It is essential for manufacturers to recognise the potential that smart factories hold, not just for their own operations but for the broader economy as well, says Parag Kulkarni.

The manufacturing landscape is undergoing a profound transformation driven by the convergence of the Internet of Things (IoT) and advanced connectivity solutions. This evolution, often referred to as Industry 4.0, is reshaping traditional manufacturing processes into smart factories that leverage real-time data, automation, and intelligent systems to enhance key aspects of manufacturing, viz., Operational Efficiency, Productivity, Product Traceability, ANDONs, Mistake-proofing and overall shop-floor visibility. As a leader in industrial automation, Mitsubishi Electric India has been playing a pivotal role in enabling IIoT-driven manufacturing.

Smart factories represent a paradigm shift in manufacturing, where machines, devices, and systems are interconnected through IoT technology. This connectivity allows for seamless communication and data exchange among various components of the manufacturing process. As a result, manufacturers can optimise operations, reduce costs, and respond more effectively to market demands. The integration of IoT devices enables remote monitoring and management, predictive maintenance, asset tracking, and energy management, all contributing to enhanced operational efficiency.

Key components of smart manufacturing

1. Connectivity: The backbone of smart manufacturing is robust connectivity. IoT devices such as sensors, actuators, and controllers are deployed throughout the factory floor to collect ‘real-time’ data on various process parameters like temperature, flow, level, humidity, etc., and status inputs from the target system. This data is transmitted to central systems for analysis and decision-making. To facilitate connectivity, we offer deterministic, high-speed and robust communication in CC-Link IE TSN with up to 1 GBPS bandwidth.

2. Automation: Automation is integral to smart manufacturing. IoT-enabled machines and processes can operate autonomously based on the data they collect. For instance, industrial robots equipped with IoT sensors can perform tasks such as assembly and quality control with minimal human intervention. Also, remote-health monitoring of the robots is another example of Artificial Intelligence used as an add-on function.

3. Data analytics: The big data collected from the connected devices are analysed using advanced analytics techniques including machine learning and artificial intelligence. This analysis provides insights into production processes, identifies trends, and predicts potential issues before they escalate into costly problems. Mitsubishi Electric offers the ‘MaiLab’ – a data science tool for manufacturing improvement, which supports smart manufacturing by integrating AI-driven data analysis into factory operations, enabling manufacturers to achieve higher efficiency, quality, and productivity. It collects and analyses real-time and historical data from industrial devices, automates anomaly detection, and provides actionable insights for predictive maintenance, process optimisation, and quality control. With its user-friendly interface and seamless integration with Mitsubishi Electric's factory automation ecosystem (e.g., PLCs, SCADA, robots), MaiLab simplifies AI adoption, reduces downtime, improves decision-making, and facilitates energy efficiency – key pillars of Industry 4.0 and smart manufacturing. Additionally, users can simply define their problem statement or objectives and apply the datasets in form of XLS data, CSV data, directly from Databases or from Mitsubishi Electric make controllers.

4. Predictive maintenance: Traditional maintenance practices often lead to unpredicted down-time due to routine checks or unexpected equipment failures. With IoT enabled sensors, monitoring machine health in real-time, manufacturers look forward to a transition from preventive to predictive maintenance strategies. IO-Link is a typical interface available for IoT enabled sensors. This proactive approach minimises down-time by scheduling maintenance only when needed.

5. Digital twins: Digital twin technology allows manufacturers to create virtual replicas of a plant-asset. Mitsubishi Electric’s MELSOFT Gemini supports smart manufacturing by providing 3D simulation and digital twin capabilities to visualise, simulate, and optimise production processes. It enables virtual commissioning to test systems before deployment, identifies inefficiencies for process optimisation, and creates real-time digital twins for monitoring and predictive maintenance. By integrating seamlessly with Mitsubishi Electric’s factory automation ecosystem, it reduces costs, minimises risks, and enhances collaboration, driving efficiency and flexibility in manufacturing operations. It can also be combined with MELSOFT Mirror software for line simulation.

