BASF 3D Printing Solutions exhibits new brand for industrial additive manufacturing solutions at Formnext 2019

TOM WALKER| November 12, 2019
BASF 3D PRINTING SOLUTIONS EXHIBITS NEW BRAND FOR INDUSTRIAL ADDITIVE MANUFACTURING SOLUTIONS AT FORMNEXT 2019
BASF 3D Printing Solution will be exhibiting an expanded product range and a new brand presence at Formnext 2019. With the introduction of its new Forward AM corporate brand, BASF continues to pursue its goal of driving industrial scalability at the next phase of additive-based manufacturing.

Spotlight

JWC Environmental

JWC Environmental, a Sulzer Company, is a global leader in solids reduction, separation and removal systems for customers in a broad range of municipal and industrial applications. Wastewater treatment plants, food processors, oil refineries, waste to energy producers, consumer goods manufacturers, airports, correctional facilities and agricultural operations are just some of the many areas that have relied on JWC’s technologies for over 45 years to run efficient and compliant operations.

OTHER ARTICLES

Lessons Learned in Electronics Transforms Other Discrete Manufacturing Operations

Article | May 10, 2021

Jason Spera, picture left, recently shared his vantage of the changes for factory floor automation in 2021. Jason is CEO and Co-Founder, Aegis Software. Spera is a leader in MES/MOM software platforms for discrete manufacturers with particular expertise in electronics manufacturing. Founded in 1997, today more than 2,200 factory sites worldwide use some form of Aegis software to improve productivity and quality while meeting regulatory, compliance and traceability challenges. Spera's background as a manufacturing engineer in an electronics manufacturing company and the needs he saw in that role led to the creation of the original software products and continue to inform the vision that drives Aegis solutions, like FactoryLogix. He regularly speaks on topics surrounding factory digitization, IIoT, and Industry 4.0. Contact Jason on LinkedIn.

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Scaling, Optimizing & Pivoting with Smart Manufacturing Industry 4.0

Article | January 20, 2022

A smart factory that leverages Industry 4.0 concepts to elevate its operations has long been a model for other industries that are still figuring out how to travel the digital manufacturing route. Smart manufacturing technology is all you need to know if you're looking to cash in on this trend. “Industry 4.0 is not really a revolution. It’s more of an evolution.” – Christian Kubis In this article, we'll look at the advantages that many smart factory pioneers are getting from their smart factories. In addition, we will look at the top smart factory examples and understand how they applied the Industry 4.0 idea and excelled in their smart manufacturing adoption. Industry 4.0 Technology Benefits Manufacturing Industry 4.0 has several benefits that can alter the operations of manufacturers. Beyond optimization and automation, smart manufacturing Industry 4.0 aims to uncover new business prospects and models by increasing the efficiency, speed, and customer focus of manufacturing and associated industries. Key benefits of Manufacturing Industry 4.0 in production include: Improved productivity and efficiency Increased collaboration and knowledge sharing Better agility and adaptability Facilitates compliance Improved customer experience Reduced costs and increased profitability Creates opportunities for innovation Increased revenues World Smart Factory Case Studies and Lessons to Be Learned Schneider Electric, France SAS Schneider Electric's le Vaudreuil plant is a prime example of a smart factory Industry 4.0, having been regarded as one of the most modern manufacturing facilities in the world, utilizing Fourth Industrial Revolution technologies on a large scale. The factory has included cutting-edge digital technology, such as the EcoStruxureTM Augmented Operator Advisor, which enables operators to use augmented reality to accelerate operation and maintenance, resulting in a 2–7% increase in productivity. EcoStruxureTM Resource Advisor's initial deployment saves up to 30% on energy and contributes to long-term improvement. Johnson & Johnson DePuy Synthes, Ireland DePuy Synthes' medical device manufacturing plant, which started in 1997, just underwent a multimillion-dollar makeover to better integrate digitalization and Industry 4.0 smart manufacturing. Johnson & Johnson made a big investment in the Internet of Things. By linking equipment, the factory used IoT technology to create digital representations of physical assets (referred to as “digital twins”). These digital twins resulted in sophisticated machine insights. As a result of these insights, the company was able to reduce operating expenditures while simultaneously reducing machine downtime. Bosch, China Bosch's Wuxi factory's digital transformation uses IIoT and big data. The company integrates its systems to keep track of the whole production process at its facilities. Embedding sensors in production machinery collects data on machine status and cycle time. When data is collected, complicated data analytics tools analyze it in real-time and alert workers to production bottlenecks. This strategy helps forecast equipment failures and allows the organization to arrange maintenance ahead of time. As a consequence, the manufacturer's equipment may run for longer. The Tesla Gigafactory, Germany According to Tesla, the Berlin Gigafactory is the world's most advanced high-volume electric vehicle production plant. On a 300-hectare facility in Grünheide, it produces batteries, powertrains, and cars, starting with the Model Y and Model 3. For Tesla, the goal is not merely to make a smart car, but also to construct a smart factory. The plant's photographs reveal an Industry 4.0 smart factory with solar panels on the roof, resulting in a more sustainable production method. On its official website, Tesla claimed to use cutting-edge casting methods and a highly efficient body shop to improve car safety. Tesla's relentless pursuit of manufacturing efficiency has allowed them to revolutionize the car industry. Haier, China The SmartFactoryKL was established to pave the way for the future's "intelligent factory." It is the world's first manufacturer-independent Industry 4.0 production facility, demonstrating the value of high-quality, flexible manufacturing and the effectiveness with which it can be deployed. The last four years, SmartFactoryKL has been guided by particular strategic objectives that drive innovation; the aim is to see artificial intelligence integrated into production. Two instances of AI-driven transformations include an "order-to-make' mass customization platform and a remote AI-enabled, intelligent service cloud platform that anticipates maintenance needs before they occur. Final Words Enabling smart manufacturing means using the latest technology to improve processes and products. The aforementioned smart factory examples are industry leaders and are thriving by implementing Industry 4.0 technology. Small and medium-sized enterprises (SMEs) may use these smart factory examples to learn about the adoption process, challenges, and solutions. Industry 4.0 is aimed at improving enterprises and minimizing human effort in general. So adopt the smart factory concept and be productive. FAQ What is the difference between a smart factory and a digital factory? The digital factory enables the planning of factories using virtual reality and models, whereas the smart factory enables the operation and optimization of factories in real time. Where does Industry 4.0 come from? The term "Industry 4.0" was coined in Germany to represent data-driven, AI-powered, networked "smart factories" as the fourth industrial revolution's forerunner.

