Connected Machines
Industry 4.0 is the fourth and latest industrial revolution, and it is transforming the manufacturing landscape. It seamlessly connects production lines, machines, and workers to create smarter solutions. By sharing valuable information and constantly monitoring progress, companies can revolutionize their business models and pave the way for a more efficient future. With Industry 4.0, businesses are able to integrate automation, data, and analytics to optimize their operations and drive innovation. The innovations enabled by Industry 4.0 will enhance product quality, reduce costs, and improve overall efficiency. The shift towards smarter, more connected factories and supply chains will create a competitive edge and unlock new opportunities for growth.
Uses for connected machines
Machines that are connected drive digitalization in production and manufacturing. They’re crucial for the Industrial Internet of Things (IIoT) since they gather data in real-time, analyze it, and help make decisions. They improve efficiency, productivity, and cut costs by seamlessly merging with other technologies. Uses include: predictive maintenance, quality control, inventory management, and supply chain optimization.
Sensors
Modern technology plays a crucial role in converting analogue information, such as temperature and pressure, into digital format for easy processing.
Edge Devices
The factory’s innovative systems are seamlessly and securely connected to state-of-the-art smart machines, enabling lightning-fast network communication and unparalleled efficiency.
Edge Computing
Edge computing is an innovative and efficient solution that aggregates, bundles and filters the vast amounts of data that are collected, resulting in highly effective routing of traffic to the cloud.
IIoT applications
Various apps are readily available to cater to the diverse needs of production, including but not limited to monitoring conditions, efficiently managing assets, keeping a tab on spare parts usage, as well as effectively monitoring energy usage at all times.
IIoT platform
The platform is the central hub where all relevant data comes together, serving as the foundation for all production applications and processes.
Backend-Integration
In order to truly maximize their value, connected machines must establish direct links with compatible systems, such as pre-existing SAP landscapes, which can enhance their overall functionality and effectiveness.
SAP Intelligent Asset Management and a Digital Twin: a sample application
A leading metal curing specialist reached out to Zircoo for assistance with a comprehensive digital campaign. Their primary objective was to enhance transparency in production maintenance, while also allowing clients to access pertinent SAP data. Leveraging Zircoo’s cutting-edge IIoT Portal, we developed tailored applications that effortlessly catered to their specifications. Our innovative solution empowers employees to effortlessly update data, while clients can conveniently access machine status with SAP AIN.
Benefits of connected machines
Smart machines as a product of an Industry 4.0 networked production system offer operators many advantages. These relate both to traditional production processes and new business models:
Time savings
Connected machines document and collect relevant production data, offering insights into inefficiencies and opportunities for improvement. With this critical information, businesses can better schedule production and implement more efficient processes for long-term success.
Transparency and traceability
With our innovative technology, we make it easy to track every step of your product's journey, even after it has been delivered. This means that you can identify exactly when and where each part was produced and installed. Not only does this support seamless auditing, but it also streamlines the handling of guarantee claims, making it easy to quickly address any issue that may arise in the field.
Product quality
In a networked production system, data collection, collation, and evaluation become critical for gaining a transparent overview of all production processes. Fine-tuning the system leads to enhanced product quality, reduced production costs, and minimised scrappage rates. It's a process that demands diligence and attention to detail at every stage.
New business models
Industry 4.0, the fourth industrial revolution, has brought about a significant shift in the manufacturing industry, highlighting a preference for renting services as opposed to purchasing equipment outright. The rise of connected machines allows manufacturers to not only offer value-added services to their customers but also opens up opportunities for creating new and innovative business models.
Challenges of connected machines
Alongside the numerous benefits of connected machines, there are also several challenges that companies must consider when planning their deployment. It is highly recommended that companies seek the guidance of a digitalisation expert to navigate these potential obstacles.
Compatibility
Machines connect and collaborate with other devices in the network, thereby leveraging the collective capabilities to optimize production processes. Therefore, seamless integration of protocols and systems is of utmost importance to ensure efficient and effective communication among the interconnected machines.
Consistent planning and networking
A reliable partner is essential for successful network production. An experienced team can handle every step, from planning to real-time execution and data analysis. A seasoned partner ensures smooth production from start to finish.
Suitable IIoT applications
Each industry and product has unique demands, necessitating customized software solutions to visualize raw data and convert it into actionable decision-making insights. Our clients leverage a tailored IIoT Portal equipped with bespoke apps to extract maximum value from their data.
Connected machines in practice
The uses of connected machines are as different as they are numerous. Here are two examples of projects where we have supported our customers:
New Services for New Revenue Streams
An innovative electric motor manufacturer has developed cutting-edge connected products that transmit valuable real-time data to their base, providing customers with unparalleled insights even after their purchase. Customers are empowered to optimize run times through the power of predictive maintenance, ensuring maximum efficiency and cost savings.
Continual Product Improvement
Through the power of integrating regular feedback from connected machines and creating a digital twin with the SAP Asset Intelligence Network, our valued customer gains valuable insights into its processes and weaknesses. By analyzing the collected data, our customer can delve into important questions such as when the system becomes overloaded and how individual components react in specific conditions. Armed with this knowledge, our customer is prepared to make permanent improvements to product quality and further elevate their business to new heights.
Zircoo– your partner for planning and implementation of connected production systems
Connected machines and edge computing are just the beginning of Industry 4.0 for companies. Ziroo has years of experience in manufacturing and production. We offer planning, development, implementation, and ongoing operations for bespoke concepts in collaboration with customers. As an SAP partner, we excel at integrating cutting-edge connected production processes with existing ERP systems for efficient data-driven resource planning. With our configurable Ziroo IIoT Portal, customers can utilise AI and machine learning technology to maximise data potential. Our breakthrough templates, which mostly use standard solutions, ensure custom solutions are developed quickly, while still meeting specific requirements.
FAQ:
How Does Machine-to-machine (M2M) Communications Work?
In contrast to M2H communications, where the machine interacts with a human user, M2M communications uses the automated exchange of data between different devices such as production machinery, mobile devices or vehicles. This form of communication is the foundation for providing a wide range of services, including remote servicing, monitoring, and predictive maintenance. The critical components of M2M communications are the data end points, which includes connected machines, a communications network, which can be either cabled or wireless, and a data integration hub, that collects and monitors all the data for analysis.