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Smart Manufacturing Quality Automation

Manufacturers have long embraced the concept of continuous improvement and innovation. In that spirit, what better way to kick off 2019 than by looking to see what the next year has in store for manufacturing? Smart Manufacturing Quality Automation 

Over the past few years, it has been impossible to escape headlines about the Industrial Internet of Things (IIoT)/Industry 4.0. New models for technology-enabled manufacturing have already moved into the implementation phase at many of the world’s top manufacturers.Smart Manufacturing Quality Automation 

One of the hallmarks of smart, connected manufacturing is elevating the role of humans in decision-making processes, and allowing machines to make more decisions in cases where machines are faster and sometimes more capable. Machine decisions are enabled by analyzing data from an ever-increasing array of sensors and production data.

Integrating data and analytics from production equipment with design, engineering and continuous improvement in manufacturing leads to faster optimization of production and new product design. We learn what works, what breaks, what customers love and loathe, and when products need to be repaired or retired. Smart Manufacturing Quality Automation 

Better feedback loops result in better products and production processes, enabling us to better serve customers. Sounds like the makings of some solid New Year’s resolutions:

1) Collect data everywhere.

2) Learn things from it.

3) Design better products.

4) Produce them more intelligently.

5) Rinse and repeat — and do it even smarter this time.

But let’s get more specific. Here are three ideas to consider as you lay out priorities and plans for the year ahead. Smart Manufacturing Quality Automation 

Access and Analytics with Real Time Data is Proving its Value to the Enterprise

Data transparency helps manufacturers improve quality and customer satisfaction. Streamlining audit and regulatory burdens, enhancing the accuracy and accessibility of track and trace data, and ensuring quality from raw materials to packaging – all of these critical benefits come from collecting and integrating data in real time, at scale.

Another aspect is delivery data. Today, when you buy products on Amazon, you go online, order a product and receive an expected delivery date. If there’s any delay, they let you know of the change. They even alert you as soon as the product arrives. Retail shoppers worldwide have grown to love tracking their packages online. Unfortunately, it doesn’t usually work that way in manufacturing. The ability to see where the product is in the line and when it’s going to ship would be huge.Smart Manufacturing Quality Automation 

Over the past five years, new IIoT technology and the cloud have led to the development of a modern Manufacturing Execution Systems (MES) that can track and consolidate critical manufacturing data in real time, delivering new levels of visibility across the global supply chain.Smart Manufacturing Quality Automation 

With a cloud-based MES platform, data generated throughout the manufacturing and testing process is converted into a virtual representation of the factory and production. This provides supply chain managers and operations executives with access to a digital factory floor via laptop, with a real-time view into status at product, workstation, production floor, plant, regional and global levels. The system can monitor yield, throughput, work-in-progress (WIP), labor efficiency and productivity against pre-defined targets. More and more companies have implemented this technology in production over the last few years.Smart Manufacturing Quality Automation 

This real-time visibility not only empowers executives with a clear understanding of what’s happening in their factories, it also instills a greater sense of accountability among workers to address developing conditions before they are automatically escalated to factory management.Smart Manufacturing Quality Automation 

This technology can also be extended beyond a manufacturer’s own operations to third party suppliers that agree to use it, providing insights into the status of their operations and component availability.Smart Manufacturing Quality Automation 

Regulatory Scrutiny Will Drive Deployment of Technology to Improve Quality in the Factory 

Automotive and medical devices have become highly sophisticated in both functionality and manufacturing complexity. They must meet strict compliance requirements, with manufacturers having to track every component, piece of manufacturing equipment, and operator action for every device serial number, throughout the manufacturing process.

Emerging developments in manufacturing systems, machine-to-machine (M2M) communications and the cloud are helping to efficiently “mistake-proof” complex production processes, preventing some of the most common causes of manufacturing errors. And, should a manufacturing issue be uncovered later, these new systems can quickly and effectively isolate products that must be recalled.

In an increasing number of factories now, all equipment, materials and operator actions are scanned via bar code systems connected to the cloud MES platform, enforcing compliance at every step. This ensures the highest level of quality and predictability because processes are pre-programmed. Replication in the cloud validates all activity, ensuring compliance.Smart Manufacturing Quality Automation 

If a product fails an inspection or a test, it is routed out of the main process flow and repaired. It is then reinserted back at the point before the failure occurred to ensure it passes the test it originally failed.

