Building a Smart Factory – Part 2: Defining the 21st-century smart factories

Smart Factories (also known as Connected Factories) have many definitions. One way to define them is a group of technology innovations. When used together, these innovations support consolidated, connected, and flexible manufacturing processes. The processes run manufacturing, supply chain, and related back-office operations.

Smart Factories enable machines and people to make intelligent decisions, which result in automated or human actions. Some definitions include smart factories reaching “self-optimizing operations.” In these cases, the factory continuously adapts to demand and variations in supply. It also corrects processes that exceed tolerances.

Another reason to build smart factories is that employees responsible for monitoring and controlling production lines can do so remotely. They can work with less human attention. Factories can now adapt to the workflows in real-time by machines communicating with other devices and humans.

How would one recognize a smart factory?
Usually, a Smart Factory is defined by its core functions, which include:

Digital connectivity: 
Smart factories use sensors and other devices to collect production equipment data. This data is sent to the Internet of Things (IoT) via specific protocols for storage and further analysis. The insights extracted from the data enable monitoring production, logistics, and product design processes throughout the shop floor facility and beyond. This sensor-driven capability increases the awareness of what is happening at several levels of factory operation. For example, traditionally, vibration sensors provide alarms that indicate when bearings, motors, or machines need to be shut down. Now the deep insights of the data pattern could enable predictive maintenance actions. These actions avoid larger production problems that would occur if the abnormal condition were left unattended. With smart sensors, factory staff members can work with suppliers, partners, and customers more effectively.... This umbrella term includes advanced robots, machine vision, distributed control processes, and drone technologies. Industrial robots detect and avoid people and other unexpected obstacles as they work. Avoiding such common disruptions is a huge advantage. It can prevent production delays and downtime. Ultimately, automation applies intelligence at the factory level. It creates a dynamic production environment, which improves product quality and reliability. Automated processes also involve intelligent agents and other cyber-physical systems. These operate more efficiently and distribute manufactured goods more quickly. This response is to market demand. Smart equipment makes it possible to automate much of what is required to produce smaller manufacturing runs. Minimizing downtime for recalibrating and resetting equipment makes manufacturing more customizable. It helps manufacturers respond more quickly to changing market tastes.Cloud-based data management and analytics: The industrial Internet of Things (IIoT) is the global network of internet-connected, physical objects and devices. These devices are used in the industrial environment based on cloud infrastructure. The IIoT enables these objects to communicate with each other. Additionally, they communicate with nonindustrial, internet-enabled devices and systems.Facility-wide communications and the ability to use manufacturing data is what make factories smart. New technologies are developing and converging to make smart factories possible. Smart factories connect production hardware, processes, and humans with data provided by sensors. These sensors are connected to the Industrial Internet of Things throughout factories and beyond. By combining all parts of the production process, a manufacturer can streamline and speed up building. They can also test products across every platform. In smart factories, all industrial assets are connected in the same facility and between production facilities. At each stage of production, sensors exchange data in real-time. Data analytics applications monitor operations to ensure ideal process performance. The evolution of smart factories is trending towards data-based management cultures and fully autonomous operation. Developing independent operation requires that plant managers change their perspective. They should move from a go-it-alone, problem-solving culture to a monitor-and fine-tune process culture. This type of change is often overlooked and undervalued. Manufacturers need to expect current organizational structures to be a significant obstacle. This is in achieving smart factory design and process goals.