push it. The receiver inside control panel are receipting the on off signal and send to controller. This can overcome cable and ducting problem in future especially for upgrading old system. But how wireless radio can safe in hazardous area? here maybe the answer - ControlDesign - Can We Go Wireless in Hazardous Areas?

2. Siemens Wireless LAN

Siemens Wireless LAN are other options for industrial that do not want to placing a contruction for cable/LAN/fiber optic communication. With a face to face antenna and 500 mtr range, the signal are industrial grade for old factories or wide area factory that do not want to have a new construction for hardware communication. My experiences are design wireless lan because IT depertment do not want to share their optical fiber and LAN to electrical dept. So the electrical dept want to have its own communication between storage tanks and to their control room without digging or construct for fiber optic cable.

3. Rockwell Auomation Connected Enterprise

Smart manufacturing is the gateway to digital transformation. Connected smart devices open new windows of visibility into processes. Data and analytics enable better and faster decision making. Seamless connectivity spurs new collaboration.The Connected Enterprise makes all this possible. It converges plant-level and enterprise networks, and securely connects people, processes, and technologies.

4. Omron RFID System

The Omron RFID are making the goods can be recorded with a high speed. No more manual entry data.


Did upgrade to newer system more costly? Let see this on newet blog: Look for "Indonesia Problem in System Upgrade".


- Thank You -