Digital Transformation in a Time of Crisis
As COVID-19 strikes, all companies in various sectors are facing a huge challenge of sustaining their businesses. People are being forced to make hard decision on whether to close their doors or digitally innovate even further. Article by Makino.
COVID-19 has paved the way for digital transformation as businesses shift operations to cope with office closures, restricted movement and supply interruption.
Digital transformation has always made sense but adoption has been slowed as people deal with some of the overwhelming concepts around Industry 4.0, the sheer size of the task, and struggle to figure out where the value is coming from and where they can find the “digital dividend”.
Now, the needs are compelling and urgent and those that fail to transform will likely be left behind and risk becoming irrelevant and uncompetitive.
Transformation in Manufacturing Industry
To create an ecosystem that is digitally enabled, one must have the ability to model a disruption in real-time, the agility to respond to that disruption, and the resilience to cope with whatever the world has to throw at it.
This is demanded not only by the manufacturers, but also by their customers, inventors, creditors, and insurers. As a result, an extensive digitisation of the shop floor, including its integration with all the other systems, is becoming essential rather than nice to have. It provides the necessary first layer of high-quality data, upon which another layer of insight generation, decision support, and control of production processes—all in real time—must be superimposed. Such systems must become an order of magnitude better than what exists today.
Digital Transformation with Makino
Makino has been actively moving towards the trend of digitalisation. Its facility is designed to meet the growing demand for high-quality products and sophisticated precision engineering capabilities by adopting Industry 4.0 and the principles of Industrial Internet of Things (IIoT).
Despite transforming the facility into a Smart Factory, Makino also acts as a partner which helps their customers to drive them and motivates them towards transformation.
Retool Your Business Processes to Compete in the Global Die/Mould Market
Common practice and misconceptions can lead mould, tool and die owners to conclude that automation offers few benefits to their businesses due to the demands for tight tolerances and one-off or small runs of complex 3D shapes. In today’s competitive global marketplace, with pressures to improve quality and pricing without increasing investment in machines or labour, the time is right to consider taking a production approach.
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Thailand’s Electronics Sector Still A Magnet For Investors Amid Pandemic
The COVID-19 pandemic and the US-China trade friction have failed to slow Thailand’s resilient electronics and electrical (E&E) industry which on the contrary many investors see as a haven, Thailand Board of Investment (BOI) data shows.
In the first nine months of 2020, the number of foreign and domestic companies which applied to invest in Thailand’s E&E sector actually rose to 106 projects, from 94 projects in the same period in 2019, making it by far the most popular sector, totaling over $1.2 billion in investment applications submitted to the BOI.
With a supply chain of some 2,500 companies and 800,000 employees ranging from researchers with doctoral degrees to vocationally trained technicians and experienced assembly line workers, it is the country’s largest manufacturing employer, according to Thailand’s Electrical and Electronics Institute (EEI).
“E&E is fundamental to Thailand 4.0”, said EEI president Narat Rujirat, referring to the innovation-driven growth strategy of Southeast Asia’s second largest economy.
This ambitious vision involves creating a regional hub for futuristic industries including medical devices, electric vehicles, robotics and automation. At its heart is the technological transformation of one of Thailand’s long-established core industries, electrical and electronics, into what is today termed “Smart E&E” and the emergence of the so-called Internet of Things (IOT).
Thailand’s E&E sector has burgeoned into a global powerhouse and is the world’s second largest exporter of computer hard disc drives, air conditioners and washing machines, according to GSB Research, a unit of Thailand’s largest state-owned bank.
In total, Thailand’s E&E industry generates $56.5 billion worth of exports in 2019, or 24 percent of total exports, according Thailand’s Ministry of Commerce and GSB Research.
In addition to a strong supply chain and skilled human resources, Thailand’s attraction for E&E investors also stems from its strategic geographical location at the crossroads of Asia, which has enabled it to become one of the world’s top exporters.
Investors also benefit from privileges offered by the BOI. E&E companies focused on innovation and research and development can receive tax breaks of up to 8 years and other incentives such as renewable smart visas of up to four years for international talent and investors in key sectors such as smart electronics, as well as their families. The BOI also supports companies by helping establish industrial linkage, sourcing of local suppliers and business matching. Many companies have developed strong partnerships with local academic institutions.
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Continuing the Automation Legacy
John Young, APAC director EU Automation, discusses the benefits of bringing legacy control systems into the fourth industrial revolution.
The cyclopic is an electric, foldable bike that’s set to be the most compact on the market. The invention takes inspiration from the Penny Farthing. Its handles are fixed upon the larger front wheel, and the back wheel folds inwards so the bike can fit into a portable bag that rolls along. The cyclopic is designed to offer users with a space-saving, lightweight solution to city travel.
