The latest buzzword IIoT is being seen as life changing and transformative for the manufacturing industry. Industrialists are in awe of the tremendous opportunities it has to offer to improve the operational efficiency of the manufacturing plant. Seeing the potential of Industry 4.0 and the wide spectrum of technologies it incorporates, not many companies or organizations can do it alone. Syslogyx is one of the few companies capable of creating a full fledged end to end IoT/IIoT solution. Whether you want to change a complete conventional industrial production to a connected, intelligent manufacturing through smart factories, products, and services or you want to optimize only a certain process of your business operation to bring efficiency, Syslogyx acts as a one stop shop for its customers!
“Whether you want to change a complete conventional industrial production to a connected, intelligent manufacturing through smart factories, products, and services or you want to optimize only a certain process of your business operation to bring efficiency, Syslogyx acts as a one stop shop for its customers!”
A complete Smart Factory consists of the following sub-solutions. Depending upon the business process of your organization, each of these sub-solutions contributes towards boosting your operational efficiency.
1. An Economical but Efficient ERP Solution
- An ERP System is an obvious choice to meet all the integration goals of a company. However, there are a couple of critical variables.
- Each plant capacity being different, the generic ERP is a terrible fit for the business processes.
- Apart from being expensive, there is a limit to customization for flexibility to your business.
- The Smart Factory application unifies the multiple business processes of an organization, pertaining to Planning, Materials Management, Manufacturing, Finance, Supply Chain, Human Resource management and Customer Relationship Management (CRM) helps build a competitive edge.
- Moreover, while the current ERP systems are not Industry4.0-ready, it would act as a base for the future implementation of Smart Factory/Industry4.0
2. Integrate Existing ERP with Machines
- Since most of the manufacturing companies are already using an ERP system, the Smart Factory solution offers a way to increase the operational efficiency within the existing plant settings.
- It enables machine to machine communication and lets machines talk directly to the ERP software so as to eradicate all the offline factory operations
Machine shares its live production with the ERP software and vice versa thus leaving no room for manual errors.
3. Raw Material and Inventory Tracking
- With the increasing number of assets each day, it becomes highly difficult to track and manage them.
- In a Smart Factory, the assets are embedded with RFID codes and networked sensors that communicate huge volumes of data about them.
- It enables tracking from raw materials used in production, determining the actual status and condition of a product to locating inventory.
- The raw material can itself tell the operator if it is the right product for the current manufacturing order.
4. Predictive Maintenance
- The manufacturing enterprises bear huge losses as a result of the equipment failures and machine downtime.
- The IoT-enabled predictive maintenance solution would alert you about the equipment failures or maintenance issues before they happen.
- It uses Artificial Intelligence and Machine Learning to analyze and predict when an equipment needs to be maintained or replaced before a failure occurs, reducing unscheduled downtime.
- It maintains event logs, time- and date-stamped lists of every event that occurred on a machine which helps troubleshoot or find the root cause of a machine problem in less time.
5. Power Management
- Energy is often one of the largest expenses for manufacturers and unfortunately the companies only obtain limited data about their energy consumption patterns.
- Taking advantage of the connectivity in a smart factory, manufacturers can now track energy consumption patterns at the device level.
- Managers get to detect abnormal energy consumption patterns, as well as actionable insight about waste, regulatory compliance, and more. This results in cost savings and easier compliance.
6. Live Data Analysis and Centralized Monitoring
- Massive amount of data is being generated in the manufacturing plants each day.
- This data needs to be effectively analyzed to identify problems that lead to inefficiencies; helps generate valuable insights for humans or autonomous decision making.
- Managers can instantly find out the status of production and can control and manage the systems from a remote operations center.
7. Electronic Controlling Module
- Enterprises are in great need of a wireless notification system that can be used to immediately alert managers and technicians that they are needed on the line.
- In Smart Factory, a system like this is set up so that an operator just clicks a button and a tower light connected to the gateway’s outputs indicates which production line needs attention, and colors are assigned to indicate the department whose assistance is required.
- Additionally, the alerts are also sent to a remote device like mobile to the concerned people from the concerned department.
All these solutions contribute tremendously in improving the overall operation efficiency of the manufacturing process.