Manufacturing is going through a major overhaul, and the shift is largely due to big data and analytics, the Internet of Things (IoT), and robotics.
“It’s all about collecting and analysing data to improve efficiency,” Chris Probst, Omron’s automation technology product manager, says.
“The amount of data doesn’t matter – it’s what you do with the data that counts,” he says.
This was one of the key messages of Omron’s food and packaging seminar, held last week in Sydney, Melbourne, and Brisbane.
Called Smart factory solutions with IoT technology, the seminar allowed Omron to unveil its latest smart factory solutions encompassing Internet of Things (IoT) technology.
This included the latest applications in robotics, machine vision, safety, big data, traceability, PackML and IO link.
Probst says many Australian companies are now talking about the Internet of Things (IoT) technical revolution, but not many are prepared for it.
“Companies that embrace new technologies will be better positioned to adapt to changing marketing conditions and customer needs,” he says.
They can also boost productivity by up to 30 per cent.
“This is the next generation of manufacturing where people and machines work together,” Probst says.
He has no doubt collecting data – and using it to measure performance – holds the key to the future for Australian manufacturers.
Hal Varian, professor of information sciences, business, and economics at the University of California at Berkeley and Google’s chief economist agrees.
“The ability to take data – to be able to understand it, to process it, to extract value from it, to visualise it, to communicate it – that’s going to be a hugely important skill in the next decade,” he says.
Wei-Jian Ong, product manager for Omron’s Sysmac controllers based in Singapore, says data collection and analysis can help manufacturers streamline their operations.
“The collection of data is now vital for industry,” Ong told guests at the Sydney seminar.
“The Internet of Things (IoT) is basically a network of devices with network connectivity for the collection and exchange of data.
“With IoT you can monitor, analyse and act – you can coordinate and monitor your production line. All machines work together to perform at optimum level.”
An estimated 13.5 billion devices will be connected by 2020 worldwide.
Programs such as PackML, or Packaging Machine Language, are now being widely adopted by industry globally, Ong says.
PackML is a universal programming standard defined by the Organization for Machine Automation and Control (OMAC) and by the International Society of Automation's Technical Report 88, which defines a common approach, or machine language, for automated machines.
The primary goals are to encourage a common “look and feel” across a plant floor and to enable and encourage industry innovation.
Omron PLCs can work seamlessly with databases such as SQL, which is the standard language allowing manufacturers to communicate with a database.
The SQL database can collect huge amounts of data (Big Data), that can be used to measure the performance of each machine and increase yield.
With Omron’s NJ SQL version controllers you can send the OEE (Overall Equipment Efficiency) data from machine to database and then use that data with MES and ERP systems.
To improve efficiency and improve productivity more factories now turning to robotics – using fixed (Articulated, SCARA and Parallel robots) and mobile robots (AIVs – Autonomous Intelligent Vehicles).
Omron AIV mobile robots use laser scanners and other advanced technologies that allow them to determine their own path, avoid obstacles and be re-tasked quickly.
“AIVs not only save on labour costs, they can increase operational efficiency,” Probst says.
“Mobile robots are easy to deploy, with no facility modifications required.
“They work safely around people and can operate 24/7.”
Probst says smart factories are also helping to significantly improve workplace safety.
And with improved safety, employers can minimise worker injuries, machinery downtime and loss of production.
“The Smart Factory of the future will improve workplace safety, improve yield and traceability, drive down production costs and eliminate errors, Probst says.
“This will enable a ‘flexible’ manufacturing revolution.”