While manufacturers don’t use equipment that has been around as long as the original penny farthing, most facilities do still rely on older equipment in their production lines. As the first generation of factory automation comes to an end, the future of many control systems may seem bleak. In fact, a 2019 survey carried out by Dell Technologies found that 91 per cent of midsize and larger organisations face major hurdles to digital transformation. The notion that these organisations should scrap all their legacy systems in favour of new infrastructure is impractical. Instead, manufacturers should consider how their existing equipment can connect to the Internet of Things (IoT).
Out with the Old?
“The programmable controller’s time was right. It invented itself because there was a need for it, and other people had that same need.” Those are the words of Dick Morley, the father of the programmable logic controller (PLC) as he reflected on his invention, 40 years later. When the PLC was invented in the late 1960s, it was built to give manufacturers better insight into their plant’s processes. This need hasn’t changed very much in subsequent years. Real-time machine control is still a necessity, but the adoption of new technologies means that older PLCs may be lagging behind.
So, are these legacy systems destined for the scrap heap? Not necessarily, they just need to be able to monitor more processes. If we consider the monitoring needs of a variety of industries, it is clear that each one has its own set of requirements. A water utility may be required to monitor the health of its phonelines to make sure they’re working in case of an emergency; while a packaging facility that uses injection moulding may need to retrieve data on the speed of its machines.
While control systems such as the PLC won’t be made redundant any time soon, their functions and capabilities will need to extend in order to manage these increased data requirements.
Smarten Up
Manufacturers may need some support to take their control systems into the future. Modern PLCs often come with an Ethernet interface, which older or less expensive systems do not have. Instead, many legacy systems adopt a sometimes-bewildering range of serial communications and proprietary protocols that lack the interoperability most manufacturers require.
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KUKA Webinar: Embracing Robotic Application In Boosting APEC Economic Performance
In collaboration with Netherlands-Thai Chambers of Commerce (NTCC), KUKA is hosting a webinar as part of the NTCC Industry 4.0 series: “Embracing Robotic Applications in Boosting Economic Performance within APeC” on Wednesday 30 September 2020 from 16:00 – 17:15 (ICT).
This sharing session will emphasise on Industry 4.0 and Smart Manufacturing, Market Intelligence for Robotics and Trends for APeC countries, including case studies, opportunities and challenges. Guest speakers include; Mr. Alan Fam, Chief Regional Officer of KUKA Robotics – APeC, Mr. Neoh Sin Joo, Regional Sales Director of KUKA Robotics – APeC, and Mr. Tawiwat Reongpunyaroj, Chief Executive Officer of KUKA Thailand & Vietnam.
Event details
Date: Wednesday 30 September 2020
Time: 16:00 – 17:15 (ICT)
Platform: Zoom (webinar link will be sent to you after registration is completed.)
Register for this free webinar now!
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NUM Launches Digital Twin Technology For CNC Machine Tools
CNC specialist NUM has launched digital twin technology that enables machine tool manufacturers to reduce their time to market dramatically, by using powerful Industry 4.0 simulation techniques.
Powerful 3D simulation realistically illustrates the dynamic operation of the machine.
Originally known as pairing technology, and first used by NASA in the early days of space exploration, digital twin technology is now rapidly gaining industry acceptance as one of the most cost-effective means of accelerating the development of products, processes and services.
For automation products such as machine tools, a digital twin is a virtual model that uses simulation, real-time data acquisition/analysis and machine learning techniques to allow full evaluation of a machine’s dynamic performance before constructing a physical prototype. The same technology can also be employed for customer presentations, virtual commissioning and operator training purposes – and all well before the actual machine itself has even been built.
NUM offers two versions of digital twin technology, to best suit customers’ needs. Both versions are designed for use with NUM’s, open-architecture Flexium+ CNC platform. One version uses a naked Flexium+ controller and resident virtualisation software running on the system’s industrial PC to simulate the twinned machine automation. The other version uses the actual Flexium+ controller that will eventually be incorporated in the machine, linked via EtherCAT to a standalone PC running specialist high speed hardware simulation software to represent the mechatronics of the twinned machine.
The virtual controller version includes a software development kit for creating the software model of the machine. The model is a standalone PLC program that uses predefined components to simulate individual machine elements, such as sensors, spindles, pneumatic cylinders, etc. It is loaded into the integrated PLC of the Flexium+ controller. The Flexium NCK in the controller executes the NC programs and simulates the changing position values of the machine’s axes. To help users visualise the process, NUM’s package includes the CODESYS Depictor software tool produced by CODESYS GmbH, which is used to produce 3D visualisations from the IEC 61131-3 code created by the simulation.
