Industry 4.0 is drastically transforming the shop floors, production systems, business models, supply chains, and all the associated operations. The industry 4.0 manufacturing integration is leading the way towards better visualization of industrial network, hyper flexibility in production management, intelligent tracking of processes and supply chains, self-optimization, enhanced adaptability, etc. This upsurge in manufacturing and management capabilities is turning out to be extremely rewarding concerning monetary gains and end-quality of the product. Industry 4.0 sets up a collaborative environment between physical systems and humans to establish smart business operations to sustain growth and resilience to unprecedented circumstances.

To help understand the potent of industry 4.0 automation more precisely, below we have gathered some invaluable benefits of execution.

Industry 4.0: Potential Benefits of Implementation

1. Strategic Competitive Advantage: Factory automation makes it easier to widen your product and service offerings, bringing in new possibilities for your business to escalate. The industry 4.0 automation manufacturing tools and processes provide greater flexibility of operations, lower operating costs with the use of automation and robotics, and foster better customer relationships through optimum product quality. By strategically utilizing industry automation, organizations can garner incomparable outcomes.

2. Organizational Performance: The industry 4.0 solutions used for factory automation generates a conducive environment for powerful organizational transformation. Functional proficiency, better utilization of assets, enhanced use of factory data, digitalization of production systems, strengthened connectivity between equipment and systems, reduced risk of errors, automated restructuring of procedures, and improved worker safety, etc. are some of the crucial aspects positively impacting the organizational performance of the enterprises.

3. Decreased Costs and Higher Gains: Industry 4.0 manufacturing reduces costs involved in day-to-day operations, resulting in boosted profits. The use of automation technologies helps increase product accuracy, reduces lead times, decreases labor costs, enhances labor productivity etc., resulting in decreased costs. Industry automation allows continuous monitoring and process regulation of huge production lines by reducing the risks of failures, cycle-times, equipment breakdown expenses, etc. With higher sustainability of assets and real-time surveillance, a substantial amount of costs can be saved.

4. Enhanced Quality of Products: Industrial automation technology and tools can detect quality errors at every step of production and are equipped with automated resolving capabilities. The collaborative use of robotics applications, automation tools, cobots, sensors, IIoT-empowered quality enhancement, etc. ascertains optimum product quality.

5. Opportunities for Innovation: The surplus amount of data generated and processed through industry 4.0 automation tools, fuels opportunities for product and process innovations. Based on historical and current data, the connected devices predict process improvement areas and their impact. Moreover, with digital twin technology, simulation, and AR/VR, new product development can be initiated without manual prototyping. The interoperability of assessing real-time data, that industry 4.0 provides is the principal advantage of industry 4.0 automation to create growth opportunities.

Industry 4.0: Challenges and Solutions

With greater benefits, come greater challenges. Industry 4.0 automation brings along some underlying risks that come into view during and after the transformation process. An article by Industry Week states, 2 of 3 companies piloting digital manufacturing solutions fail to move into the large-scale rollout. Hence, it’s important to pay attention to those obstructions, evaluate their consequences, and deploy solutions before they hinder the functionality of the enterprise.

With close analysis and understanding of implementing factory automation, we have listed down potential challenges and solutions to overcome them.

1. Workforce Preparedness: Industry 4.0 automation encompasses a collaborative approach between humans and machines, significantly changing the working environment. Operators and technicians will require training and assistance in developing the technical know-how of industry automation. Hence, while selecting an industry 4.0 implementation partner, always check for their training and documentation service offerings.

2. Cybersecurity: With increased connectivity of equipment, large-scale exchange of data, virtualization of servers, and expansion of interconnected networks, cybersecurity concerns have gained momentum among businesses. To address this challenge, advanced security models need to be included while executing industry automation.

3. Functional Disruptions: In the period of transformation from traditional setup to factory automation, the functioning of the industrial process undergoes major changes and might come to a pause for some time. Henceforth, it’s quintessential to have a strategic plan ready well before carrying out industrial automation. Besides, businesses should also consider the timelines provided by the vendor for enforcement of the entire process. This will help create a structured and concrete plan to overcome functional disruptions.