Several companies have now connected some or all their manufacturing equipment to a local or cloud network. This includes bar code scanners and label printers at individual workstations and operator badge scanning.Smart Manufacturing Quality Automation 

With this connectivity and the right programming, these smart manufacturing systems, and the data running through them, result in a “forced quality framework” that eliminates some of the most common production errors.

M2M, the Cloud, and Industry 4.0 Will Facilitate Use of Automated Warehouses for Improved Productivity

Large electronics manufacturers may build thousands of products, such as printed circuit board assemblies, every hour. Keeping surface mount technology (SMT) lines fed with components is critical. Running out of materials triggers immediate downtime, hurting productivity, and resulting in a significant financial impact to the manufacturer.

Traditionally, technicians would monitor SMT equipment to see when materials are running low. Now, companies are implementing closed loop systems to ensure all required components are delivered to production at the right time — leveraging cloud-based MES solutions, M2M connectivity and Machine-to-Human communication.

In some factories we work with, an SMT machine automatically sends a signal to the MES when a component needs to be replenished; the MES in turn forwards it to the automated warehouse system. The system prioritizes the order, and the operator locates the component in the warehouse and triggers the replenishment procedure in the inventory management system.Smart Manufacturing Quality Automation 

The component is then placed at a collection station and an autonomous guided vehicle (AGV) collects and transports it to the SMT line where it is needed. When the AGV leaves the stockroom, the technician is alerted via text so that he or she is ready at the SMT line to load the material when it arrives at SMT line.

This sort of process, relatively simple when the right data connections are in place, minimizes line down situations, and enables “automated backflushing” of components for better materials and inventory management. These capabilities clearly benefit supply chain and inventory management, and can be programmed to fit specific shop floor scenarios.

Here’s to Applying Technology the Right Way in 2019, for Smart Manufacturing

For many manufacturers, change equals risk. Disruption in their supply chain or factories can cost millions, and also impact a brand or a company’s reputation.

Given this, many manufacturers are understandably reluctant to embrace far-reaching changes to their traditional industrial infrastructure and processes. However, manufacturers can start down this path by resetting expectations and asking their personnel to think differently. With the three examples described above, we’ve seen the power of new, but now proven manufacturing systems.

This technology has been implemented by some companies already, and presents an opportunity for others in 2019. Smart Manufacturing Quality Automation 

The exercise of making New Year’s Resolutions is really just about pausing to reflect, re-center and make a plan for moving forward. Leverage new technology as a driver for change. And don’t forget to ask your best suppliers and partners about their new tactics and innovations. Smart Manufacturing Quality Automation 

Everyone – including executive teams – must recognize that the path to digital manufacturing is going to be different than previous operational changes.  In the factory of the future, technology and I.T. are as vital as continuous improvement.

Srivats Ramaswami is CTO at 42Q.

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Industry 4.0 Automotive Supply Chain

When it comes to the automotive industry, innovation isn’t anything new. A rich history of ideation – including Alfred P. Sloan Jr.’s commitment to new concepts such as automotive styling and Henry Ford’s introduction of the assembly line – defines an industry in which change occurs more often than not.Industry 4.0 Automotive Supply Chain

The latest in a long series of new developments is poised to be delivered by Industry 4.0, or the fourth industrial revolution. Made popular in the manufacturing arena, Industry 4.0 is ready to reshape the automotive industry. From smaller equipment to a more dynamic supply chain, see what changes are on the horizon.

More Efficient Equipment

Dreams of driverless vehicles are decades old. But with the help of Industry 4.0, those fantasies are turning into reality. Automotive giants such as Ford and GM plan on leveraging Industry 4.0 to deliver cars without gas pedals or steering wheels as early as 2019. Although time will tell whether such proclamations come to fruition, there’s no denying the difference Industry 4.0 is already making in the automotive supply chain.

Among the most immediate impacts of Industry 4.0 is an uptick in automation. Rather than requiring workers to shadow a piece of equipment throughout their shift, suppliers can dedicate their time toward more immediate needs. If an emergency arises, for example, workers can have confidence that automated equipment will get the job done.