The other version of NUM’s digital twin technology package accommodates real-time data acquisition and analysis. It is based on the ISG-Virtuous hardware simulation software produced by Industrielle Steuerungstechnik GmbH (ISG). The Flexium+ controller that is intended to be used in the physical machine is connected via an EtherCAT network to a standard PC, and interacts with the simulation software in real-time. The PC acts as the twinned virtual machine – with all simulated, virtual components behaving like real components in terms of their interfaces, parameters and operating modes – to accurately replicate the structure and dynamic performance of the real machine. The movements of the machine are displayed realistically on the PC, using the supplied 3D simulation software.
NUM’s new digital twin technology provides machine tool manufacturers with a very powerful and cost-effective means of reducing their developments costs and accelerating their time to market. The virtual controller version is especially useful for the early development stage of a project, before the CNC system has been finalised, while the real-time hardware simulation version has the advantage that all sequencing (PLC) and motion control (CNC) programs that are created during development can simply be transferred to the real machine as soon as it becomes available.
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ITAP 2020: Forging Ahead With Industry 4.0 In The New Normal
Helping manufacturers build a position of strength to operate in a COVID-safe world remains mission critical for this year’s Industrial Transformation ASIA-PACIFIC – A HANNOVER MESSE EVENT (ITAP) from 20 to 22 October.
The event, in its 3rd edition, comes at a time when business transformation is pivotal to survival, scalability and sustainability. The COVID-19 situation has brought tremendous disruption to all industries and economies, forcing manufacturers and businesses to rethink their business strategies, relook business operations, recalibrate their resources and reskill their workforce. There has never been a more urgent need for a deeper understanding and adoption of Industry 4.0 (I4.0) solutions to emerge stronger in a post COVID-19 world.
Going digital-first for expanded outreach and growth opportunities
Amidst global travel and border restrictions, ITAP 2020 is poised to stage a first hybrid edition yet as it goes virtual with a custom-built interactive platform and physical bolt-on activities to optimise engagement and knowledge transfer opportunities beyond physical event barriers of time, language and geography. With ‘Forging Ahead with Industry 4.0 In the New Normal’ as the driving theme, ITAP 2020 devises innovative ways in the virtual space for stakeholders to continue to explore I4.0 solutions to aid and complement business operations.
“Business survivability and transformation are the two biggest challenges our customers in the manufacturing industry are now facing. More than just about increasing productivity, it is about finding new opportunities to urgently accelerate and support their agility and responsiveness,” said Mr Aloysius Arlando, CEO SingEx Holdings Pte Ltd, who co-organises ITAP. “In these trying times, establishing a hybrid platform will allow the community to easily collaborate on feasible solutions, optimise engagement and knowledge transfer, and find new growth opportunities.”
Heeding the call for bite-sized learning
This will not be the ITAP community’s first experience with virtual engagement sessions this year. Since May, SingEx Exhibitions has held regular virtual sessions under the ITAP Connect series, comprising interactive web engagement sessions to enable the community to continue interacting despite not being able to meet in person, as well as share case studies and learnings across borders with solution providers, domain experts and one another.
The sessions will also continue in the lead up to the main engagement from 20 to 22 October, when all learning and networking engagements will then be hosted on a dedicated virtual interactive platform. Registered participants will gain access to round-the-clock content on this platform with personalised recommendations of solutions and products, targeted networking and lead generation opportunities. The platform will also provide companies with a one-stop portal to showcase their solutions and conduct demonstrations for their products and services fashioned in the spirit of ITAP’s signature Learning Journey Approach and thematic zones – Gateway to I4.0, Robotics Experimental Experience Zone, the Collaboration Lab, as well as the Digital Sandbox. These will be complemented by physical bolt-on activities at specific locations with safety measures put in place to provide first-hand access to latest innovations, as well as maximize showcasing and networking opportunities for industry stakeholders in Singapore.
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Mühlhoff Starts Production On Large Presses After Fire With Help From Schuler Service
What a shock: at the turn of the year an arsonist sets fire in the production halls of Mühlhoff Umformtechnik on its site at the border with the Netherlands. The column of smoke can be seen for miles, resulting in damage in the high double-digit million euro range, including loss of production. But just six months later, the automotive supplier can start up again with its large presses: Schuler Service has already repaired two of the four damaged presses, and a new 2000-ton system from the TSD series is scheduled to go into operation in early 2021.