4. High Investment Cost: While higher investment costs are some of the major issues pertaining among the decision-makers, with an effective transformation model in place, the investment costs can be recovered in a specific duration. As industry automation solutions enhance scalability, agility, and resiliency to meet changing work environments, there are higher chances that the benefits will exceed investment costs in a certain period.

5. Revisiting Business Models: Factory automation with industry 4.0 brings about fundamental changes in the way businesses work. From business models to pre-defined working strategies, to the functioning of entire systems and processes, the factory transformation creates a multifaceted impact. Therefore, it’s inevitable to reexamine and create a concrete framework for the business model as the automation transformation takes place.

Understanding the Future Scope of Industry 4.0 

Industry 4.0 automation has turned out extremely rewarding in terms of financial aspects and quality of products, despite higher investment costs. For instance, take the case of Siemens’ PLC manufacturing plant in Amberg, Germany, where it has taken digitalization to the point by automating the production of its automation systems. The result is a reported 99.99885 percent perfect production quality rate—an impressive one given the plant produces around 12 million Simatic PLCs each year (Source). The smart factory and industry 4.0 manufacturing are setting up a benchmark for businesses to escalate their overall plant efficiency and achieve performance excellence. Moreover, industrial wireless communication, cybersecurity, remote monitoring, and customization will be the primary focus among businesses that are under the transformation stage.

Factory automation in the future will elevate the level of potency as industry 4.0 technologies will operate alongside humans, supporting them to best leverage smart machines and advanced technologies. Moreover, automation and robotics applications will continue to accelerate in industries as they lay a foundation for industry 4.0 technologies to operate. Regardless of what new technologies emerge in the coming years, automation and robotics will hold an inevitable position in years to come.

If your business hasn’t incorporated automation and robotics yet, then it’s high time you embrace this technology!

How ENWPS can help you succeed?

ENWPS can help business transform their factories to adopt and fully embrace industry 4.0 automation. Our turnkey solutions include,

1. Design and engineering
2. Supply, Installation, and Commissioning
3. PLC, HMI, and SCADA Programming
4. Robot Programming
5. Data Analytics
6. IoT Implementation
7. Allied Services

With over 20 years of experience in providing automation and robotics solutions, we have developed an extensive understanding of industry ecosystems to guide businesses for the successful integration of advanced technologies.

Our experts are just an email away. Get in touch at: rfq@enwps.com!

With the advent of the industrial internet of things (IIoT), digitization, automation robotics, big data analytics, artificial intelligence, and the concept of interconnectivity in the manufacturing ecosystem, facilities are gradually transforming into smart factories. A Smart facility combines production processes and operations with a digital network of connected devices and machinery. It goes beyond simply automating the production processes. At a broader level, it maximizes the performance of the enterprise by extending the capabilities of machines to respond in real-time to meet changing conditions in the facility and demands of the consumers without human intervention. The smart factory/ plant technology enables flexibility in the manufacturing system allowing evidence-based optimization of the processes, assembling real-time data, and providing control of the overall system to independently run production processes.

Smart Factory Technology 

Smart factories accumulate a variety of equipment and devices to streamline and optimize manufacturing processes. The interactions and combinations of diverse smart factory technologies contribute to the transformation of a factory into an intelligent workplace. Below are some key technical requirements of a smart factory setup.

1. Industrial Sensors: They are interlinked to industrial machines, devices, and processes for allowing the exchange of information between machines and humans for optimizing shop floor operations. Various types of sensors are deployed according to the required output. For instance: temperature sensors, pressure sensors, level sensors, proximity sensors, optical sensors, etc., each one has distinct utility in the industrial setup.

2. Cellular 5G/LTE: The modern industrial cellular networks are the substitution to wired Ethernet traditionally used in industries. It allows operators and factory managers to communicate with ease inside the factory premises and from distant locations outside the factory. Cellular 5G/LTE offers mobility, ease of use, reliability, higher bandwidth, and low latency, ensuring smooth machine-to-machine and machine-to-human communication for unleashing the true potential of the industrial assets.

Related Blog: Digital Transformation Will Drive IoT and 5G development

3. Industrial Internet of Things (IIoT): It is one of the key components in a smart factory that includes a combination of various information and operations technology devices to collect valuable data, analyze it, exchange across machines and operators, and improvise it for generating higher output.

