May 2019

www.smartmachinesandfactories.com May 2019 | 13 | smart plastics igus ® Caswell Road Northampton NN4 7PW Tel 01604 677240 Fax 01604 677242 sales@igus.co.uk plastics for longer life ® Industry 4.0: smart plastics eliminate downtimes Intelligent products give a maintenance alert ahead of time and can be integrated into standard predictive maintenance; smart plas- tics allow your equipment to run continuously as well as reducing maintenance costs. igus.co.uk/smart Avoid unplanned downtime 08:11 practice, however, that approach would be unreasonable for most manufacturers, requiring a considerable period of system shutdown and typically over-investment as existing machinery is replaced and the complexity of technology increases virtually overnight. Not only does this make it difficult to manage, but almost impossible to see where upgrades have contributed to ROI. In contrast, taking small and strategic steps to digitalisation can prove more beneficial for most manufacturers. Remember, this is evolution, not revolution. Upgrading to Industry 4.0 in manageable steps not only allows businesses enough time to make well-researched and considered decisions, but also gradually introduces employees to the new technology around them. This step- by-step approach also enables manufacturers to see precisely how digitalisation is adding value to their processes, and by reducing complexity, makes it possible to easily connect other machinery down the line – saving time and money. 2: Getting off on the wrong foot Industry 4.0 is about flexibility – of manufacturing processes, of machinery, of facilities, of people, of outputs. With that in mind, selecting the correct standard at the start of your digital journey is essential, but is a step some machine manufacturers and end users overlook. To be truly flexible, any upgrades need to be able to accommodate change. After all, Industry 4.0 is in constant motion, making change inevitable. For machines, that requires connections which not only meet the standards of today, but also to be easily modified in response to future changes. So when making investments for the future, manufacturers need to be sure their machinery will provide the flexibility it needs for change. 3: A lack of planning In the digitalised factory, data sits at the heart to create an environment of connected manufacturing and continuous improvement. In harnessing that data, sensors are key. Attached to cells, machines or tooling equipment, these sensors measure variables such as temperature, pressure, vibration and power consumption to provide an inside view of the machinery which powers their facility. The problem, however, arises in how that data is evaluated and interpreted. When taking their first steps into the Industry 4.0 arena, manufacturers are often overwhelmed and can fall into the trap of using vast numbers of sensors to collect mass amounts of data. To overcome this, people need to be brought into this automated process. By visualising the data which is being collected, employees can share their expert insights and knowledge to help manufacturers understand what is important to measure – from machine performance through to functions such as logistics and purchasing. Only then can the true impact of digitalisation be seen. 4: Overlooking security As the world around us becomes more digital, cyber attacks become increasingly prevalent. So while Industry 4.0 brings a host of benefits for manufacturers, it can also make them