While manufacturing has always been a numbers game — meeting quotas, balancing demand and supply, and managing downtime — discrete and process manufacturers have always relied on yesterday's data to forecast what tomorrow would bring. The industry is at an interesting crossroads. Not only do we now have quick and affordable access to computational power, but we can also collect data from a new source: machines. It's difficult to overestimate the increased efficiency of such capabilities in terms of uptime, productivity, and other important performance indicators. That is why this data-driven approach to manufacturing is dubbed Industry 4.0.
At the forefront of this digital revolution are rugged mobile devices. Not only are they convenient to tote and use, but developments in processing power and memory enable today's mobile devices to act as powerful data processors on the edge, near to information sources. Additionally, their form factor and familiarity with everyday life facilitate staff adoption.
Here are several ways rugged mobile devices can assist you in using Industry 4.0.
- Provide a data access platform
Rugged mobile tablets enable you to monitor plant activities on-site or remotely via mobile phones. Employees can utilize the manufacturing execution system (MES) of the company to monitor production lines at the granularity required. Industrial Internet of Things (IoT) data can be used to feed algorithms visualized in supervisory control and data acquisition (SCADA) systems (SCADA). These can be found on mobile devices as well. Effective mobile device management can also help provide a more exemplary access level, allowing sensitive data to be viewed by only authorized employees. Supervisors of plant facilities can obtain real-time plant floor surveillance to ensure that supervisory activities are carried out efficiently.
- Facilitate the development of augmented reality applications
Augmented reality superimposes digital pictures of an idealized version of a part or process on top of "reality." This comparison and contrast technique enables viewers to visualize what an exceptional result should look like. Mobile devices equipped with augmented reality applications can assist in troubleshooting machine malfunctions. The plant worker can access digital manuals via the augmented reality app. They can then use the insights to resolve the problems. Additionally, experts can connect with the plant worker via video conferencing. They can "see" the equipment remotely and share expertise in order to discover faults and share expertise.
- Facilitate inventory management and supply chain management
Inventory management is largely automated in a smart factory, with replenishment orders being sent out concurrently with raw material consumption. When factories exchange inventory data with external vendors, they may keep all stakeholders informed and program inventory chains to replenish stock without sending purchase orders. Regardless of the degree of automation in the supply chain and inventory management, plant workers frequently need to verify the quantity of raw materials or spare parts on hand to ensure proper output. Rugged mobile devices equipped with inventory management software enable employees to swiftly scan the supply chain and estimate how current conditions will effect their daily tasks. Additionally, employees can use the gadget to ship spare parts and other commodities from other factory locations as needed.
- Establish predictive analytics and a higher level of automation
One of Industry 4.0's much-heralded benefits is the reduction of downtime through predictive maintenance. Rather than relying on typical run-to-failure production procedures or premature replacement of costly components, machines can continue to operate until they exhibit signs of difficulty. In essence, data from IoT sensors can predict when an item is about to fail well in advance of the failure occurring.
Rugged mobile devices mounted on machines serve as a conduit for this data. These devices process IoT data in close proximity to the data's "edge," or source. Machine learning techniques enable facility operators and supervisors on the shop floor to get notifications. Mobile industrial tablets assist in implementing these new technologies in close proximity to the equipment. When intervention is required, it becomes faster and frequently more successful. Additionally, these predictive maintenance solutions enable increased automation. This enables the smart factory to operate almost independently until human involvement is required.
- Employees must be trained
Employees can be trained on asset usage and safety protocols using mobile devices tied to the assets. To operate equipment, employees must get specialized training. Facility managers can download and install these exams and training sessions on associated mobile devices. This way, personnel can complete important procedures on-site rather than recalling previous teachings and risking inaccuracy. Employees can also "visit" the equipment using augmented reality apps on their mobile devices. This program enables workers to visualize how each component appears in real life prior to seizing the reins and initiating operations.
Complementing mobile use on the plant floor with a thorough mobile device management (MDM) protocol for security and data access is necessary. As a result, staff are able to make the most of their mobile devices. Productivity increases across the board, regardless of whether employees utilize these devices for workforce management, robotics control, or access to enterprise asset management (EAM) systems.
Benefits from Industry 4.0 do not have to be limited to huge original equipment manufacturers (OEMs). Manufacturing organizations of all sizes may migrate from paper-based processes to digital ones, with incremental gains in efficiency. Wherever you are on the path to a nearly autonomous smart factory, rugged mobile devices assist in delivering Industry 4.0 benefits. You need every advantage you can get in an increasingly competitive and unpredictable global industrial environment. Leveraging mobility enables you to maximize these benefits.