6 Nonnegotiable requirements for your smart factory transformation

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6 Nonnegotiable requirements for your smart factory transformation

6 Nonnegotiable requirements for your smart factory transformation

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May 27,25

The smart tech world is seemingly never-ending, but a few essential staples create an unshakable foundation. Here, Emily Newton suggests six essential ingredients for a transformation to smart factory.

6 Nonnegotiable requirements for your smart factory transformation

Automation and manufacturing experts compete to be the most technologically advanced operation in their niche. Smart factory buildout is a combination of quality equipment and commitment to innovation. While organisations take vastly different approaches, several standard elements are vital to a successful transformation.

1. Connectivity and data acquisition

Comprehensive data collection is the foundation of many smart factory requirements. Each device, software and machine should have information-gathering capabilities. Facilities should consider installing sensors to measure metrics like temperature and pressure to maintain environmental conditions.

Other smart manufacturing components include:

Programmable logic controllers (PLCs)
Industrial-strength Ethernet
Wireless communications like Wi-Fi and Bluetooth
Data acquisition systems

Companies may also use artificial intelligence and machine learning. Though these tools are not must-haves, they can process large volumes of data and enhance competitive advantage. Despite adopting a more complex tech stack, 20 per cent of manufacturers mentioned asset efficiency was a leading advantage of committing to a smart transition.

2. Data storage and processing

Data streams need several safe locations, including cloud servers and external hard drives. Storage is critical for continuous information processing. The hardware and infrastructure also provide peace of mind by backing up data in case of corruption or breach.

Companies can incorporate more advanced storage equipment during smart factory buildout, like data warehouses and lakes, edge computing devices or SQL databases.

3. Analytics and visualization

Not everyone within a facility has the same data science capabilities, so software is vital for creating visualizations of processing efforts. It makes insights more accessible to the broader workforce. The images take raw data and make it digestible, showing staff how well they achieve key performance indicators or customer feedback.

For example, facilities to reduce energy consumption need to view each piece of equipment contributing to high usage to make an action plan. Case studies have shown smart software can lower facility energy requirements by 50 per cent through comparative analysis.

Factories should consider analytics software and reporting tools to make data as versatile as possible. They can be web-based applications or human-machine interfaces. Statistical analysis is another prime opportunity to leverage AI and algorithmic training to expand the usefulness of visualizations.

4. Cybersecurity

Digital transformation promises improved productivity, scaling and profitability. However, the data is unusable when in hackers’ hands. Around 51 per cent of businesses think attacks on smart facilities will increase in the future, though 47 per cent say this is of little concern to C-suite executives.

Protecting digital assets is nonnegotiable, as exposure damages reputations and puts stakeholders in danger. Facilities must delegate cybersecurity tasks to trained professionals who will constantly monitor data resources.

Additionally, factories must vet third parties with strict criteria. Many smart tools and equipment will come from outside vendors and should have equally high security standards. Internal and external defenses may include:

Firewalls
Endpoint security
Business continuity planning
Virtual private networks
Encryption
Data minimisation
Intrusion detection systems

5. Automation and control

Even the most robust team cannot realistically handle terabytes of data. Installing automation technologies is vital for maximizing the constantly incoming information. Experts can adjust the controls to automatically generate visualizations based on preassigned programming.

Over time, corporations will identify the most time-consuming elements of the smart transition and experiment with ways to automate specific processes. Software-based algorithms can shoulder some responsibility and reduce machine downtime by 30 per cent to 50 per cent by lowering human error and automating maintenance notifications.

However, there are more tangible applications. For example, an automated guided vehicle could have orders to transport pallets to a department based on the time of day. CNC machines remove tedious, manual cutting tasks using the most effective historical blueprints to inform future models. Other helpful equipment includes actuators, proportional-integral-derivative controllers and advanced remote control panels. The most beneficial tools will vary based on the factory’s niche.

6. Skills and training

Education is the final nonnegotiable. Tools, programs and installations only have value if operators know the best ways to employ them in their workflows. Seminars and classes will fill skills gaps, increasing digital literacy in staff across all demographics and tenures.

Facilities can go beyond the conventional classroom and embrace advanced training tools. Assets like simulation software with virtual and augmented reality expose workers to real-life circumstances in safe, controlled environments, giving people hands-on experience without the repercussions of failure.

Learning management systems complement training efforts by tracking each worker’s progress and educational needs. This technology will help with one-on-one training and ensure skills coherence and consistency throughout every department.

Smart factory requirements for long-term success

It is inspiring to imagine a completely revamped facility with advanced sensors and data-gathering equipment. The data pours into software and motivates companies to achieve their goals. The smart tech world is seemingly never-ending, but a few essential staples create an unshakable foundation. Focusing on these prerequisites will make customised and disruptive inclusions more effective and sustainable in the long term.

About the author:

Emily Newton is a tech and industrial journalist and the Editor-in-Chief of Revolutionized magazine. Subscribe to the Revolutionized newsletter for more content from Emily.

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