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How smart manufacturing can optimize your factories for the new era

The focus of every industrial revolution has been increasing the productivity of production systems. The fourth industrial revolution is here, and it’s seeking to improve both production and management systems. Digital transformation driven by smart manufacturing (also known as Industry 4.0) is the basis of this latest one – creating opportunities to achieve levels of productivity and specialization not previously possible.

Combining data generated through the Industrial Internet of Things (IIoT) and analytics creates a new set of capabilities known as predictive maintenance and quality. Fueled by smart manufacturing, these new capabilities are changing the way we do and see business, helping recognizing patterns and predicting failures or product quality issues before they happen.

Introducing the new industrial IoT platform

Most factories are composed of operation technology (OT) assets such as machines, equipment lines and robotic devices that aren’t always connected. The current trend is leaning toward smart manufacturing with a more IT-based factory floor to help save time, labor, cost and maintenance and upkeep. With OT and IT converging, the IIoT platform is emerging as a new, innovative concept for smart manufacturing with artificial intelligence (AI)-based technologies, including analytics, big data and cognitive manufacturing.

Smart manufacturing can spur a new surge of manufacturing productivity.

Targeting the pain points for key manufacturing personnel

In order to understand the impact of Industry 4.0 solutions, we must examine the key people involved in all aspects of a factory. True transformation happens when all unique challenges and each pain point is targeted.

Transforming your factory with a three-tiered architecture solution from IBM

Keeping the needs of different types of workers in mind and using our extensive manufacturing experience, IBM developed a three-tiered distributed architecture to implement smart manufacturing more efficiently. The model addresses the autonomy and self-sufficiency requirements of each production site and balances the workload between the three tiers.

Mapping IBM’s three-tiered architecture.
  1. Edge level. The most physical part of the factory where product-related activities are performed.
  2. Plant or factory level. Where plant and local activities are orchestrated and connected.
  3. Enterprise level. Where analysis of all levels of information happens, and information storage for visualization and analytics is provided.

Leveraging the three architecture tiers to drive performance

IBM offers a suite of enterprise asset management (EAM) solutions to help drive cost savings and operational efficiency across the factory value chain. The portfolio of EAM solutions from IBM analyzes a variety of information from workflows, context and the environment to drive quality and enhance operations and decision making. The portfolio of EAM solutions from IBM helps deliver a smart manufacturing transformation.

Production quality insights use IoT and cognitive capabilities to sense, communicate and self- diagnose issues to optimize each factory’s performance and reduce unnecessary downtime. Insights help reduce unplanned downtime.

visual quality inspection

Visual Quality Inspection Proved as Gigantic Power in Manufacturing

Focus on providing confidence on quality

Quality assurance is paramount parts of the manufacturing process. It is the part which comes at the end of the production where the final product is inspect for defects and errors before selling it to the customers. This is important because not only it minimize the errors in production, but also prevents humans from items which can be potentially be perilous.

Industries which are involved in producing end products such as Auto parts, mirrors, sanitary ware, Laminates, pharmaceuticals, consumer goods, beverages and foods etc. can immensely profit from visual quality inspection systems

How Do Visual Inspection Systems Work?

Visual Quality Inspection Systems take use of digital sensors, RFID Tags and QR Code which are protected inside the cameras. These cameras use the optical sensors for capturing images which are then processed by computers in order to measure specific characteristics and parameters for decision making

Benefits of Visual Inspection Systems

Save time for Inspection and more on production number: After Visual quality inspection systems have been planned and tuned in to the manufacturing process, they can do immense of production checking in a really short amount of time as compared to human inspection.

Accurate Inspection without any human interference: In human inspection systems, there’s always a great chance of errors and no matter how experienced and focused the employees are, these errors can never brought down to a negligible level. Human capabilities have limitations which Visual Quality Inspection systems haven’t. And this is how they eliminate the chances of error in inspection to a great extent and deliver a higher quality of products.

Compatible with every use-case: Another benefit of Visual Quality Inspections is that in case production method changes, these systems also alter accordingly with great ease.

Increase in Accuracy: They also improve the production efficiency. They can identify errors at a faster rate. Analysis of these remark defects can be made quickly and necessary corrections can be made immediately.

Remote Access: Unlike humans, these systems can work nonstop for twenty-four hours. They can also be operated and programmed from a remote place.

By adopting the visual inspection system in the manufacturing process, companies can boost production and also prevent the wastage which is generated by defected and faulty products. This will save not only the revenues, but also ensure complete customer satisfaction.

If your unit makes products at a mass level and you are looking for a modern and reliable inspection system, then buy Trident- Visual Quality Inspection platform which is trusted by numbers of industrial units for its accuracy and reliability.

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