4. Cloud Computing: Cloud computing is demand-based accessibility of system resources, databases, servers, process information, and all relevant data from shop floor devices to make real-time, data-driven decisions and alterations in the manufacturing process. It also aids in the collection of information about supply chains, logistics, delivery services, and other operations in the industry.

5. Data Analytics: The sheer amount of data generated by industrial systems and processes can help in innumerable ways. Detection of error patterns, spotting underperforming systems, insights about the production process, improving and controlling quality based on historical data, predictive maintenance analysis, etc. all can be monitored and optimized with help of data analytics.

Characteristics of a Smart Factory

For any factory to be transformed into a smart factory, the following attributes of smart factory technology need to be addressed and included.

1. Interconnectivity: The prerequisite of a smart factory is to connect all the machines, devices, systems, and processes to produce real-time data that can be used for decision making.

2. Optimization: A optimized factory is self-sufficient in making decisions about the ongoing operations to enhance operational efficiency with minimal human intervention.

3. Proactiveness: The ability to anticipate and act before the actual problem arises and hampers the system efficiency is associated with the proactiveness of a manufacturing unit. It not only increases uptime but significantly impacts the accuracy, quality, and costs involved.

4. Transparency: From real-time data visualization to transforming them into actionable insights, defines the transparency of an industrial unit. It allows operators and managers to view real-time machine/system performance, take steps to improvise, and accelerate progress.

5. Nimbleness: Scalable industry layout, adaptability to changes in a working environment, deviations in production schedules, the introduction of new products, etc. with minimum manual assistance is one of the key features of smart factory automation.

Why do industries need to shift towards Smart Factory?

The market analysis states, the Global Smart Factory Market was valued at USD 270.74 billion in 2020, and it is expected to reach USD 422.88 billion by 2026, registering a CAGR of approximately 9.33% during the forecast period (2021-2026). The underlying reason is, smart manufacturing can amplify the output while significantly reducing the production costs. Below, we have gathered key reasons to help you gauge the benefits smart factories offer.

1. Machine-Driven Data: Gone were the days when operators had to manually create a tabular sheet for gathering all production data and checking production efficiency. Inventory management, asset tracking, delivery planning, and all other managerial tasks were conducted manually. Today, with help of business intelligence tools, the unstructured data is collected and processed into lucid formats for better data visualization and powerful analysis. It allows manufacturers to make better decisions for optimizing the facility’s performance.

2. Productivity Enhancement: Any industry irrespective of size, constantly looks for opportunities to increase the gross profit margins and reduce operational costs. Smart factories provide complete visibility of assets through interconnected systems, provide smart insights, spots bottlenecks in the process if any, reduce wastage, and self-optimize for improved process efficiency.

3. Production Flexibility: It refers to adaptability, agility, and improved responsiveness of the manufacturing setup to administer product enhancement and consumer demands. With the rise of breakthrough technologies, like integrated production management systems, factories are becoming more intelligent allowing the highest level of manufacturing flexibility and customization of the products.

4. Benefits of Digital Transformation: The usefulness of deploying smart manufacturing solutions includes improved production scheduling, product development, quality control, logistics management, planning machine maintenance, keeping a track of machine downtime, increasing uptime, and strengthening overall plant productiveness.

Upgrade with ENWPS

Smart manufacturing heavily relies on the digitization and connectivity of the industry ecosystem. It provides greater accessibility of data to make intelligent moves, ultimately adding up to the performance capability and profit gains of the business. The solutions that smart factory technologies offer have become indispensable for modern manufacturers if they wish to remain competitive and satisfy modern customer demands. At ENWPS, our team of qualified engineers possesses the required knowledge and expertise to help you upscale to smart manufacturing. Our services encompass supply, installation, and commissioning of the various equipment required for optimizing manufacturing processes.

Elevate your business with expert assistance! Shoot an email at: rfq@enwps.com

Introduction: Role of Industry 4.0 Technologies in Manufacturing-Units

Industry 4.0 is bringing about phenomenal changes in the way businesses handle manufacturing operations. Digital technologies like artificial intelligence, big data, and analysis, augmented reality, etc. are helping businesses gain insights and visibility into operations for optimizing industrial resources. These insights and information gathered are valuable for historical analysis, eliminating irregularities, and supporting automated decision-making for machine-controlled optimization of the industrial process. Augmented by advanced technological solutions, Industry 4.0 has immense advantages helping businesses gain a competitive edge, stay relevant, and acquire customers.

