Everyone is talking about Industry 4.0. But what is it, exactly, in particular in the speciality field of screwdriving and feeding systems? The term “smart factory” is essential for this explanation. Smart factories are created by the digital linking of embedded production systems and dynamic engineering change processes. And that is precisely what Industry 4.0 is about: combining production and automation systems with modern information and communication technology. Digital processes provide employees of a Group of companies – including any worldwide operations – are provided with simpler and faster methods for communicating and evaluating data. Production, logistics and machine operation run more smoothly and with fewer faults
WEBER-Technology
THE SIGNIFICANCE OF INDUSTRY 4.0
The significance of Industry 4.0 in screwdriving and feeding systems
How Industry 4.0 changes screwdriving and feeding systems
When production comes to a halt, modern companies are now able to share production information with one another in real time and respond accordingly much more quickly. Ultimately, Industry 4.0 also makes it easier to manage a corporate group’s subsidiaries, even those located around the world.
WEBER also offers all standard interfaces that can be integrated with our customers’ systems. For bolted joints, we record the results of the bolting operations and torque curves and transfer them to the company’s own manufacturing execution systems (MES systems). This ensures that all data is available at any time via standardized interfaces. Statistical functions can also be performed locally through the controller. Using their own tools, our customers can independently perform comprehensive analyses. This allows them to quickly identify anomalies in the production process—and respond to them. In addition, numerous other statistical functions and evaluations are possible using artificial intelligence.
This offers a decisive advantage, particularly in fastening and feed systems for the automotive industry. Post-production inspections of fasteners help prevent product recalls—and save money. In addition, device connectivity generally increases productivity. Problems are detected immediately and resolved quickly.
What is so revolutionary about Industry 4.0?
Industry 4.0 is revolutionary because of the optimised self-organisation of companies. The digital development promotes better cooperation between machines and between humans and machines. But it is not only optimised communication strategies that play a role here. In light of the increasing global interconnection, companies now have attractive opportunities of improving their value chain, making their production flexible and customising their products and services.
How current business models for screwdriving and feeding systems are changing with Industry 4.0
Business models in connection with screwdriving and feeding systems are changing with Industry 4.0 because more services are available for the product. Remote services, for example, can be used by engineers to work remotely and carry out programming changes off-site. Electronic QR codes offer customers worldwide easy access to descriptions of machine commissioning, detailed documentation or services. Additional software functions can easily be ordered for data-driven business models.
How companies can save Industry 4.0
Modern companies are much better at avoiding recall campaigns than they used to be. This saves not only work time but also money. How does it work? With automated screw-fastening processes, for example, all data is recorded and verified through random sampling. The error rate drops to near zero through continuous (including retroactive) verification.
For automotive customers, it can happen that a supposedly in-process (IO) graph exhibits minimal deviations that are identified as “false IO” at a very early stage through continuous digital monitoring. This helps avoid rework cycles later on. While an initial investment in digital applications is required, this investment is definitely worthwhile in the medium to long term for complex, globally operating companies.
Using so-called “digital twins,” it is now possible to create 1:1 replicas of all prototypes on digital platforms. This allows for time savings during commissioning and the start of production through advance simulations.
You can find detailed information on this here:
https://www.vdi-nachrichten.com/shop/digitale-schraubentechnik/
Source: VDI 2019 ISBN 978-3-18-092347-5
Implementation Industry 4.0
Industry 4.0 links physically remote production machines, transport systems and storage systems with the corresponding planning and control systems. This interconnection creates interfaces that require a common standard (stage 1). The real-time control of the machines changes daily work processes. Machines are operated not only be employees, but humans and machines collaborate actively (stage 2). All this results in cost-efficient production. It also allows manufacturers of screwdriving and feeding systems to better address customer requirements (stage 3). Each stage is the prerequisite for the next.
Here is an overview of all 3 stages.
Stage 1: Cyber-physical system (CPS)
- Ubiquitous computing: Information processing with embedded hardware and software, intelligent production equipment, products and machines
- Standardised interfaces
- Internet of things and services: Linked over the Internet (IPv6), provision of services over the Internet
- Cloud Computing: Big Data Analysis, Bereitstellung of IT-Resource
- Cyber Security required
Stage 2: Cyber-physical production system (CPPS)
- Machine-to-machine communication: partially autonomous control
- Human-machine interaction, e.g. virtual reality
- Automated data transmission to MES systems
- Big data analysis (using artificial intelligence)
Stage 3: Industry 4.0
- New company visions
- Strategy adaptation
- New business models and processes
Bottom line: Opportunities with Industry 4.0 – Overview
In summary, the development of Industry 4.0 offers extensive opportunities, in particular for manufacturers with a high standard of automation:
- Automatic data evaluation
- Faster action times
- Higher economic efficiency
- Better production flexibility
- Control across companies
- Location-independent
- Saving resources and energy
More WEBER technologies
Here’s how to integrate screwdriving systems for automated assembly into your production environment.
Automated feeding – a guide
What you should know about interfering edges at the screwdriving location
Flow Drilling Screwdriving – Guide
Automatic Setting and Feeding of Blind Rivet Nuts – Guide
Screwdriving systems – a guide
Swivel arm
Technical cleanliness – a guide
Screwdriving Technology for Robotic Applications
WEBER Schraubautomaten
WEBER Schraubautomaten GmbH is a family-run and innovative company that attaches great importance to the sustainable design of the value chain. The result is high-quality products with maximum process reliability that make production processes more efficient. Your success is our success.
