Until recently, most manufacturing
plants operated like they were built on desert islands, isolated from other
factories and from the business networks, supply chains, and customers they depend
on. For managers at these “disconnected” factories, the feeling was like flying
blind, with only hazy visibility into downtime and quality problems. Rarely did
they understand (or address) the root causes of inefficiencies.
This is a recipe for high costs
and non-competitiveness, so the smartest manufacturers have been rushing to retool.
Today, more manufacturers are using IoT (Internet of Things) and IP networks to
connect everything within the plant and share information across multiple
locations and business networks. Once machinery and systems are connected,
manufacturers can harness the information to automate workflows and maintain and
optimize production systems without human intervention.
Iconic motorcycle maker
Harley-Davidson does this at its York, Penn. plant, where the company installed
software that keeps a record of how different equipment is performing, such as
the speed of fans in its painting booth. The software can automatically adjust
the machinery if it detects that a certain measurement—such as fan speed,
temperature, or humidity — has deviated from acceptable ranges.
“What used to take hours or
days to troubleshoot problems now takes seconds,” the plant’s infrastructure
design manager said. Plus, adding machines to the line is plug-and-play easy, allowing
for quick changeovers to new models and reducing time to market.
Scores of other manufactures
are getting connected lately, adopting new plant architectures that converge
operational technologies (OT) with global IT networks. As a result, companies are
reporting new levels of overall equipment effectiveness (OEE), supply chain
responsiveness, and customer satisfaction.
Wireless and mobility are key
features of the new factory floor. Toolmaker Stanley Black & Decker, for
example, has attached small RFID tags to parts to help tablet-carrying floor
managers spot and fix bottlenecks on the line. These are just a couple examples
of the new breed of Web-connected factories that is transforming the face of
global manufacturing. To dive deeper, see our recent
white paper that explores the technologies behind this worldwide
manufacturing renaissance.