Key Industry 4.0 Technologies:

Below are some of the top digital technologies in Industry 4.0 automation, that businesses are leveraging to their advantage. We have also gathered smart uses and advantages of these technologies in a manufacturing setup.

Big Data and Analytics

Manufacturing industries generate a plethora of data on daily basis, and it’s humanly impossible to assess the entire information manually and be able to drive value from it. However, by tapping into today’s modern data processing capabilities and proper documentation, the unorganized information can be converted into actionable insights.

Advantages:

1. Improving asset performance and optimization with real-time information about processes and equipment. It can help prevent unexpected machine breakdowns and avoid downtime.
2. Allowing to collect, analyze, and evaluate data for introducing product customization based on customer feedback or requirements.
3. Enhancing supply chain management through effective reporting and documentation of each step involved in the process.

Autonomous Robots

These are self-sufficient and extremely intelligent automated machines capable of performing end-to-end tasks without human help. Autonomous Robots are agile, speedy, and capable of handling complex operations with precision. They are equipped with sensors and cameras making them self-reliant to handle their work arenas without any external inference.

Advantages:

1. Autonomous Robots can operate in hazardous environments. Their operational efficiency widens their utility in industries as it results in improved staff safety.
2. They are capable of re-work, eliminating errors, improving accuracy, and boosting productivity rates.
3. Ultimately enhancing revenue by minimizing production lead times and achieving customer satisfaction.

Industrial Internet of Things

The Industrial Internet of Things is the foundation stone of Industry 4.0 technology. It refers to the use of smart sensors and actuators capable of transmitting the required information, that help gather and monitor real-time data in a manufacturing setup. This harmonization in industrial components makes up for tremendous benefits in terms of enhancing the usefulness of data and optimizing industry operations.

Advantages:

1. Improving product quality, process performance, and operational efficiency by enabling data-driven decision-making.
2. Enhancing overall equipment effectiveness (OEE), predicting potential failures in process and equipment.
3. Creating an interconnected network to monitor industrial operations remotely anywhere and anytime.

Simulation/ Digital Twins

Simulations or Digital twins makes use of digital models for producing virtual replicas of industrial process, facility, supply chain, etc. Based on data from IoT sensors, devices, PLCs, actuators, and other interconnected devices, a digital twin is developed for elevating the workflow of the industries.

Advantages:

1. Digital Twins/ Simulation strengthens research, development, and design of products to enhance the performance outcomes.
2. It allows operators and factory managers to anticipate issues that might reflect in the future and also indicates the areas of improvement in product or process if any.

Cybersecurity  

With the emergence of varied industrial technologies, increasing dependency upon digitalization of manufacturing operations, and interconnectivity, a grave need for a vigorous cyber security system has aroused. To prevent vicious cyber-attacks and malware it’s inevitable to adopt a cyber-security approach.

Cyber-physical systems are one of the most ingenious innovations of Industry 4.0, with real-time data collection, analysis, and transparency of manufacturing operations and also ensuring the security of data being gathered.

Advantages:

1. Improved security of company’s credentials.
2. A business holds valuable information of its clientele and if one can prove that its business effectively protects data against cyber threats, it will encourage trust in customers and lead to attracting new customers.

Augmented Reality (AR)

Augmented reality is the fusion of the real-world and computer-generated interactive world, gaining immense popularity among modern manufacturing units. AR is a powerful technology capable of simplifying critical operations and reinforcing industrial operations.

Advantages:

1. Increasing efficiency of product development. With AR technology, products can be tested and improved at the design phase, saving costs of manual prototyping.
2. AR can assist operators in various complex tasks. For eg.- assembly of a space aircraft, with guided instructions, the operator can keep a check on each step ensuring no errors.
3. Moreover, AR also supports troubleshooting and maintenance activities in industries, aiding in quality assurance, reducing overhead costs, and improving throughput.

Artificial Intelligence (AI)

Artificial Intelligence is the combination of different technologies enabling software and industry equipment to sense, comprehend, learn, and act on their own or support human activities.