Mühlhoff managing director Markus Wermers had only been in office for three months when the fire broke out: “Just a few days later, Schuler Service was on site with nine employees.” Together, the decision is made to first repair the machines with 800 and 1,300 tons of press force that were only a few years old. In order to do this, the specialists have to replace the entire electrical and control system, and also remove several mechanical parts in order to have removed the contamination with soot and extinguishing water manually.
Mühlhoff can send some of the dies to the Schuler site in Erfurt so that parts production can continue there on a 1,600-ton press with TwinServo technology. “Other suppliers have also stepped in to process our orders,” recalls Wermers, who is currently running the business from a container in the parking lot – the administration building was also damaged by the major fire. He is grateful to his competitors for being able to continue to supply customers from the automotive industry with parts: “Everyone has helped so that everything can now gradually start up again.”
Mühlhoff Umformtechnik goes even further and is also investing in a new press from the TSD series with ServoDirect technology and 2,000 tons of press force. In addition, the system features the camera-based system “Visual Die Protection” and the “IIoT Connector” from Schuler, which enables numerous other Industry 4.0 functions such as process monitoring or predictive maintenance. “This means that we are optimally positioned for the future,” says production and project manager Christian Pennekamp with conviction. Pennekamp has been responsible for the configuration and project planning of the complex press systems at Mühlhoff for more than ten years.
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Schuler Appoints New Head Of Service
Torsten Petrick has been appointed as the new Head of Schuler Service as of July 1, 2020. Previously, he built up and managed the company’s global procurement. Graduating from the Technical University of Braunschweig and until 2008, Petrick worked in various management positions in the Maintenance, Repair and Overhaul (MRO) division of MTU Aero Engines AG. Graduating from the Technical University of Braunschweig
“The service is available to customers around the world around the clock to ensure the productivity and safety of both Schuler systems and third-party products,” emphasises Petrick.
Digital solutions are now intended to further improve the flexibility and agility of the Schuler Service. With the camera-based “Visual Die Protection” or the “IIoT Connector” for presses in the era of Industry 4.0, Schuler offers several products for networking forming technology.
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Process Efficiency in Focus
For the last few years, process efficiency has been one of the hottest industrial topics, as well as one of the pillars of the Industry 4.0 paradigm. Article by Gianfranco Gotter, Salvagnini Group.
Salvagnini offers a configurable system with store-towers and automatic loading, unloading, separation and stacking connections, which can be integrated with other technologies downstream, such as the panel bender, to machine a single batch, or JIT with small or very small sized batches.
When talking of combined sheet metal machining technologies, we tend to assess productivity only in terms of the production cycle time. But the industry has changed: flexibility and efficiency, of both individual machining stations and within the production process, are fundamental requirements for managing increasingly small batches and high code rotation indexes. Not by chance, for the last few years, process efficiency has been one of the hottest industrial topics, as well as one of the pillars of the Industry 4.0 paradigm.
Processing speed and flexibility are the factors leading to the choice of a combined system. But we have to consider at least four other decisive factors: the quality expected, the geometries of the parts being machined, the possibility of complying with lean production principles, and the automation options available.
While quality is an intuitive concept, to assess part geometries, lean production and system automation options, we have to look more closely at their meanings.
Part Geometries
Rather than talking of traditional and new fields of application, it is perhaps more correct to divide the combined market into two macro-groups according to customers’ final product features, and the geometries of the parts to be produced. In the first group, we find companies that manufacture not particularly complex but highly configurable geometries.
In this context, the combined technology is interesting, because it allows two activities to be condensed into a single process. In a traditional production context, these would be two separate and consecutive activities—and here, a number of inefficiencies may occur: availability of the subsequent machining station and the operator, handling of semi-finished parts, process errors, waiting times linked to tool changes, and so on. In this sense, the combined system demonstrates all its flexibility.
The second group, on the other hand, includes companies that manufacture products consisting of parts which, due to their design and functional characteristics, require machining that cannot be done on a conventional punching machine but require technology that overcomes the limits of the laser to obtain, for example, forming operations.
In this case, too, the winning feature is the combination, the sum of the two punching and laser cutting activities. Not so much with a view to flexibility as to process optimisation and the availability of two different technologies in a single system. This group generally includes younger customers who machine parts for the IT, electronics, gaming, telecommunications, medical, automotive and aerospace sectors.
Compliance with Lean Production Principles
When it comes to lean production, I think above all of the possibility to reduce stocks, waiting times and activities with low added value. As an example, the hidden costs of intermediate, often superfluous handling can reach surprising levels. But I also think of activities like separating parts from the skeleton, or moving parts from one work station to the next: these low-added-value activities require time and labor. They are manual operations which also imply risks: for example, in contexts with a medium-high production mix and medium-large batches, damaged or lost parts are not rare.
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