Simon Keogh, general manager, Factory Automation & Control Products, Siemens UK & Ireland, says SMEs through to large corporates with one eye on the longterm implications of Industry 4.0, should be taking advantage of today’s automation technology. Tools such as simulation and engineering software to help reduce investment risk, drive operational efficiencies, enhance production flexibility and increase competitiveness
There has been much discussion about the future impact of ‘Industry 4.0’, the term originating in Germany to describe the next great industrial revolution leap made possible by the utilisation of cyber-physical systems. Advocates highlight a utopian view that, for example, will see the creation of selforganising, intelligence-led, fully optimised, digital factories producing highly customised products. This will be as a result of the computerisation of manufacturing based on higher levels of network interconnectivity and enhanced digital communication between machines and equipment.
But, while many grapple with the potential of such a substantial manufacturing advancement, we are today already witnessing the influence of digitalisation within the industrial environment, and the fundamental power of automation tools such as simulation and engineering software that are making real inroads within an industrial context. As a result, a number of companies are benefitting from reduced capital expenditure investment risk, improved operational efficiencies, enhanced production flexibility, shortened time to market and augmented competitiveness.
REDUCING RISK, INVESTING MORE
With the UK industrial sector acknowledged to spend considerably less than its German counterpart on automation technology investment, encouraging increased numbers of manufacturers to instigate a more proactive investment strategy is an ongoing challenge.
Mindful of difficult economic conditions, a traditional preference to rely on legacy systems and uncertainty of the ultimate benefits of automation technology, means many companies have shied away from investing in the proven automation systems that can underpin future competitiveness.
Seeing the investment risk and not the investment benefit has meant the UK’s industrial sector remains behind the likes of Germany when it comes to productivity success. Turning around the anti-investment sentiment will take time and requires action and support from all stakeholders, including the Government and the banking community, to ensure real momentum can be generated in this critical area. Linked to investment sentiment and a wish to lessen the perception of risk, are the tangible benefits to be gained through the adoption of key automated simulation and engineering tools. Siemens’ Totally Integrated Automation (TIA) Portal is a prime example of a gateway to a digitalised world that coordinates the production process by integrating software and hardware.
Product lifecycle management tools will, in a virtual digitalised world, design, prototype and simulate products to optimise development timescales. While other automation tools can, for example, design and simulate an assembly line to support the optimisation of logistics processes and production throughput – without the need to invest significant sums up front. This digital capability is scalable, affordable and available across the manufacturing spectrum.
CONNECTING CRITICAL PHASES
By taking a holistic view of the benefits automation technology can deliver, manufacturers can unlock the potential for operational improvement and increased competitiveness. Unified digital connections between the critical phases of product design, production planning, production engineering, and production execution, using relatively inexpensive solutions such as Plant Simulation, can shorten product development timeframes, reduce costs and provide key insight to inform future investment decisions. The preconception by management that there is an unquestioned need to invest in major plant infrastructure to upscale production capabilities, can be quickly scrutinised and challenged within a simulated environment. There are numerous examples of manufacturers avoiding significant capital expenditure after a simulation project has disclosed that better optimisation of the existing production execution alleviates the requirement for additional plant, thereby saving the company substantial funds.
THE NEAR FUTURE
With the essence of Industry 4.0 based upon the connectivity of the digital and physical worlds, the development of innovative tools such as ‘Automation Designer’ will start to have a real impact. Based upon a need for only one point of initial data entry, the system seamlessly integrates the process stages from mechanical design through to automation engineering, allowing changes to be made at any point that can then flow through the chain to save time and expensive resource commitments.
This manner of practical automation technology support starts to open up the optimisation possibilities that underpin the philosophy and vision behind Industry 4.0. Manufacturing organisations will be searching to take their product planning and production to the next level to remain competitive within their markets. The advantageous essence of Industry 4.0 is already within reach for many who are prepared to shake off a historic reluctance to invest in integrated industrial automation technology. They should seek to embrace the competitive gains associated with the ability to shorten complex product development cycles and mass produce customised products as efficiently and cost effectively as possible.
For more information, visit www.plm.automation.siemens.com/en_us/products/tecnomatix/manufacturing-simulation/material-flow/plantsimulation.shtml