Advantages:

1. AI supports design and development, maintenance, and other industrial operations based on collected data. Ultimately, assisting humans for better decision-making.
2. AI technologies have the potential of helping businesses achieve six-sigma standards by eliminating defection in manufactured products.

Role of Automation and Robotics in Industry 4.0

Automation and Robotics are the foundational technologies of a smart factory. Industry 4.0 automation technologies unlock an abundance of positive outcomes in terms of costs, productivity, accuracy, and efficient management of the entire industry processes. It enables businesses to prosper and create robust industrial ecosystems for leveraging their assets to maximum potential. The factories of the future will develop a more conducive environment for robots and people to work collaboratively to fulfill consumer demands. The unrivaled benefits and ability to generate higher ROI over time are encouraging manufacturers to adopt, incorporate and act upon industry 4.0 technologies.

Scale up your facility with ENWPS!

ENWPS provides turnkey industrial automation solutions across various sectors of industry. Our solutions have facilitated our clients to scale up production management, optimize assets to reduce downtime, save up costs of rework or scratch, and drive maximum productiveness.

Fortify your industrial operations, with assistance from qualified professionals. Connect with us at: rfq@enwps.com!

Introduction

The manufacturing industry has undergone a series of revolutionary changes from the first industrial revolution in the 18th century to the present era of Industry 4.0. From the introduction of steam engines in the first industrial revolution to the concept of mass production in the second to the inception of electronics and information technology in the third industrial revolution; the manufacturing industry has seen a paradigm shift at the functional level. In Industry 4.0 the focus has transferred to plant automation, interconnectivity, enhanced human-machine relationships, real-time data, cognitive computing, etc. These digital technologies are paving way for smart manufacturing allowing businesses to leverage data and resources to boost production efficiency, improve decision making, and drive exponential growth. Apart from technological advancements, Industry 4.0 is more about how strategically businesses are integrating these technologies into their existing setup to elevate their profit margins, foster production frequency, and upgrade product quality.

What is Industry 4.0 Automation?

Industry 4.0 automation is a comprehensive term with an emphasis on intelligent networking of machines, processes, and people within an industrial setup to optimize the production through digital technologies like cyber-physical systems, IIoT, cloud computing, robotic automation, etc. These technologies together create a manufacturing system that is equipped with sensors and actuators for remote monitoring, wireless connections for internal communication, robots for automating operations, IoT-enabled industrial systems for improved decision making, data and analytics for enhanced manufacturing efficiency, etc. By thoughtful integration of Industry 4.0 automation, businesses can stay prepared for any changes in demand, processes, or industrial environment contributing to scalability and flexibility of the manufacturing systems. It further opens opportunities for introducing new products by virtualization and helps in the competent management of supply-chains through real-time analytics.

The below comparison shows how Industry 4.0 technologies can impact operations and production efficiency with comparison to traditional practices.

Source: Ronald Berger

Industry 4.0: Technological Advancements

Industry 4.0 does not refer to a single technology. Instead, it is a fusion of several technologies integrated according to automation needs for advanced manufacturing units. It includes:
1. Cyber-Physical Systems: It aims at complete integration of physical processes and devices into a cyber network for the collection of data ensuring optimum security.
2. Autonomous Robots: These are self-reliant intelligent machines that can conclude operations without intervention from human operators.
3. IIoT – Industrial Internet of Things: It refers to the interconnectivity of data and machines for optimizing and automating manufacturing operations.
4. Cloud Computing: It is associated with the use of interconnected remote servers to store, manage, and process information.
5. Big Data and Analytics: The data collected by Cyber-Physical Systems and IIoT, needs to be analyzed and organized for improving decision making and increasing operational efficiency. Thus, Big Data and Analytics help manage and optimize the collected data.
Apart from this, cognitive computing, simulations, augmented reality, additive manufacturing, artificial intelligence, etc. also make up important parts of digital transformation technologies under Industry 4.0.