Key benefits of Gemini software

a) Effortless Digital Twin Creation: Create digital twins effortlessly using a rich library of over 4,000 pre-defined elements and an intuitive Drag-and-Drop editor.

b) Offline Equipment Simulation: Simulate equipment or machine (asset) behaviour in offline mode without connecting any physical control system (PLC) or actual equipment.

c) Space Optimisation: Optimise shop-floor or manufacturing setup space using the best-fit simulation capabilities of Gemini software.

d) Comprehensive Line Simulation: Achieve detailed line simulation by combining Gemini with Mirror software for a complete package.

Benefits of smart manufacturing

The adoption of smart manufacturing practices offers numerous benefits:

• Increased/Optimised Efficiency: By automating processes and optimising workflows through APQ analysis, manufacturers can significantly enhance production efficiency.
• Cost reduction: Improved resource management leads to lower operational costs. For example, energy management systems can optimise energy consumption across the plants.
• Enhanced Quality Control: Continuous improvement in quality using powerful techniques like mistake-proofing/poka-yoke, first-time right assembly processes, visual inspection using hi-tech 3D vision camera systems, real-time monitoring of process parameters ensures that any deviations from standards are detected early, allowing for immediate corrective actions.
• Flexibility and Customisation: Smart factories can quickly adapt to changing customer demands with intelligent Manufacturing Execution Systems (MES) with tightly integrated Production Planning and Control data with the enterprise systems like SAPR/3, S4/ HANA, ORACLE with bi-directional dataflowin real-time. This flexibility is crucial in today’s fast-paced market environment.
• Sustainability: By optimising resource utilisation and reducing waste through better monitoring and control systems, smart manufacturing contributes to more sustainable production practices.

Challenges in implementing smart manufacturing

Despite its advantages, the transition to smart manufacturing is not without challenges:

1. Cybersecurity risks: As we progress towards smart and connected factories, they also become more vulnerable to cyberattacks. Ensuring robust cybersecurity measures is essential to protect sensitive data and maintain operational integrity. Many companies choose to implement On-Premises IIoT deployment, to reduce the cybersecurity risks.

2. Integration with legacy systems: Many manufacturers operate with legacy systems that may not be directly compatible for upward connectivity. Thoughtful upgrades of such legacy systems can enhance the equipment life with minimum investments.

3. Skill gaps: The shift towards smart manufacturing requires a workforce skilled in advanced technologies such as AI, data analytics, and IoT management. Upskilling existing employees or hiring new talent is necessary for successful implementation. Also passing down the long-acquired skills takes time.

Future trends in smart manufacturing

Looking ahead, several trends are likely to shape the future of smart manufacturing:

• AI-Driven Insights: As AI continues to evolve, its integration into manufacturing processes will provide even deeper insights into operational efficiency and predictive capabilities.

• 5G Connectivity: The rollout of 5G networks will enhance connectivity in smart factories by enabling faster data transmission and supporting a greater number of connected devices.
• Sustainable Practices: Environmental sustainability will remain a priority as manufacturers seek ways to reduce their carbon footprint through smarter resource management.
• Collaborative Robots (Cobots): The use of cobots will increase as they work alongside human operators to enhance productivity while ensuring safety on the factory floor.

Smart manufacturing represents a significant leap forward for the industrial sector, driven by the power of IoT and connectivity solutions. By embracing these technologies, manufacturers can not only improve their operational efficiency but also adapt more swiftly to changing market demands while ensuring sustainability. Mitsubishi Electric India is at the forefront of this transformation, providing innovative solutions that enable manufacturers to thrive in an increasingly interconnected world.

As we move deeper into this era of Industry 4.0, it is essential for manufacturers to recognise the potential that smart factories hold, not just for their own operations but for the broader economy as well. Embracing this revolution will pave the way for a more efficient, responsive, and sustainable future in manufacturing.

Parag Kulkarni is National Sales Lead, Digital Transformation Solutions, Mitsubishi Electric India-FAID. Spearheading Mitsubishi Electric India's digitisation efforts, Parag’s role as Senior Manager involves driving the e-F@ctory program nationally, supporting the digital transformation goals of manufacturing industries. His expertise in requirements and business analysis has been pivotal in establishing numerous successful customer references.