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Managing manufacturing operations remotely via connected technology

Wearables, cobots, IIoT transform metal stamping facilities for the future in wake of pandemic

IoT technology in a auto manufacturing plant

Cobots are designed to work alongside and interact with humans, enhancing productivity and safe distancing. Images provided

The COVID-19 pandemic has been the ultimate test for stampers across the globe. Even as parts of the world begin to reopen, the hard truth is that fundamental changes to plant floor processes must be made. You must protect the health and safety of workers by allowing for social distancing—and do so without compromising quality and accuracy.

To tackle today’s challenges, consider connected technology.

Embracing Technology

Any technology must have operational meaning, purpose, and application to merit investment consideration. Even before the emergence of COVID-19, stamping leaders approached technology investments carefully. In today’s turbulent climate, it is vital for investments to have even more strategic focus.

According to recent research, nearly 40% of manufacturing decision-makers are relying on information technology and operational technology convergence and the industrial internet of things (IIoT) to drive growth. While navigating the uncertainty of COVID-19, manufacturing leaders will make decisions to invest in technology that will be a defining factor in overcoming challenges to meet their business objectives.

In this new normal, the most viable and pragmatic solutions include IIoT systems, augmented reality, wearables, and cobots. Here’s what you need to know about them to make the right decision for your business.

The Surge of IIoT

Predicted to grow into a $200 billion market by 2021, IIoT is a network of intelligent devices connected to form systems that monitor, collect, exchange, and analyze data. Examples of critical data that help you run a more efficient stamping floor include production rates, performance time, quality specifications, and inventory information. That data easily can be collected remotely and used to make real-time business decisions that ultimately lead to improved profitability, quality, accuracy, and efficiency.

The upward momentum of IIoT is clear, and benefits for stampers are undeniable, especially as you implement new social distancing guidelines. Operations that can be performed remotely are:

  • Condition monitoring and maintenance. With IIoT tracking plant floor maintenance, personnel can monitor machines both locally and remotely for unusual behavior, such as a press that is malfunctioning or operating inconsistently.

  • Production monitoring. IIoT enables production planners and supervisors to monitor overall equipment effectiveness (OEE), production rate, scrap, part count, and cycle times either on-site or remotely.

  • Quality and traceability. With IIoT, quality managers can get a direct feed of machine process data for each part that is manufactured without stepping foot on the stamping floor.

    Robotic automation in a manufacturing facility

    Data collected via IioT easily can be collected remotely and used to make real-time business decisions.

With the help of IIoT, you can position your company at the forefront of innovation, with increased operational visibility that allows you not only to see what’s happening, but also to predict what’s to come.

New Perspective With Augmented Reality, Wearables

Augmented reality generated significant hype over the past few years, but has since evolved into a practical application that helps you and your operators to do your jobs more efficiently and safely.

One of the most notable and pragmatic applications of the technology is to deliver real-time work instructions and knowledge to workers using augmented reality wearables such as smart glasses and headsets.

Wearables can transform training, safety, and transparency in several ways. First, they make remote training possible, allowing workers to easily access step-by-step work instructions without having the trainer on-site. Second, the advanced technology behind wearables helps manufacturers to prioritize health and safety, as employees can work effectively while practicing social distancing. Finally, wearables can improve organizational communication through increased data collection. They empower shop floor workers and machines to communicate better by way of real-time transfer of data collected in the cloud.

Case Example. One real-world example of how a company successfully

implemented augmented reality and wearables is Kamco Industries, an automotive components manufacturer based in Ohio. To solve operational problems on the shop floor, Kamco enlisted mixed-reality smart glasses from Microsoft, called HoloLens, to work through problems remotely. When an operator ran into a problem with a malfunctioning machine air line during production, she reached out to a supervisor to help troubleshoot, although he was out of the office. Using Skype with smart glasses, the supervisor and operator were able to walk through the problem—a disconnected air line. Having the capability to resolve the problem without the supervisor having to be on-site was an enormous benefit for the company because it saved time and reduced machine downtime.

This remote troubleshooting capability has become especially valuable after the onset of the pandemic, as the company looks for opportunities to minimize the number of on-site workers to facilitate social distancing on the plant floor.

Teaming up With Cobots

Collaborative robots, or cobots, will be the watchword on the plant floor in the coming months. Unlike their traditional robot counterparts, they are designed to work alongside and interact with humans.

Cobots are also different than their robot predecessors because they do not need to be placed inside safety cages, but instead may operate directly next to a person while completing tasks such as assembly and welding. Cobots are built with specific safety characteristics that stop movement or shut them down to prevent worker injuries if a hazard exists. Some workspaces that integrate cobots may also rely on safety area scanners and mats to further ensure operators’ safety.

The concept, which emerged in the mid-1990s, has since increased its footprint in industrial settings steadily. Cobot technology value and usage continue to grow because of the pandemic.

Because the assembly of certain products requires people to work in proximity on the line, interspersing cobots between operators can increase social distancing without compromising quality and efficiency.

Smart glasses use to aid manufacturing production

When an operator at Kamco Industries, Ohio, had difficulty with a malfunctioning air line, an off-site supervisor was able to detect the source of the problem and resolve it remotely via the use of smart glasses and Skype.

Once considered a luxury, cobots are being increasingly recognized as integral to future growth plans.

The coronavirus has forced stampers to address the challenges of the pandemic without compromising operations. To succeed, it’s essential to examine plant floor processes that require high-touch and interpersonal interactions. Modern technologies such as IIoT, augmented reality, wearables, and cobots offer multiple opportunities to reduce contact and implement social distancing.

When applied correctly, these technologies not only have the power to get you through the COVID-19 new normal, but also to improve operational efficiency and accuracy for long-term business benefits.

Jerry Foster is chief technology officer for Plex Systems.

Virtual reality (VR) and IioT used in a manufacturing setting

Data collected via IioT easily can be collected remotely and used to make real-time business decisions.