Smart Manufacturing
Smart manufacturing is a convergence of modern data science techniques and artificial intelligence to form the factory of the future. Smart manufacturing is about increasing efficiency and eliminating pain points in system. It's characterized by a highly connected, knowledge-enabled industrial enterprise where all organizations and operating systems are linked, leading to enhanced productivity, sustainability, and economic performance Industry 4.0 demands smart systems integrated with intelligence to have a better human-machine interface.
Industry analysts are predicting that the next decade of innovation, productivity and growth in manufacturing will be driven by the demand for mass customization and a convergence of technology advances that are enabling a new generation manufacturing infrastructure for "Smart Manufacturing" technology advances in connected factory automation, robotics, additive manufacturing, mobile, cloud, social and digital 3D product definition. In fact, this new era of manufacturing is dubbed the Fourth Industrial Revolution. The technology advances and integration standards behind the connectivity of the "Internet of Things (IoT) empower devices from smart phones to smart shelves to sensor embedded automation controls to be active participants in a new connected digital reality. The coupling of loT technologies with advances in plant floor automation and information systems is referred to as the "Industrial Internet of Things" (IoT). The new generation of noT enabled smart machines for manufacturing will have onboard computers that directly support Internet protocols and allow direct communication with enterprise applications. Internet connectivity methods let companies thread external web services like social and cloud platforms into their processes, and enable more ways to connect internal systems inside the firewall of corporate intranets to mobile and analytical applications. Emerging capabilities in additive manufacturing, advanced robotics, sensor enabled equipment and other new approaches to fabrication, open new process improvement opportunities both in the plant and across the Piy chain. Sophisticated computer modeling and simulation tools are evolving to give engineers for greater scope in designing a manufacturing process before building the production lines. These new technologies and capabilities are dramatically changing the management of manufacturing operations. The next generation Smart Factory feeds real time information to a more empowered workforce through a combination of smart facilities, machines and equipment with built in sensors, self diagnostics and connection to other smart systems
McKinsey and Company defined in a manner that added the power of big data, cloud computing and the wide-spread implementation of new technologies “ driven by four disruptions: the astonishing rise in data volumes, computational power, and improvements in transferring digital instructions to the physical world, such as advanced robotic sand 3-D printing".
Smart Manufacturing Processes: Three Dimensions:
(1) Demand Driven and Integrated Supply Chains
(2) Dynamically Optimized Manufacturing Enterprises (plant + enterprise operations)
(3) Real Time, Sustainable Resource Management
● Smart design/Fabrication:
Digital Tools, Product Representation and Exchange Technologies and Standards, Agile (Additive) Manufacturing Systems and Standards. Mass Customization, Smart Machine Tools, Robotics and Automation (perception, manipulation, mobility, autonomy), Smart Perception, Sensor networks and Devices Smart Communication systems Information, Mobility. Communication Technologies, Protocols, Cyber Physical Systems, the next generation of Embedded Systems and Networks, IT and OT convergence, co-creation and collaboration enablement.
Smart Applications:
Online Predictive Modeling, Monitoring and Intelligent Control of Machining Manufacturing and Logistics/Supply Chain Processes, Smart Energy Management of manufacturing processes and facilities.
● Smart and Empowered Workers: Eliminating Errors and Omissions, Deskilling Operations, Improving Speed/Agility. Improving Information Capture/Traceability. Improving Intelligent Decision Making under uncertainty Assisted/ Augmented Production, Assisted/ Augmented Assembly, Assisted/Augmented Quality Assisted/ Augmented Maintenance, Assisted/ Augmented
● The First Industrial Revolution:
This revolution also called conventional product cycle, no computer technology invented in this revolution The first industrial revolution, which really was a revolution, and among others things to invention of steam machines, the usage of water and steam power and all sorts of other machines, would lead to the industrial transformation of society with trains, mechanization of manufacturing and loads of smog.
● The Second Industrial Revolution:
The industrial revolution termed as CAD/CAM product cycle in which single alone CNC technology just begins. Manual CNC programming, transfer line was used for mass production It was typically seen as the period where electricity and new manufacturing Inventions which it enabled, such as the assembly line, led to the area of mass production and to some extent to automation.
● The Third Industrial:
Revolution had everything to do with the rise of computers, computer networks (WAN, LAN, MAN), the just rise of robotics, FMS, Computer Integrated Manufacturing (CIM), Automation, Group Technology(GT) and Cellular Manufacturing in manufacturing, connectivity and obviously the birth of the Internet, that big game changer in the ways information is handled and shared, and the evolutions to digitalization.