In the same way worker efficiency is expected to increase with Industry 4.0, equipment itself may become easier to implement. The mining industry has made use of automation from Industry 4.0 by reimagining what’s necessary. In fact, IoT-controlled vehicles are being designed without a cockpit to free up space. The best part? No dip in performance. Automotive manufacturers looking to maximize their factory floor should consider making similar use of automation. By weeding out what’s no longer necessary, manufacturers stand to drive greater efficiency.Industry 4.0 Automotive Supply Chain

Greater Connectivity

Businesses are always looking to back their decisions with data. According to research from Forrester, 74 percent of firms want to be data driven. Just 29 percent, however, know how to turn analytics into action. That’s where Industry 4.0 can make its presence felt.

By enhancing connectivity between every part of the supply chain, Industry 4.0 will hasten the transition from a linear structure to one that’s more responsive. Instead of operating independently, everyone along the supply chain can adapt based on customer demand. Say, for example, an in-car infotainment system is selling more quickly than expected. Stakeholders can leverage that information to modify production plans on the fly and ultimately increase efficiency.Industry 4.0 Automotive Supply Chain

Better yet, time to market also figures to decrease. Access to customer engagement data at every point in the supply chain helps eliminate some of the mystery around new features. Rather than guessing what sales might look like months in advance, stakeholders can use the data made available through a dynamic supply chain to determine which infotainment systems are in high demand and which should hit the shelf. Options that are no longer relevant can be substituted throughout the supply chain in favor of those that are selling faster.Industry 4.0 Automotive Supply Chain

Lower Production Costs

From dashboard selections to the steering wheel, consumers have come to expect full control over what ends up in their vehicles. While it may seem like the norm, this era of customized cars is still evolving. For much of the automotive industry’s early history, there haven’t been too many options on the table. Just take a look at Ford’s Model T. One engine type and color was all that customers could choose from. While customization is bound to increase customer satisfaction, greater costs may come with it.

To meet the needs of each customer without blowing past their budget, stakeholders throughout the automotive supply chain can leverage Industry 4.0. Greater insight into the most popular combination of features makes it easier to allocate resources accordingly. If, for example, a new navigation system along with a specific set of wheels see a significant spike in sales, stakeholders can spend more time and money on keeping those features in stock rather than developing other selections. In the event that a customer wishes to purchase a feature that doesn’t happen to be among the top sellers, Industry 4.0 technologies like 3D printing can slash production costs.

With more distribution partners on their way, competition in the automotive industry will continue to grow. Suppliers can stand out from the crowd by turning their attention toward customization options that consumers want. Instead of spending thousands of dollars on a wide range of selections, suppliers should focus their production efforts on options that matter most. As spending decreases, so may prices.Industry 4.0 Automotive Supply Chain

Change is coming to the automotive supply chain – and Industry 4.0 is a big reason why. Stay one step ahead of the competition by keeping an eye out for smaller, more efficient equipment, a dynamic supply chain structure and increased savings. All of which Industry 4.0 is set to deliver to the automotive supply chain.

George Whittier is the chief operating officer at Morey.

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Developing Countries Industry 4.0

Developing Countries Industry 4.0
Developing Countries Must Better Prepare for Industry 4.0, Expert Says

Developing countries must step up efforts and implement better strategies to prepare for the impact of increased automation and the implementation of smart technologies in Industry 4.0, a technology expert said. (Antara Photo/M. N. Kanwa)

By : Sheany

Jakarta. Developing countries must step up efforts and implement better strategies to prepare for the impact of increased automation and the implementation of smart technologies in Industry 4.0, a technology expert said on Friday (26/01).

Industry 4.0, or the Fourth Industrial Revolution, involves the use of advanced technologies, including cloud computing, cognitive computing and the Internet of Things (IoT), which will transform people’s personal and professional lives.

Many parts of the developing world currently do not possess adequate manufacturing capacity and rely on cheap labor to attract foreign investment.

