Over the last fifty years, the industrial era has experienced numerous fluctuations and challenges, with influences from war, pandemics, global economic downturns, and industrial risks. As new obstacles emerge, the contemporary manufacturing industry must rise to the occasion and defy conventional norms. Persistent issues such as low productivity, inconsistent product quality, incomplete real-time data, and limited process visibility continue to hinder manufacturing operations. The future of manufacturing lies in the concept of a Connected Shop floor - a transformative approach that will revolutionize the industry's sophistication and maximize its capabilities to tackle the challenges at hand. An essential aspect of this approach is the integration of intelligence through a combination of people, processes, and technology. In this blog, we are focusing primarily on the technological components that play a crucial role in shaping a Connected Shop floor, such as leveraging AI, IoT, and data analytics to create a synergy between human workers and smart machines.

What is a Connected Shop floor?

The implementation of a Connected Shop floor is crucial for the advancement of Smart factories in the future. This involves integrating machines through IoT technology and utilizing AI to digitize industrial manufacturing processes. By leveraging Connected Shop floor, machines can be enhanced with IoT devices to collect production data in real-time. ERP platforms play a key role in connecting business users across different functions within an enterprise, such as finance, vendor management, and leadership. This integration provides a comprehensive overview of daily manufacturing processes, enabling quicker decision-making. In addition to improving operational efficiency, a Connected Shop floor also enhances health and safety protocols, reducing the risks of hazards, breakdowns, and industrial accidents. By considering these factors, the Connected Shop floor will undoubtedly pave the way for Dynamic Manufacturing.

Building Blocks of a Connected Shop floor

Manufacturing operations often experience significant downtime between machinery breakdowns and the resumption of normal operations, resulting in decreased output and delays. According to Lean Manufacturing principles, it is possible that a plant may not be operating at its full design capacity and load. It is crucial to have immediate access to information about the plant and spare parts, as emphasized by Lean Manufacturing. Additionally, historical data, such as the last preventive maintenance on plant machinery, plays a key role in optimizing operations.

Optimal Connected Shop floor

By embracing Smart Manufacturing, a Connected Shop floor has the potential to yield the following benefits:

Connecting Manufacturing Infrastructure

The integration of digital kiosks and enterprise software platforms binds machines in the manufacturing setup, transforming it from an isolated working entity into an essential component of the corporate boardroom. The connection extends to the entire organization, with various teams including operations, maintenance, company management, and regulators now linked with the shop floor. Utilizing IoT, energy consumption patterns can be monitored to predict failures, reduce energy and compliance expenses, and minimize unplanned downtime.

Data and Analytics in Real-time

The traditional practice of retrieving production data post manufacturing can now be eradicated. Enterprise Asset Management (EAM) effectively gathers real-time manufacturing data from various sources such as machines, energy meters, and utilities. This data is then processed in a cloud-based environment, enhanced with intelligent insights, and made accessible to different stakeholders including Supervisors, Engineers, Managers, and Top Management. Each user can easily access relevant information in real time, regardless of their location.

Accelerated Decision-making through Data Analysis

The advancement of cloud-enabled data processing and reporting represents a significant improvement for end users compared to the risks associated with traditional reporting methods that may lead to severe disruptions or industrial accidents. Timely reporting, facilitated by cloud technology, allows management to make informed decisions promptly, potentially saving lives and preventing environmental disasters that were once prevalent during the industrial era.

Operational Intelligence

By leveraging IoT technology, real-time data fusion and analysis become possible, empowering managers to enhance operational efficiency and utilization. Attain Operational Intelligence by establishing a connected system that seamlessly integrates individuals, procedures, and technology.

Improved Shop floor Processes

The automation of the shop floor will bring about significant improvements in processes and worker well-being. By streamlining workflows from production planning to quality control, the overall product lifecycle will be more streamlined and efficient. User-friendly interfaces for both humans and machines, such as kiosks and ERP systems, will facilitate better communication and collaboration between workers and machines. Furthermore, the incorporation of HMI layers will enable instant and real-time reporting of any issues or delays, allowing for quick resolution by workers. Leveraging IoT technology for monitoring and detecting hazardous materials will enable users to remotely ensure safety compliance and adhere to storage and handling regulations.

Integrated Smart Manufacturing Ecosystem

The integrated shop floor has transformed into a highly connected and easily manageable manufacturing facility with immediate access to data and comprehensive visibility throughout the entire operation. Real-time data has enhanced the intelligence of machines, enabling faster and more precise detection of challenges, risks, and opportunities. Additionally, the comprehensive insight into each process ensures the production line maintains full connectivity and 360° visibility at all times.

How is Nirmalya Enterprise Resource Planning Driving Smarter Manufacturing?

Nirmalya Enterprise Platform, designed specifically for manufacturers, offers a robust platform to elevate your manufacturing enterprise to new heights. By harnessing the power of the Internet of Things (IoT), you can seamlessly connect your operation control systems with every stage of production, including the factory floor, goods in production, in transit, and at the customer site. This technology allows you to closely monitor conditions along the production line, predict machine maintenance needs, and prevent downtime by receiving prompt alerts about equipment issues, thereby enhancing overall factory efficiency. By continuously monitoring assets in the field, you can forecast and schedule necessary repairs, leading to heightened customer satisfaction. With a combination of state-of-the-art technology and industry knowledge, this empowers businesses to gain a comprehensive understanding of their current status and offers guidance for improvement.

Nirmalya Enterprise Platform offers a comprehensive solution for managing connected assets and operations seamlessly. Our innovative Connected Shop floor feature utilizes cutting-edge technologies like AI and IoT to replace fragmented systems with efficient processes, promoting enhanced agility and collaboration. This integrated approach empowers manufacturing firms to drive innovation, ensure top-tier product quality, and meet customer requirements cost-effectively and safely.

For further insights on the benefits that enterprises similar to yours are experiencing with the Nirmalya Enterprise platform, please contact us today to discover how our platform can enhance your business operations.