The term 'smart factory' refers to manufacturers using technology like automation and AI to streamline processes, with a global transition gaining significant momentum in recent years. HSO unpacks the latest emerging smart factory trends.
HSO is the digital transformation partner of the upcoming 2023 Modern Manufacturing Expo, and has been working with manufacturers for over 30 years to offer solutions that span the manufacturing value chain and support the development of Smart Factories.
HSO global manufacturing director Chandru Shankar, highlights that the supply chain disruptions of the pandemic helped ‘manufacturers seize the opportune moment to prioritise technology. Their aim was to reduce costs and enhance efficiencies by embracing Smart Factory initiatives’.
HSO’s emerging smart factory trends include:
1. Heightened focus on Overall Equipment Efficiency (OEE)
According to IoT Signals, four out of five manufacturers see overall equipment effectiveness (OEE) as a key performance indicator for smart factory success. “HSO's solutions drive holistic OEE by addressing asset management, supplier relationships, supply chain planning, warehousing, and after-sales service,” said Chandru
Predictive maintenance and condition monitoring are crucial for ensuring OEE, with these processes enhanced by IoT-connected equipment that generates valuable data, helping identify performance deviations.
“Through our connected IoT models, we establish an early warning system, preventing equipment downtime and ensuring optimal equipment effectiveness. This is particularly crucial for food manufacturers like Lays or Pepsico, who rely on early detection of equipment faults to prevent spoilage of food batches,” said Chandru.
2. Integration of IoT Sensor Data and AI across the manufacturing value chain
AI and data analytics have become central to organisations, amplified through IoT -connected equipment.
While Chandru acknowledges the benefits of widespread IoT integration, he emphasises the importance of considering the desired outcome before deploying sensors.
"Companies that hastily installed sensors on all their equipment are now facing the challenge of interpreting the vast amount of collected data. It is essential to identify objectives and the specific type of data you wish to collect before implementing IoT solutions," said Chandru.
3. Digital Twins
A digital twin is a virtual replica that mimics the behaviour of a physical object, process, or environment. While commonly used for machinery and factory operations, digital twins are increasingly applied across the supply chain. This growing trend empowers companies to run simulations and make well-informed decisions.
"By leveraging digital twins, companies can proactively anticipate challenges like capacity constraints or equipment failure, enabling them to schedule maintenance and adjust operations accordingly," said Chandru.
This proactive approach enhances overall efficiency and minimises disruptions.
4. Customisation of digital manufacturing technologies
HSO prefers the term ‘catering’ rather than customisation, due to the costs involved in total customisation. The company prefers to present a standard solution that aligns as closely as possible to the customer’s needs and then tweak and configure as necessary to cater for the desired outcome.
“Every manufacturer has their own key differentiating factors. Our goal is to understand them and ensure that our solution can enable and accelerate them right out of the box," said Chandru.
The challenges of scaling smart factories
Scaling smart factories poses various challenges, including the need to hire and upskill workers proficient in emerging technologies. The scarcity of skilled talent intensifies competition for a limited pool of qualified individuals.
Another challenge lies in determining the appropriate extent of AI implementation. Companies grapple with questions regarding the limits of AI and its potential impact on human labour. To mitigate risks, AI software developers are exploring the implementation of 'guardrails' to ensure responsible and ethical AI use.
Chandru said HSO has a competitive advantage in this domain through their partnership with Microsoft.
"AI is not an afterthought for Microsoft—it is integrated into every solution they develop," said Chandru.
Microsoft's engineering team recently launched Copilot, an AI-powered tool that provides valuable insights and recommendations, helping users prioritise tasks and proactively address challenges like weather delays and shipment issues.
IIoT in the spotlight at the 2023 Modern Manufacturing Expo
The HSO team eagerly anticipates the upcoming 2023 Modern Manufacturing Expo. In addition to its title as official digital transformation partner at the expo, Chandru will be a panellist at the co-located Smart Manufacturing Conference, contributing to an industry panel titled 'How Industrial IoT is revolutionising the manufacturing sector.'
“I look forward to meeting manufacturers face-to-face, discussing their challenges and how HSO’s solutions can assist them achieve their desired outcome,” said Chandru.