However, the emergence of Industry 4.0 has led to many companies moving their manufacturing facilities from developing countries and bringing it back to their own countries. Developing Countries Industry 4.0

“What this is going to mean, is that many of these emerging nations, which are already struggling with manufacturing and relying heavily on outsourced works, are going to fall even further behind,” Krishnamurthy Ramanathan, a former director of the Asian and Pacific Center for Transfer of Technology (APCTT), said during a panel discussion in Jakarta.Developing Countries Industry 4.0

As countries with powerful manufacturing capabilities, such as China, become more powerful, developing countries must become more proactive to not be adversely affected by it, Ramanathan added.Developing Countries Industry 4.0

For countries such as Indonesia, the topic is extremely relevant, especially considering that experts have pointed out the archipelago’s unpreparedness to embrace the Fourth Industrial Revolution due to a shortage of skills to compete in the digital age.

Developing nations must therefore consider preparing for the disruptive changes that will likely accompany a full transition to Industry 4.0, to avoid an even worse disequilibrium than what is already becoming a greater challenge in a changing world.

Ramanathan said think-tanks can play an active role in bringing these emerging issues to light as part of an effort to better prepare countries to become useful partners to multinational, advanced companies currently operating across the globe.

The need to become more proactive is even bigger, he added, because many of these countries have responded to the issue in a reactive way.

“Think-tanks should emphasize that … to make policy makers in the region understand that it is important that they address these technological issues effectively,” Ramanathan said.

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Plastic petrochemicals automotive industry 4.0 28-12-2018

-China – Polyethylene Terephthalate

PET and its begins the new year downhill.

PET Bottle grade export 990/1,020 $/ton – PET Bottle grade domestic market 7,750/7,850 yuan/ton – PET Filament grade SD domestic market 7,600/7,750 yuan/ton – PET Filament grade BR domestic market 7,600/7,850 yuan/ton

PTA Taiwan 810/825 $/ton – PTA domestic market 5,850/6,000 yuan/ton – MEG $ 615/630 $/ton – MEG domestic market 5,000/5,150 yuan/ton – PX Korea 9,00/920 $/ton

POY 150D/48F  domestic market 7,900/8,000  yuan/ton – DTY 150D/48F  domestic market 9,950/10,050  yuan/ton – PSF domestic market 8,850/8,950  yuan/ton

Plastic petrochemicals automotive industry 4.0

The company operates in the field of flexible and wearable organic electronics, also single-use, to develop devices to be integrated into clothes and fabrics while keeping intact its mechanical properties or new generation batteries.
In the next few years the development of new electronic products will be based more and more on eco-sustainable organic materials such as bioplastics: for this reason Bio-on, listed on the Aim on the Italian Stock Exchange and active in the high quality bioplastic sector, has established Eloxel, a company who owns with Kartell, both participate with 50%. Research in this field has already been carried out in the Bio-on laboratories for two years and during this year the first worldwide patents based on bioplastic, natural and 100% biodegradable in the field of new batteries and eco-compatible piezoelectric materials were deposited .
Plastic petrochemicals automotive industry 4.0

-Crude Oil Prices Trend

Plastic petrochemicals automotive industry 4.0

-Smart Manufacturing in 2019: Customer Satisfaction, Quality, Traceability and Warehouse Automation Top Trends

Manufacturers have long embraced the concept of continuous improvement and innovation.

In that spirit, what better way to kick off 2019 than by looking to see what the next year has in store for manufacturing? Smart Manufacturing Quality Automation

Over the past few years, it has been impossible to escape headlines about the Industrial Internet of Things (IIoT)/Industry 4.0.

New models for technology-enabled manufacturing have already moved into the implementation phase at many of the world’s top manufacturers.

Plastic petrochemicals automotive industry 4.0

-Developing Countries Must Better Prepare for Industry 4.0, Expert Says

Jakarta. Developing countries must step up efforts and implement better strategies to prepare for the impact of increased automation and the implementation of smart technologies in Industry 4.0, a technology expert said on Friday (26/01).

Industry 4.0, or the Fourth Industrial Revolution, involves the use of advanced technologies, including cloud computing, cognitive computing and the Internet of Things (IoT), which will transform people’s personal and professional lives.

Plastic petrochemicals automotive industry 4.0

-What Industry 4.0 Means For the Automotive Supply Chain Industry 4.0 Automotive Supply Chain

When it comes to the automotive industry, innovation isn’t anything new. A rich history of ideation – including Alfred P. Sloan Jr.’s commitment to new concepts such as automotive styling and Henry Ford’s introduction of the assembly line – defines an industry in which change occurs more often than not.Industry 4.0 Automotive Supply Chain

The latest in a long series of new developments is poised to be delivered by Industry 4.0, or the fourth industrial revolution.