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Why Manufacturing Companies Must Consider Business Intelligence

Article | December 14, 2021

Do manufacturing businesses require Business Intelligence (BI)? The answer is YES. Manufacturing is one of the most data-intensive businesses, producing massive amounts of data ranging from supply chain management to shop floor scheduling, accounting to shipping and delivery, and more. All of this information would go to waste if not properly categorized and utilized. Scrutinizing and analyzing your data with business intelligence will help you become a more efficientand productive organization. Your organized data can show you where the gaps or inefficiencies are in your manufacturing process and help you fix it. Many companies simply are not willing to change or think they are done once they make a change. But the truth is technology, consumer demands, the way we work, human needs and much more are constantly changing. Michael Walton, Director, Industry Executive at Microsoft BI has the potential to improve the operations of an organization and transform it into an organized one. According to Finances Online research, more than 46% of organizations are already employing a BI tool as a significant part of their company strategy, and according to Dresner Advisory Services research, 8 in 10 manufacturers who use BI for analytics have seen it function successfully. How Manufacturing Operations Are Improving with Business Intelligence? As revealed by the BI statistics above, we can see that business intelligence is critical in manufacturing. To further illustrate how business intelligence supports the manufacturing industry, let's look at some of the business intelligence benefits that are making a difference in the manufacturing industry. Advances Operational Efficacy While modern enterprises create massive amounts of data, not all of this data is relevant. Today's business intelligence solutions take all of the data from your organization and transform it into an easily comprehensible and actionable format. It enables you to minimize or fix errors in real-time. Additionally, it helps you to forecast raw material demand and assess procedures along the supply chain to ensure maximum efficiency. Allows for the Analysis and Monitoring of Financial Operations Business intelligence solutions provide insight into sales, profit, and loss, raw material utilization and can usually assist you in optimizing resources to increase your return on investment. Understanding your cost-benefit analysis, BI enables you to manage production costs, monitor processes, and improve value chain management. Assists in the Management of Your Supply Chain Manufacturing companies engage with various carriers, handling these multiple processes can be complicated. BI enables manufacturing companies to have more accurate control over shipments, costs, and carrier performance by providing visibility into deliveries, freight expenditures, and general supplies. Contributes to the Reduction of Inventory Expenses and Errors Overstocks and out-of-stocks are substantial barriers to profitability. Business intelligence can assist you in tracking records over time and location while identifying issues such as product faults, inventory turnover, and margins for particular distributors. Determines the Efficiency of Equipment Several factors can cause inefficient production. For example, errors with equipment due to improper installation, maintenance, or frequent downtime can reduce production. So, to keep industrial operations running well, one must monitor these factors. Manufacturers can maintain their machines' health using data analytics and business intelligence. It provides real-time information about your production lines' status and streamlines production procedures. How Business Intelligence Helped SKF (SvenskaKullagerfabriken) to Efficiently Plan Their Future Manufacturing SKF is a key supplier of bearings, seals, mechatronics, and lubrication systems globally. The company posses its headquarter in Sweden and has distributors in over 130 countries. Due to SKF's extensive worldwide reach and product diversity, they constantly need to forecast market size and demand for their products to modify their future manufacturing. Generally, SKF experts developed and kept their forecasts in traditional and intricate excel files. However, the efforts of maintaining and reconciling disparate studies were excessively high. As a result, SKF used require days to generate a simple demand prediction. Later, SKF integrated its business data assets into a single system by utilizing business intelligence in production. Following that, they could swiftly begin sharing their data and insights across multiple divisions within their firm. They are now able to aggregate demand estimation fast and does not face cross-departmental issues about data integrity for the vast number of product varieties they manufacture. This intelligent data management enabled SKF to plan their future production operations efficiently. Final Words Business intelligence in manufacturing makes a big difference in the organization's entire operations. Given the benefits of business intelligence in manufacturing, a growing number of manufacturers are implementing it in their operations. According to Mordor Intelligence, Business Intelligence (BI) Market was worth USD 20.516 billion in 2020 and is anticipated to reach USD 40.50 billion by 2026, growing at a 12% compound annual growth rate throughout the forecast period (2021-2026). Hence, we may say that the business intelligence is crucial for manufacturing and is booming, thanks to its enormous potential and the numerous benefits it provides to various businesses. FAQ Why is business intelligence so important in manufacturing? Organization intelligence may assist businesses in making better decisions by presenting current and past data within the context of their business. Analysts can use business intelligence to give performance and competitive benchmarking data to help the firm run more smoothly and efficiently. What value does BI add to manufacturing? Business intelligence solutions provide insight into sales, profit, and loss, raw material utilization and can usually assist you in optimizing resources to increase your return on investment. Understanding your cost-benefit analysis enables you to manage production costs, monitor processes, and improve value chain management. What is business intelligence's key objective? Business intelligence is helpful to assist corporate leaders, business managers, and other operational employees in making more informed business