Real-World Application of Industry 4.0

To help understand how these technologies impact manufacturing ecosystems, below are some of the smart use cases in the real world.
1. Supply-Chain Management: The innovative solutions provided by Industry 4.0 technologies empower businesses with better data visibility, deeper insights, and improved analysis of entire supply chains. It helps eradicate extra costs, reduce lead times, efficiently manage logistics activities, keep a check on inventory levels, and control all the associated tasks. Therefore, optimizing the entire supply-chain process.
2. Asset-Tracking: It refers to identifying and tracking ongoing production processes, machines, human resources, raw materials, etc. By keeping a track of assets, Overall Equipment Effectiveness (OEE) can be strengthened, tactful positioning of equipment and personnel can be done to increase operational efficiency, and ultimately the manufacturing cost of end-product can be reduced.
3. Augmented Reality: Augmented reality involves the use of extra sensory input, for visualizing into existent scenarios. It turns the manufacturing ecosystem into an interactive arena that is capable of quickly identifying problems at initial level and keeping the operations up and running. Augmented reality-enabled devices like- HoloLens’s can be used for employee training, mostly in case of hazard-prone industrial areas.
4. Cobots: We are already aware of autonomous robots used in manufacturing operations for automating industrial processes. However, various manual tasks need human involvement apart from mainstream operations. Cobots are referred to the robots that collaboratively perform manual operations, together with humans. The application of cobots can be found in activities such as quality assurance, material removal, maintenance tasks, etc.

Valuable Outcomes of Industry 4.0 Automation

1. Decentralization of Processes: With help of automated robots, PLCs, SCADA, and HMI systems, the dependency on human operators is reduced allowing machines to make automated decisions based on performance data for managing manufacturing operations.
2. Interoperability: It is associated with the communication ability of computer systems, robots, cyber-physical systems, sensors, and other devices to exchange and make effective use of information. It can help in managing inventory levels, supply chains, detecting errors in operations, etc.
3. Real-time Data Analytics: It includes the use of sensors, IoT devices, etc. that instantaneously feed data and algorithms for quick processing of errors in manufacturing processes, aiding in predictive maintenance, analyzing shop-floor operations, etc.
4. Digital Virtualization: It includes creating virtual simulation models of industrial processes for training, testing, optimizing, etc. without interrupting the plant operations. It’s also beneficial for analyzing the effectiveness of the operations when introducing innovations in the industrial processes.
5. Agility and Flexibility: It allows any production line operation to change instantly according to customer-specific requests without the need to reconfigure the entire assembly line. With help of pre-programmed modules fed into the system, introducing design variations and new models has become extremely easy and quick.

Challenges in Implementation of Industry 4.0 Automation and How to Overcome Them?

With enormous opportunities, Industry 4.0 automation brings in potential challenges that stop business owners from completely incorporating Industry 4.0 technology into their facilities. Some of those challenges are mentioned below:

1. Security: Identity theft, the threat of losing intellectual property, sensitive information about manufacturing processes or client information, etc. are some of the growing concerns among manufacturers. For this purpose, various cybersecurity measures can be adopted on a prior basis for mitigating the involved risks.
2. Availability of Resources and Required Manpower: Industry 4.0 solutions can be easily integrated into a facility’s existing setup while eliminating concerns about available resources. Although Industry 4.0 is a knowledge-intensive technology, with proper training and documentation, industry personnel can easily grasp new changes. Hence, it’s important to look for reliable and supportive service partners when implementing Industry 4.0 solutions.
3. High Costs: One important aspect of automation is that not every process needs to be altered. As all businesses are different and so does their requirements and goals. Hence identifying the processes required to optimize for Industry 4.0 is the key to making efficient use of it. If implemented with a strategic and concrete plan, the costs incurred in implementation can be recovered within a stipulated time. Calculating ROI on a timely basis, checking testability, etc. can save high costs involved in introducing Industry 4.0 into a facility.

Let’s Upgrade Your Industrial Process!

By now, you must have assessed the significance of choosing the right service provider for implementing Industry 4.0 solutions. ENWPS has a two-decade legacy of providing automation and robotics solutions in different industry verticals. From supply, implementation, training, and documentation, our expert team handles all the activities so that our customers can fully rely upon us.

Planning to upgrade your facility? Reach out to us at: rfq@enwps.com for quick assistance. We are looking forward to helping your facility embrace Industry 4.0 automation solutions!

