Unpacking smart factory trends

The term “smart factory” refers to manufacturers using technology like automation and AI to streamline processes. It leverages interconnected systems and intelligent machines to control aspects of production.

HSO, Digital Transformation Partner of the upcoming 2023 Modern Manufacturing Expo, has been working with manufacturers for over 30 years to support the development of smart factories and offer solutions across the manufacturing value chain.

The global transition towards smart factories has gained significant momentum due to the supply chain disruptions caused by the pandemic, which gave manufacturers the opportunity to prioritise technology, according to HSO Global Manufacturing Director Chandru Shankar.

HSO highlights the emerging smart factory trends as follows:

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. To ensure OEE, it is crucial to have predictive maintenance and condition monitoring processes, enhanced by IoT-connected equipment.

HSO’s connected IoT models establish an early warning system to prevent equipment downtime and improve equipment effectiveness, which may assist food manufacturers such as Lays or PepsiCo, which rely on early detection of equipment faults.

2. Integration of IoT sensor data and AI across the manufacturing value chain

AI and data analytics are central to organisations, amplified through IoT-connected equipment.

While Shankar 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.”

3. Digital twins

Digital twins are virtual replicas that mimic the behaviour of physical objects, processes or environments. They are commonly used for machinery and factory operations and are being increasingly applied across the supply chain, allowing companies to run simulations prior to making decisions.

Using digital twins, companies can anticipate challenges like capacity constraints or equipment failure, enabling them to schedule maintenance and adjust operations accordingly, Shankar said.

4. Customisation of digital manufacturing technologies

HSO presents a standard solution that aligns with a company’s needs before catering to its desired outcome by tweaking and configuring as necessary.

“Every manufacturer has their own key differentiating factors,” Shankar said. “Our goal is to understand them and ensure that our solution can enable and accelerate them right out of the box.”

The challenges of scaling smart factories

Scaling smart factories poses challenges such as the need to hire and upskill workers proficient in emerging technologies. With a scarcity of skilled talent, there is intense competition for qualified individuals.

Determining the appropriate extent of AI implementation is another challenge. With the limits of AI and its potential impact on human labour unclear, AI software developers are considering implementing ‘guardrails’ to ensure responsible and ethical AI use.

HSO has a partnership with Microsoft in this domain. Microsoft was recently launched Copilot, an AI-powered tool that provides insights and recommendations to help users prioritise tasks and address challenges such as weather delays and shipment issues.

IIoT in the spotlight at the 2023 Modern Manufacturing Expo

Shankar will be a panellist at the Smart Manufacturing Conference, which runs alongside the Modern Manufacturing Expo. He will contribute to an industry panel titled ‘How Industrial IoT is revolutionising the manufacturing sector’.