Our generation lives in the midst of the Fourth Industrial Revolution, in which smart, ever more efficient, automated, and customizable factories come together that combine production with cyber-physical systems (systems that integrate software, communication, and physical equipment), Internet, and the Internet. Things, Big Data, Artificial Intelligence and Cloud Computing. The so-called Industry 4.0 is based on six principles for its development and implementation: interoperability, ability to operate in real time, virtualization, decentralization, service orientation and modularity.

Here in Brazil, a good example of a factory that was born with these principles is thyssenkrupp's unit focused on the production of automotive components, located in Poços de Caldas (MG). The plant is already recognized as one of the leading references in industry innovation and digitization within the country's automotive chain.

"Poços de Caldas was our fourth 4.0 plant in the world and went through testing before it started operations. We ordered the machine, learned everything about it, installed it, hired operators, trained these people and did six months of parts testing." , comments engineer Lucas Viana, operations manager of thyssenkrupp's Camshafts unit for Brazil, in an interview with Canaltech.

The expert explains that the concept of cyber-physical environment plant brings a digital network behind equipment and machines. Software works in real time, bringing information to robots and operators, and the servers are connected to the other factories of the company. "It's a state-of-the-art automation system on every machine. They are smart and so they measure, identify and check parts on time," he says.

With the QR Code, for example, the machine identifies parts, verifies that the model is correct, and then applies the necessary components. Image reading software, in turn, recognizes the serial number of the product and records a photo to compose the part sheet. Then she goes to the press machine for a strength test and, if everything is within the parameters, moves on. Otherwise, the part is discarded. Thanks to this automated and more precise process compared to manual procedures, the scrap level drops considerably, thus increasing plant productivity.

According to Lucas, at the factory there are about 100 steps as described, all in an automated, digital environment. "We work on a concept of production cells in which operators feed, visually inspect, monitor and adjust the machines," he explains.

Benefits

According to Lucas, the main benefits of building a digital and automated factory are productivity gains, economy and high product quality. "You produce much more with an automated machine because the cycle of each part is much shorter. And despite having a higher flow of products, robots ensure the quality of parts," he says.

Moreover, he points out that the overall cost of production falls because such a large manufacturing space is not required, and the products gain much more advanced design because they are produced with embedded technology. "Today we can build a much smaller part for an engine. With this, it consumes less fuel and emits less pollutants," says Lucas.

Investments and Upgrades.

The high technology behind the processes can scare the uninformed, but the thyssenkrupp engineer makes sure that investing in a factory like this one pays off more than you might think. "Today there are a lot of companies that make technologies of this type. Robots have been very cheap. Software is still the most expensive part, but it still makes up for what they deliver. Not to mention that the machine interface is great and operators adapt easily." , ends.

At the Poços de Caldas plant, software is used to manage the other systems, so that everything can be kept up to date and with licenses up to date. And since this factory in Brazil is virtually connected to others of this kind that thyssenkrupp has spread around the world, the ideas for modernization and improvement are presented at biannual team meetings and then applied as a test in some of the plants, only to be later verified, replicated on other drives - and this can be done remotely thanks to Industry 4.0.

An example under test is the predictive maintenance system that is already attached to the machines. Using sensors, the machines send real-time information to a supercomputer in Germany, and Artificial Intelligence can anticipate potential problems that may occur. Another concept that can generate savings and increase productivity.

Industry 4.0 is a technological leap that brings automation to maximum power. It enables machines to perform increasingly complex functions, not just welding steel plates, for example, but also tasks that require intelligence. The goal of the new industry is to become increasingly efficient, intelligent, fast and accurate.

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Source:https://canaltech.com.br/inovacao/conheca-a-operacao-de-uma-ciberfabrica-154751/