Guy Collins from specialist automation and control distributor BPX outlines the value of having a well-chosen, trusted guide on the journey to implementing Industry 4.0.
For all the talk of Industry 5.0, just implementing Industry 4.0 remains a difficult challenge for a lot of manufacturers. Often, their business is successful, but the attraction of bridging IT and OT in a seamless, digitised way to deliver intelligent insights, autonomous decision-making, and improved productivity remains tantalisingly out of reach. The inevitable focus on the core business makes it difficult to devote resources to the requirements and challenges of deploying data-driven, smart manufacturing technologies to boost agility and competitiveness.
Although the answer is perhaps that the move to smarter manufacturing is not a leap but a series of well-judged smaller steps towards an end goal, many companies will need guidance to determine how to make those steps without disturbing existing processes or introducing new risks. They need a knowledgeable partner, offering the best routes and warning of the perils of the journey.
A well-chosen guide should demonstrate an understanding of the environment and know the intricacies of blending IT and OT to develop a roadmap tailored to a company’s specific vision, constraints, risks, and requirements. That trusted advisor should be able to help in three essential ways.
Learn the terrain – assessments are key
Smart manufacturing implementations should start with an assessment to learn the environment and understand the level of digital readiness. A typical assessment reveals critical information about the path ahead:
- The current state of automation and connectivity.
- The available technical skill set of existing staff.
- Challenges and needs related to data exchange with customers and suppliers.
- Responsiveness of the manufacturing process to customer demands and changing market dynamics.
Assessments help determine the capacity of important systems such as Manufacturing Execution Systems or Enterprise Resource Planning platforms. What could be the benefits of artificial intelligence (AI) or augmented reality (AR) implementations? What about a customer’s environmental, social, and governance (ESG) status? How can sustainability and energy consumption goals be met? Looking into all these areas is essential to mapping out the digital journey.
Act as interpreter – bridge the gap
Experienced guides also serve as valuable interpreters. IT and OT teams have historically worked independently with little interaction, speaking different languages, working with different equipment, and approaching challenges with different mindsets.
Convergence creates the need to bridge these teams so each can understand the other’s priorities, challenges, and goals. Only by getting both teams on the same page can an organisation successfully move forward with planning and execution.
Follow the best path – plan a step-by-step route
A guided path to intelligent manufacturing may be preferable for many organisations. A company may need to go through Industry 3.1 and 3.2 before ascending to 4.0. An experienced technology advisor will plot a step-by-step route that may start, for example, by placing Industrial Internet of Things (IIoT) sensors on existing manufacturing motors and drive systems to begin collecting shop floor data.
Information collected can show how to improve maintenance efficiency and reduce energy consumption. A quick, early ROI win can help make the case with management for further technology investment in areas such as AI and advanced robotics. A progressive approach helps to educate all of those involved on the steps to take next so they can make well-informed investments.
A pathway to digitisation
At BPX, we take our role as a technology guide seriously. Our motto is “Help to Choose, Help to Use.” We apply a half-century of industrial automation experience to help our customers select the right products and solutions for their applications and ensure they can optimise the value they get from their investment. We leverage our trusted relationships with leading suppliers such as Schneider Electric, Mitsubishi Electric and Omron to help our customers plot their best route to Industry 4.0.