● The Fourth Industrial Revolution:
We move from just the Internet and the client-server model to ubiquitous mobility, the bridging of digital and physical environments (in manufacturing referred to as Cyber Physical Systems), the convergence of IT and OT, and all the previously mentioned technologies (Internet of Things, Big Data, cloud, ete) with additional accelerators such as advanced robotics Al /cognitive which enable Industry 4.0 with automation and optimization in entirely new ways that lead to ample opportunities to innovate and truly fully automate and brining the industry to the next level.
Elements of Smart Manufacturing
◆ Internet of Things(IoT)
◆ Digital Transformation
◆ Artificial Intelligent
◆ Cloud Computing
◆ Big Data (Advanced Data Analytics)
Internet of Things (IoT):
The loT is the infrastructure of interconnection among objects. In manufacturing systems, each device is embedded with electronic software, sensors, and actuators and is connected to Internet networks. The ioT enables manufacturing devices to exchange data within manufacturing devices and between manufacturing devices and their service providers or consumers From the technical point of view, we can describe the IoT as a combination of sensors such as RFID, other communication devices (ie, embedded computers), CM applications, Enterprise Resource Planning (ERP) integration and business intelligence technology Sensors are embedded in physical objects such as vehicles and heavy equipment (cranes, automated guided vehicles (AGV), and loaders), machines, and robots. A standard communication protocol is an essential enabler of IoT deployment. The communication and foundation of the loT are the inspiration for Cyber - Physical System (CPS).
Definition of IOT:
The Internet of Things (IoT) is a network of things which are connected to the Internet. These things include IoT devices and IoT-enabled physical assets. They range from consumer devices such as smart home solutions or pet trackers to sensor-equipped connected livestock and crop, industrial assets such as machines, robots, oil and gas facilities or even workers. The Internet of Things also has its own technology stack that starts from connecting things, capturing the data and communicating it and ends with applications. It's among others here that edge computing and fog computing come in. Also ioT gateways and IoT platforms play an important role in that stack as do many network standards with ever more wireless IoT connectivity options. We define the Internet of Things a network of connected devices with 1) unique identifiers in the form of an IP address which 2) have embedded technologies or are equipped with technologies that enable them to sense, gather data and communicate about the environment in which they reside and/or themselves.
Internet of Things characteristics:
● Connectivity: This doesn't need much further explanation Devices, sensors, they need to be connected to an item, to each other, actuator, a process and to the Internet' or another network
● Things: Anything that can be tagged or connected as such as it's designed to be connected From sensors and household appliances to tagged livestock Devices can contain sensors or sensing materials can be attached to devices and items.
● Data: Data is the glue of the Internet of Things, the first step towards action and intelligence.
● Communication: Devices get connected so they can communicate data and this data can be analyzed.
● Intelligence: The aspect of intelligence as in the sensing capabilities in ioT devices and the intelligence gathered from data analytics (also artificial intelligence).
● Action: The consequence of intelligence. This can be manual action, action based upon debates regarding phenomena (for instance in climate change decisions) and automation, often the most important piece.
● Ecosystem: The place of the Internet of Things from a perspective of other technologies, communities, goals and the picture in which the Internet of Things fits, The Internet of Everything dimension, the platform dimension and the need for solid partnerships.
loT Applications:
● Predictive and preventative maintenance
● Supply chain management
● Inventories and logistics.
● Factory floor efficiency will have the largest impact
● Increasing productivity by as much as 25 percent.
● lot + data analytics + machine learning .
Digital Transformations:
Digital transformation is the process of using digital technologies to create new or modify existing business processes, culture, and customer experiences to meet changing business and market requirements. This reimagining of business in the digital age is digital transformation.The reasons for digital transformation are, Acceleration of Change the pace of digital change is rising exponentially, making it very difficult to maintain a position of industry leadership, and requiring an acceleration of new digital solutions brought to market. The branch of scientific or engineering knowledge that deals with the creation and practical use of digital or computerized devices, methods, systems, etc advances in digital technology Digital technologies are electronic tools, systems, devices and resources that generate store or process data. Well known examples include social media, online games, multimedia and mobile phones. Today, myriad devices are digital including a smart phone, tablet and smart watch, In contrast, there are numerous non-digital (analog) devices, such as a thermometer, electric fan and bicycle Automobiles, washing machines and many other products are both digital and analog.