Industrial Automation Technology is continuously evolving and bringing in new solutions to help businesses improve operational efficiency, adapt to changing requirements, gain financial advantages etc. Modern automation solutions are capable of performing all the tasks from planning, prototyping, production, assembling, to inspection, and associated operations. Industrial automation systems are no more considered a luxury, but it has become the way of doing business.

Below are highlighted some of the key reasons to invest in industrial automation that manufacturers need to consider.

Enhanced Productivity and Efficiency

Today, manufacturing has become far more sophisticated that achieving accuracy and precision without the interference of machines is not possible. Various manufacturing operations like turning, drilling, welding, graphic modelling, making geometrically complex parts, etc. involve the application of automated equipment. It ensures that all the product limits and fits are attained with exactness, resulting in faster, consistent, and quality products.

The Cost Benefits of Automating

Every industry regardless of size aspires to reduce production costs to increase profit margins. Apart from looking for cheaper raw materials, automating the manufacturing process can be an intelligent approach to reduce manufacturing costs. With the use of PLCs, robots, automated production lines, etc. manufacturers can enable swift production, reduce transfer time between machines, save labor costs, etc. In addition, automation systems are designed to detect errors at a very early stage hence saving the expense of wasted raw materials, and sudden machine breakdown. Apart from this, the costs involved in the overall management and monitoring of the manufacturing process can also be reduced using automation systems.

Reduced Manufacturing Lead time

The shorter the lead times, the more efficient the manufacturing process becomes, resulting in reduced production costs. Lead times are vital to manufacturing processes and can’t be underlooked. Automation technology like IIoT empowers manufacturers to make smart decisions for strategic production planning and ultimately reducing lead times. Other automation technologies like- ERP solutions and additive manufacturing are helping manufacturers to efficiently manage supply chains and keep a check on inventory levels.

Quality Control

Automated operations are carried out with greater conformity and uniformity preventing defects. Automation systems are pre-programmed to perform specified tasks, moreover, various sensors and actuators are deployed to obtain real-time process information to keep an eye on each step. Leading to better product quality. Additionally, machines can work tirelessly with precision, unlike human beings as a result product quality is never compromised.

Increased Industrial Safety

One of the most important aspects of investing in automation systems is increased industrial safety. Automation systems allow operators to manage processes away from production lines, reducing the risks of accidents. Automated equipment and devices are designed to work in harsh environments that go beyond human capabilities.

Accuracy and Repeatability of the Automation Systems over Humans

Integrating automation system into manufacturing plants not only result in a consistent production rate but also consistent quality. Moreover, automation systems free up employees from repetitive tasks, eliminating the factor of monotonicity simultaneously ensuring product accuracy. It also allows employees to focus on creative tasks like planning or business development strategies. Automation systems and humans together make for a favorable working environment capable of delivering promising outcomes.

Prevents Downtime with Predictive Maintenance

Predictive maintenance uses data from previous breakdowns to create a model that predicts failures before they occur. This intelligent model prevents unexpected machine downtime, increases the lifespan of the machine, and cuts the expenses of machine failures. Through predictive maintenance, operators can schedule maintenance conveniently and gradually maximize machine uptime.

Understanding the Future Potential of Industrial Automation

Automation has equipped industries with innovative, reliable, and agile solutions resulting in a new surge of growth. Today PLCs and robots have become the staple of industries to perform, manage and monitor manufacturing operations. Automation tools are simplifying tasks, boosting productivity, providing flexibility to introduce variations, increasing scalability, and much more. Moreover, with the advent of cloud computing, cyber-physical systems, augmented and virtual reality, and other digital technologies, businesses are shifting to intelligent and smart manufacturing. This shift translates to increased profits, new opportunities, powerful economies, and a new age of manufacturing. It will continue to evolve and expand bringing in new solutions and perspectives to the industry.

Industrial Automation Technology Solutions By ENWPS

ENWPS provides customized automation solutions enabling facilities to optimize their resources to the fullest for accumulating all the advantages that automation technology offers. From conceptualizing, designing, implementing, and everything in between, our teams of professionally qualified engineers take care of all the automation needs of businesses. To avail our services, connect with us at: rfq@enwps.com, +91 2066420320, and our team shall be happy to help you!