The creation, or modernization, of a smart factory is one of the most important challenges for the manufacturing sector. Without exaggeration, we could call it  the challenge of the century since the potential fallout is only comparable to that of the adoption of automation in the last century. The goal of a smart factory is to become a system  flexible, fully connected and able to provide, and rely on, a constant and reliable flow of data.

Through connectivity and the use of real-time data, the smart factory is able to adapt to market demands, contingent conditions, optimize automatically and adopt self-learning processes to maintain performance and competitiveness.

Smart Factory: the canonical definition

According to the Gartner’s definition of the smart factory is a concept used to describe the application of modern technologies to create a hyper-flexible and self-adaptive manufacturing capability. Speaking of Smart Factory,  a definition has already appeared on our pages, in which we also placed special emphasis on the human factor: considering first automation and then the smart factory as competing concepts with the enhancement of personnel and technicians, in fact, is a rather common mistake. Instead, in this in-depth study, we are going to focus mainly on the technical aspects that constitute, at the level of principle, the requirements needed to start a process of implementation, or transformation, of the smart factory.

The basic requirements of the smart factory

Speaking of the Smart Factory, the meaning to be attached to the requirements is, of course, rather generic: implementation in the real world is complex and articulated but, as always, starting from the founding principles allows us to better grasp the overall vision and make strategic decisions. We could somewhat call them design principles, which must be followed both for the construction of new plants and factories and for the modernization of existing ones.

  • La Modularity refers to the ability of the components of a system (in this case the plant or facility) to be separated and combined quickly, possibly in real time and without the need for prolonged downtime. In this way, systems can respond to external or internal demands quickly. Modularity also makes it possible to respond efficiently to malfunctions and to integrate new modules or functionality in an agile manner.
  • Interoperability is part of a broader context that, as we know, is one of the founding principles of Industry 4.0 as well: data and information must be permeable and be able to be reached, and processed, in real time by all control and management systems. Interoperability is the first building block to achieve this: systems and machinery must be able to transfer information throughout the supply chain.
  • La Real-time response capability is another key element. A system, in this case a plant or facility, must be able to respond as quickly as possible to changes and stresses.
  • La Decentralization is another key element. The different parts that make up the system-for example, logistics, but also individual production modules and machinery-must be able to handle decisions autonomously, in real time, and in a way that is not subordinate to a centralized decision, so as not to slow down operations. Of course, autonomous decisions must  be harmonized so as not to contravene the goals of the company. In simpler words, each unit must also be able to operate autonomously.
  • Finally, the virtualization is another aspect that needs to be considered. The creation of a virtual environment that replicates the real plant, as suggested, for example, by the technique of the  digital twin, offers the ability to monitor and simulate real processes. This system also makes it possible, for example, to conduct at least first-level testing on  prototypes and production processes, containing costs and time.

Creating a smart factory ready to meet the challenges

We have seen what are the basic principles on which a smart factory project should be based; however, it is also good to emphasize a concept that is more soft but equally important, namely theharmonization of resources and solutions. Concepts such as data permeability, interoperability and responsiveness in fact can only find real application when accompanied by a  shared vision and to a consequent change management. Such revolutionary innovations, in fact, must first be embraced by management, and properly conveyed to all people, in order to be best received.

At Regesta LAB we support you throughout your digital transformation journey, helping your company become a smart business. Contact us to receive information.