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The Factory of the Future

Article | December 2, 2021

The world of manufacturing is continuously evolving in the 21st century, and companies have to combat competition, altering consumer demands, and unexpected events to be able to deliver in today’s experience. Global connectivity, innovation, and disruption are all reshaping the manufacturing industry, but a world-class business platform can help companies transform operations digitally to keep up with an evermore digitized world. The factory of the future will allow manufacturers to enhance production through the convergence of information technology with factory operations, combining the effectiveness of the virtual world with the materiality of the physical world to lower costs, increase flexibility, and better meet customer expectations. The factory of the future functions on four dimensions: resource planning, manufacturing planning, planning and optimization, and manufacturing operations. Resource planning involves defining and simpulating the plant layout, flow, assets, and resources needed to efficiently develop products in a safe environment. Normal production change requests can be quickly validated by using 3D virtual experience twin technology. This technology could also quickly pivot operations to alternative products in the case of disruptive events. Manufacturing planning enriches the resource and product definition by defining and validating a process plan and creating work instructions that meet production goals. Digital visualization of resource and process changes can also help speed up time-to-production in any scenario no matter the location by leveraging the cloud. Planning and optimization of supply chains across planning horizons will help manufacturers gain visibility with planning and scheduling by having the ability to model, simulate, and optimize alternative supply and production plans to reduce disruptions. Lastly, manufacturing operations management can transform global production operations to attain and maintain operational excellence. Manufacturers can create, manage, and govern operational processes on a global scale while maintaining operational integrity to meet altering demands. For the factory of the future to come about successfully, there needs to be connected technology and shared data. Technology has to be adaptable with robotics and equipment that can be reconstructed to house changes and new products. An AI-powered product demand simulation is necessary to maintain agility and boost productivity. A versatile, cross-functional workforce with the ability to explicate data and function well in AR environments is also required along with smart factory technology such as wearable sensors and virtual prototypes. Through all this, the factory of the future can connect technologies across the product life cycle while optimizing the workforce and increasing sustainability. Although achieving the factory of the future has several benefits, creating a feasible factory of the future plan can be challenging. In 2018, only 12% of companies had a mature factory of the future plan. One of the main challenges that companies face is a lack of internal skills to devise digital solutions. However, this can be combated by carefully considering how you can utilize digital technologies to deliver improved performance, resiliency, and flexibility. It is easier to begin with small steps and to collaborate with a partner who could support your efforts to build toward your desired transformation goal. It is important to always be prepared by evaluating your next steps, industry trends, and progress metrics. It is also crucial to focus on the people, process, and technology you’re using to have a successful transformation journey. Manufacturing with the factory of the future can provide savings in a wide range of categories. For example, it can reduce virtual vehicles build time by 80%, increase on-time performance of industrial equipment by 45%, and reduce modular construction time of construction, cities, and territories by 70%. Leading the transformation of the manufacturing space towards the direction of the factory of the future will allow manufacturers to work smart and better meet the needs of the end consumers.

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Spotlight

JWC Environmental

JWC Environmental, a Sulzer Company, is a global leader in solids reduction, separation and removal systems for customers in a broad range of municipal and industrial applications. Wastewater treatment plants, food processors, oil refineries, waste to energy producers, consumer goods manufacturers, airports, correctional facilities and agricultural operations are just some of the many areas that have relied on JWC’s technologies for over 45 years to run efficient and compliant operations.

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