Digital transformation is the changes associated with digital technology application and integration into all aspects of human life and society. It is the move from the physical to digital. Digital transformation is the profound transformation of business and organizational activities, processes, competencies and models to fully leverage the changes and opportunities of a mix of digital technologies and their accelerating impact across society in a strategic and prioritized way, with present and future The end goal of digital transformation, however, is the ability to rapidly act and react to changing data, competitive conditions and strategies fast enough to succeed, In business, digitalization most often refers to enabling, improving and/or transforming business operations and/or business functions and/or business models/processes and/or activities, by leveraging digital technologies and a broader use and context of digitized data, turned into actionable, knowledge.
Digital Twin:
The applications of DT in Smart Manufacturing are directed as below.
● Designing and verifying of products. Some authors have developed a DT framework to support product design. Such framework enables the iterative optimization of design scheme to guide designers to adjust their expectation and improve the design model.
● Monitoring product over production life-cycle: Some authors view DT as a comprehensive digital representation of product from the early design stage to the end of product life-cycle.
● Designing and verifying of processes and production lines: Some authors have developed.
● DT to assist the design of process function and production line capabilities. This DT provides engineering analysis capabilities and supports decision-making over the system design and solution evaluation.
● Enhancing resources overhaul maintenance Some authors have developed DT to trace resources digital behavior to diagnose and prognosticate faults, failure, and performance deviation. Once such problems are detected, the suitable action will be simulated in virtual model to evaluate the effectiveness of the corrective action to avoid sudden downtime.
Artificial Intelligence:
Artificial intelligence (AT) is an area of computer science that emphasizes the creation of intelligent machines that work and reacts like humans Some of the activities computers with uncial intelligence are designed for include Speech recognition, Artificial Intelligence (AI) think ingch of computer sciences that emphasizes the development of intelligence machines thinking and working like humans For example, speech recognition, problem-solving, learning and planning. Theoretical AI says that Intelligence (be it natural or artificial) has three types.
● Artificial Narrow Intelligence (ANT)
● Artificial General Intelligence ( AGI)
● Artificial Super Intelligence (AST)
Artificial intelligence (AI) is the simulation of human intelligence processes by machines, especially computer systems. These processes include learning (the acquisition of information and rules for using the information), reasoning (using rules to reach approximate or definite conclusions) and self-correction Artificial intelligence is the use of computer science programming to imitate human thought and action by analyzing data and surroundings, solving or anticipating problems and learning or self-teaching to adapt to a variety of tasks Artificial intelligence (Ai) makes it possible for machines to learn from experience, adjust to new inputs and perform human-like tasks.
Disadvantages of Artificial Intelligence:
• High Cost
• No Replicating Humans
• No Improvement with Experience
• No Original Creativity
• Unemployment
Artificial intelligence can be used to solve problems across the board.
● Al can help businesses increase sales, detect fraud, improve customer experience, automate work processes and provide predictive analysis. Logistics companies can use Al for better inventory and delivery management.
● Machine Learning Machine Learning is the learning in which machine can learn by its own without being explicitly programmed. It is an application of Al that provides system the ability to automatically learn and improve from experience. Studying artificial intelligence opens a world of opportunities. Studying Al now can prepare you for a job as a software engineer researching neural networks, human-machine interfaces, and quantum artificial intelligence.
● Artificial intelligence (AI) in healthcare is the use of complex algorithms and software to estimate human cognition in the analysis of complicated medical data. The primary aim of health-related Al applications is to analyze relationships between prevention or treatment techniques and patient outcomes. It is seen as a subset of artificial intelligence. Machine learning algorithms build a mathematical model based on sample data, known as "training data", in order to make predictions or decisions without being explicitly programmed to perform the task.
Cloud computing:
Cloud computing is the practice of using a network of remote servers hosted on the Internet to store, manage, and process data, rather than a local server or a personal computer. Simply put,cloud computing is the delivery of computing services including servers, storage, databases, networking, software, analytics, and intelligence over the Internet ("the cloud") to offer faster innovation, flexible resources, and economies of scale. In the simplest terms, cloud computing means storing and accessing data and programs over the Internet instead of your computer's hard drive The cloud is just a metaphor for the Internet. The cloud is also not about having dedicated network attached storage (NAS) hardware or server in residence. Cloud Computing is the use of hardware and software to deliver a service over a network (typically the Internet) With cloud computing, users can access files and use applications from any device that can access the Internet. An example of a Cloud Computing provider is Google's Gmail. Cloud computing is a type of computing that relies on shared computing resources rather than having local servers or personal devices to handle applications. The services are delivered and used over the Internet and are paid for by the cloud customer on an as needed or pay-per-use business model.
Benefits of cloud computing :
● Reduced IT costs.
● Scalability
● Business continuity
● Collaboration efficiency
● Flexibility of work practices
● Access to automatic updates.
