Accelerating Digital Transformation: Integrating Smart Manufacturing and Smart Machinery

The manufacturing industry finds itself at a pivotal juncture, steering towards the era of digital transformation through the amalgamation of smart manufacturing and smart machinery. This article delves into the essential journey of a manufacturing factory, traversing from "digitization" to "digital optimization" and culminating in the pinnacle of "digital transformation." Amid the buzz of 2020, digital transformation has become a focal point for the manufacturing industry, prompting a closer examination of the steps involved in this inevitable evolution.

Following the insights of FIR e. V. at RWTH Aachen University in 2017, there is a structured progression for enterprises venturing into digital transformation, outlined in Figure 1.

The initial step is digitalization, encompassing computerization and connectivity, serving as the gateway to the broader realm of digital transformation. For manufacturing sites, this involves the installation of sensors, the conversion of analog signals to digital signals, and the electronicization of work orders and manufacturing orders. The subsequent application of the Internet of Things (IoT) in the manufacturing industry, often referred to as the Industrial Internet (IIoT), facilitates data concatenation, storage, and application. Post-digitalization, the journey advances to digital optimization, leveraging digital data to enhance production capacity, streamline delivery times, optimize costs, and elevate overall quality at the manufacturing site.
Digital optimization unfolds across four pivotal stages, elucidated in Figure 1, constituting the essence of smart manufacturing, or Industry 4.0.

The first stage: Visualization (Visibility)

This stage provides insight into ongoing processes, aiding in informed decision-making and uncovering latent issues. Real and reliable data serves as the 'Reality Check', which is crucial for problem-solving. Early detection of problems, especially those difficult to discern, is essential for continued optimization.

The second stage: Transparency/Transparency

Addressing the "why" behind issues, this stage enables a direct path to the root cause, facilitating complete problem elimination. While often synonymous with visualization, transparency involves on-site reconstruction using historical data, differentiating it from its predecessor.

The third stage: Predictive Capacity

Foreseeing potential issues, this stage seeks to mitigate the traditional factory's reliance on reactive responses. Predictive capabilities empower factories to respond confidently, avoiding the panic of constant firefighting. This proactive approach minimizes waste, a key contributor to reduced factory competitiveness.
The journey towards digital transformation necessitates a comprehensive understanding of these stages, guided by the technical architecture of smart manufacturing. As manufacturing enterprises leverage Industry 4.0 principles, the strategic integration of smart manufacturing and smart machinery emerges as a linchpin for success in this transformative era.