Going from good to smart

Where are you on the journey? Digital transformation in manufacturing is certainly not new but remains a hot topic.

Maybe you started the digitisation journey way back with the installation of a PLC or CNC machine (with CAD/CAM) but have not gone any further. Perhaps you installed an MRP or ERP, and it feels like you ended up with silos of data. Maybe you have integrated an IIoT solution but are disappointed in the results. Do you see value in data and analytics and machine learning (ML) but struggle to justify and deliver a satisfactory return on investment? The digital transformation process can seem complex and confusing, yet it is extremely beneficial when done well. To help you understand and navigate the process, we have outlined a high-level three-stage approach to digital transformation.

1. Create a great factory

To have a ‘smart factory’, you need a ‘really good’ factory. As a baseline, you need to measure and understand your processes, business KPIs and the challenges you face, then analyse these to identify solutions that will maximise your ROI and business benefit.

If you rely heavily on manual resources, consider ways to ease this burden. Repetitive, mundane, and high-risk tasks can often be automated to reduce the need for additional labour or allow a reallocation of existing labour resources for better outcomes. Using visualisation (SCADA) will improve process management with fewer resources than if done manually.

Implement simple OEE/MES solutions to address the challenges experienced with productivity, performance, quality, production costs and compliance. If you haven’t done so, consider using Smart Andon for real-time feedback on production issues; Energy Management for monitoring and managing energy consumption; and Digital LEAN for digitalising your preferred LEAN methodology.

2. Vertical Integration – more advanced MES

If you have most of this in place, you are certainly in a good position to capitalise further on digital transformation. At this point in the journey, it is worth considering more advanced uses of MES and vertical integration. If you have systems such as an ERP, MRP, PLM, or similar, there is a chance they operate as silos. Integrating these systems with MES creates the ‘backbone’ for transformation and provides high-quality data for analytics, leading to significant

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business value. The key is to have as much interoperability as possible. When combined with machine learning (ML) and artificial intelligence (AI) solutions for process improvement, you have a powerhouse for effective change.

3. Horizontal integration

A business at this stage of the journey has done well in improving internal processes. It is now ready to look outside the four walls of its manufacturing operations to claim a competitive advantage using a connected supply chain. The aim is to differentiate yourself in a few significant areas including reducing the costs of raw materials through quality compliance, improving the efficiency of asset and material supply via automated inventory management, and achieving greater speed to market based on demand and customer trend feedback. The key to success will lie in the two-way exchange of information between you and your supply chain using a collaborative approach. Your ‘view’ of the supply chain should be both backwards and forwards, from suppliers to distribution centers to storefronts.

It is important to remember that digital transformation is not simply an engineering project; it is a journey. At Mescon, our goal is to help you be an excellent manufacturer and empower you to move from Good to Smart. If you are not sure where on the digital journey the business is, or you are keen to make a difference but are unsure how to get the best from your current environment, why not have a conversation with us?

Mescon Stand MA425 mescon.com.au

Bilby brings the latest Raise3D Pro 3 and FFF 3D with HyperSpeed Upgrade kit and a whole lot more.

Returning to Melbourne in 2023, Bilby3D will present the Raise3D Pro 3 PLUS large professional FFF 3D printer with impressive 300x300x600mm build volume, fitted with the new HyperSpeed Upgrade kit, allowing you to print at speeds 300-500% higher than before thanks to advanced acceleration and anti-harmonic technology. The smaller E2 and the E2-CF optimised for printing nylon+carbon fibre will also be on the stand.

The Photocentric LC Opus UV open material Resin 3D Printer uses an LCD screen to control light exposure, allowing whole layers to be exposed at a time without any distortion for high accuracy. It continues to impress with it's 310x174x220mm build chamber, though is dwarfed by it's bigger brother, the LC Magna with 510x280x350mm volume. The Opus features Photocentric's patented Vat-Lift technology to reduce peel force, as the vat back edge lifts synchronously with the platform.

Just released from Mayku, UK based manufacturer of Thermoformers, is their Multiplier. This is not just a vacuum former, but a desktop pressure former, allowing thicker materials, up to 5mm, and even higher detail. Forming at 60psi, it delivers an equivalent to 5 tonnes of force to the 400mm diameter forming bed. The Multiplier is packed with sensors feeding the smart controller with information so it can intelligently guide you via with screen interface. It can receive updates and new material profiles via Wifi. Make fully transparent prototypes, detailed final parts and cast complex objects with flexible moulds. Create parts with a high level of detail and accuracy similar to injection moulding at a fraction of the cost.

3D Scanners are becoming more popular for reverse engineering and measurement in the field. The new Einscan HXred bundle includes SolidEdge (Shining3D Version) and Geomagic Essentials. The EinscanHX is a hybrid 3D scanner, featuring rapid LED scanning as well as laser scanning for reflective and dark surfaces. It's colour camera allows texture capture as well as adding tracking by texture to geometry and marker tracking.

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