SemiExpo 2022 » Inevitable industry 4.0. How to create a digital enterprise?
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19 March 2018

In recent years, industrial production around the world has undergone significant changes. The spread of the industrial Internet of things, “big data”, robotization and other technologies are pushing us to the next industrial revolution – “Industry 4.0”. On the one hand, companies are not always ready to invest huge amounts in digitalizing production. On the other hand, they are in great danger of losing the opportunity to change the situation now, while the industrial Internet of things is at an early stage of development, and there is a real chance to outrun competitors in the next turn of digital transformation. In any case, “Industry 4.0” is no longer a fairy tale, but a reality. According to the McKinsey Global Institute, for the world economy, the annual effect from the introduction of the Internet of things by 2025 can be from 4 to 11 trillion US dollars, and much of this amount will be provided by the introduction of IoT in production. Companies that will be able to use all the possibilities of the digital revolution will occupy leading positions in the market.

As for Russia, it has a number of successful cases for the introduction of advanced technologies into production, but in general, the level of the digestation of the basic industries lags far behind other countries. 90% of the equipment in production in Russia does not view or transmit any information about its work. At the same time, the average load of machine tools in Russia varies from 30 to 50%, and few have objective data to determine why the highest efficiency index in production is so low, and how to deal with it. According to statistics, the International Federation of Robotics. Many enterprises in the country do not even use technologies of the past generation, such as electronic document management or CAM-systems. The management of such productions should not abandon the new technologies because of the low level of automation, otherwise each year their effectiveness compared to other enterprises will only fall. Meanwhile, according to a study by the McKinsey Global Institute, the introduction of the components of digital transformation into Russian production until 2025 annually the way to increase the country’s GDP in the amount of 1.3 to 4.1 trillion rubles.

 

Digitalization of production in accordance with the concept “Industry 4.0” includes:

  1. Computerization of all equipment and workplaces of employees.
  2.  Connecting assets to the intelligent systems of the enterprise, which control the entire technological process (CAD, PDM, ERP, EAM, etc.).
  3. Integration of systems, personnel, equipment into a single information field that will automate the adoption of simple solutions and provide multidimensional data for predictive analytics and create the prerequisites for the introduction of artificial intelligence. One solution to this problem is to implement the MDC (Machine Data Collection) system as the foundation of a digital enterprise to collect all production data from different sources in real time.

A successful example of this approach was the monitoring system for industrial equipment and personnel “Dispatcher” from the Russian company “Tsifra”. Increasing the efficiency of production in this case is provided not only by automatic collection and accumulation of data, but also through their processing with the help of artificial intelligence tools. “Dispatcher” does not require the construction of a “digital enterprise” from scratch. The system is a universal ready-made template for emergency digitalization of production and solving a number of important tasks: monitoring the use and loading of equipment, estimating losses, optimizing the schedules of equipment and personnel, eliminating bottlenecks in the process chain, reducing downtime, planning maintenance, connecting all equipment to a single network and many others.

Monitoring system “Dispatcher” is connected to any production equipment (machine tools, processing centers, robotic complexes, control and measuring machines, flexible production systems) and workplaces of employees with special terminals, registrars or conventional network connection. Data on the local network is transferred to the server, where they are processed and analyzed. In this case, it is possible to determine undesirable situations, for example, simple machine tools for various reasons. In this case, the responsible employees automatically receive notifications, after which they take operative measures to restore the workload. Also, the “Dispatcher” monitors the implementation of replacement plans for the manufacture of parts, monitors and classifies the causes of marriage, monitors the timely performance of support work, such as preventive maintenance and repair. Production personnel interact with the monitoring system using AIS “Dispatcher” software, which is installed on working computers or mobile personnel devices. Monitoring results are available to various services. Thanks to the “Dispatcher” of energy companies receive detailed analysis of electricity costs, technologists have the opportunity to optimize the processing of parts until video surveillance for the operations of interest.

In addition, the “Dispatcher” easily integrates with other IT-systems of the enterprise, thanks to which information about the work of equipment and personnel is received in various departments of the company – administration, accounts department, OTC, WGC, etc. The system allows you to visually monitor the operation of equipment and personnel, set up alerts, generate reports and analyze the production process in real time.

The result of the implementation of the monitoring system “Dispatcher” is an increase in the utilization rate of equipment, increasing the productivity of machine tools and, as a result, increasing the profit of the enterprise. “Dispatcher” allows the management of companies to significantly improve the efficiency of production and accelerate the digital transformation. The “Dispatcher” system has already been installed at 70 enterprises throughout Russia. On average, it allows to increase energy efficiency by 10%, and the efficiency of equipment use – by 20%.

 

Source: https://iot.ru

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