Made popular in the manufacturing arena, Industry 4.0 is ready to reshape the automotive industry. From smaller equipment to a more dynamic supply chain, see what changes are on the horizon.

Plastic petrochemicals automotive industry 4.0

-Jharkhand CM inaugurates 1st unit of Arvind Smart Textile27

Jharkhand chief minister (CM) Raghubar Das has inaugurated the first unit of Rampur Arvind Smart Textile as part of Arvind’s expansion plans. The garment manufacturing unit set up in Ranchi with an annual capacity of 16 million, will create 7,500 job opportunities. Meanwhile, the company has also extended production to Gujarat and Andhra Pradesh.

The locals are being trained through various skill development programmes to be well-equipped for the upcoming employment opportunities, said Das.

Plastic petrochemicals automotive industry 4.0

-Impact of US-China trade dispute on oil is starting to fade

Following the deal struck between US President Donald Trump and his Chinese counterpart, Xi Jinping, at the G20 summit at the start of this month, China is reportedly close to resuming imports of US crude oil.

Before the two countries entered a trade dispute, China was the world’s major importer of US shale oil, and commentators suggest that the Xi-Trump deal was, in part, an attempt by China to avoid tariffs being imposed on commodities including crude oil imports.

Plastic petrochemicals automotive industry 4.0

-Russia Blames Fed Interest Hike For Low Oil Prices

It seems that the Federal Reserve can’t get a break. For months, President Trump has been increasingly criticizing the Fed’s policy of incrementally increasing interest rates, a near-unprecedented move for an American president.

After the most recent Fed move to hike interest rates by a quarter of a percentage point last week, Trump tweeted on Monday that the Fed was the “only problem our economy has.”

Plastic petrochemicals automotive industry 4.0

-Oil market volatility seen continuing into the New Year

Energy analysts believe oil market volatility will continue until the build-up in U.S. crude stockpiles reverses.

U.S. crude fell to an 18-month low on Monday, only to post its best one-day performance in more than two years on Wednesday.

The oil market is under the thrall of macroeconomic factors that are weighing on the stock market and raising questions about crude demand in 2019.

Plastic petrochemicals automotive industry 4.0

-OUTLOOK ’19: Chems may face more tariffs in US, China trade war

Chemical companies could facemore trade barriers and tariffs if the US andChina fail to reach some kind of agreement thataddresses their trade grievances.

In 2018, the USintroduced tariffs on a range of Chineseimports.

For each of the three rounds, China hasresponded in kind, targeting chemicals andagricultural products.

US farmers are especially dependent on China asa destination for their crops, and the tariffscould reduce their income.

Farmer income is among the biggest factors indetermining demand for agrochemicals andfertilizers. When farmer income declines, salesof these products often follow.

Plastic petrochemicals automotive industry 4.0

-Formosa expects US cracker start-up, PE commercial ops in H22019

Formosa intends to achieve “steady state commercial operations” at its twonew polyethylene (PE) plants in Point Comfort,Texas during the second half of 2019, theproducer said on Wednesday.

Its third olefins plant at Point Comfort isunder construction, and “gas feed” is expectedalso in the second half of 2019. The crackerwill have a capacity of 1.25m tonnes/year.

Forthe PE plants, one will have a capacity of400,000 tonnes/year of low density PE (LDPE).The other will be able to produce both highdensity PE (HDPE) and linear low density PE(LLDPE), with a combined capacity of 400,000tonnes/year.

Plastic petrochemicals automotive industry 4.0

-Brazil’s November biofuels output remains resilient on year

Brazilian production of sugarcane-based ethanol and biodiesel remained strong in November despite the end of the harvest season, according to data released Thursday by the National Petroleum Agency, or ANP.

Sugar mills produced 2.24 billion liters of ethanol in November, an increase of 2.1% from 2.19 billion liters in November 2017, reflecting 2018’s robust sugarcane crush, the ANP said. November’s ethanol production, however, was down 31.8% from 3.28 billion liters in October, the ANP said.

Plastic petrochemicals automotive industry 4.0

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