Trabajar en la era del “Industrial Internet of Things (IIoT)”

Casos de éxito de la Fábrica Inteligente

Producir en la era del “Industrial Internet of Things (IIoT)”

El s. 21 se acelera a un ritmo tremendo, con la tecnología colonizando lugares que no nos hubiéramos imaginado hace diez años, ya sea en el terreno personal o profesional. Las continuas mejoras en la banda ancha, el aumento de la cantidad de datos a los que tenemos acceso, así como la capacidad para procesar, analizar y actuar en estos datos son términos que influirán en los procesos de fabricación en el futuro.

Estos cambios están repercutiendo en las plantas de producción y dando forma a nuevas posibilidades en la creación de productos.  Este movimiento tiene su propio nombre, Smart Factory o Fábrica Inteligente.

 

¿Qué es la Fábrica Inteligente?

Gracias a la tecnología y a Internet, el mundo se conecta cada vez más; hay un impulso significativo para hacer que los productos sean más inteligentes interconectándolos a través de sensores y otros mecanismos de recolección y transmisión de datos. Esta interconexión es la llamada Internet Industrial of Things (IIoT), la columna vertebral de Smart Factory.

Estos dispositivos interconectados se convierten en máquinas inteligentes con capacidades que van desde la simple detección y actuación, hasta el control, la optimización y el funcionamiento completamente autónomo. Las herramientas de software aprovechan toda la información permitiendo que el sistema tome decisiones más inteligentes sobre los procesos de producción.

La fabricación tradicional está convergiendo con el mundo de la fabricación digital para permitir a las empresas planificar y proyectar digitalmente todo el ciclo de vida de los productos y las instalaciones de producción. Esto ofrece enormes beneficios en reducción de costes y aceleración del “time-to-market”.

 

Smart Data y Conexión Interdepartamental

La Fábrica Inteligente proporciona un entorno altamente dinámico: todos los departamentos y máquinas están conectados digitalmente en todos los niveles de producción, y la información es lo que la mantiene fluyendo. Imagine que tiene sensores en todas las máquinas de la fábrica que ofrecen visibilidad en tiempo real de cómo funciona cada una. Y un software que analiza y puede mostrar la calidad, el rendimiento y las variaciones de cada máquina y sus operadores. Esto tiene un valor incalculable para agilizar los flujos de trabajo y mantener la producción en funcionamiento, sin interrupciones por fallos.

En EPLAN, nos dimos cuenta de que la conexión a la base de datos de una empresa es necesaria para crear una ingeniería más eficiente. La Plataforma EPLAN facilita a los ingenieros colaborar en el diseño en tiempo real en vez de que cada disciplina funcione por separado. Esta integración permite un proceso de diseño mucho más rápido y la fabricación real de la de maquinaria pueda. Algo imposible con las herramientas de CAD/CAE tradicionales.

IIoT está afectando profundamente a las relaciones con los proveedores, por ejemplo es el caso de las librerías online de componentes como EPLAN Data Portal.

EPLAN Data Portal proporciona acceso en tiempo real a los datos de dispositivos de la mayoría de fabricantes de componentes líderes en el mercado. Estos datos son añadidos a los proyectos EPLAN, asegurando que la información de los componentes esté incorporada a la documentación. El simple hecho de “arrastrar y soltar” en vez de dibujar reduce el trabajo que consume mucho tiempo y disminuye los errores manuales, aumentando la calidad de la máquina y la documentación.

 

En Tiempo Real

De la misma manera que nuestro cerebro se comunica con el cuerpo, el concepto de Fábrica Inteligente nos muestra cómo la fabricación puede comunicar, coordinar y proporcionar acciones correctivas en tiempo real.

¿Qué significa este proceso en tiempo real?

■   Mantenimiento predictivo: el flujo de datos permite que las máquinas den información que facilite el mantenimiento predictivo, previniendo los fallos y el tiempo de parada durante la fabricación.

■   Productividad predecible: la capacidad de escalar o reducir los procesos de producción de forma más precisa, incluso hasta un tamaño de lote de una unidad (batch size one).

■    Análisis adaptativo: con el análisis continuo de los datos, puede adaptar su entorno de producción en todos los niveles y aumentar la eficiencia, la velocidad y los factores de coste.

■    Menores costes operativos: más específicamente, uso de medidores y potencial de reducción para energía y costes de procesos.

 

Documentación y Prototipo Digital

Una vez que entra el pedido, la comunicación con el cliente puede ser irregular y lenta. La Fábrica Inteligente, con su enfoque más fluido, también puede significar una mejor sinergia con el cliente. Al utilizar prototipos digitales, los fabricantes pueden comunicar el proceso de diseño de manera más efectiva y obtener valiosas aportaciones del cliente en los puntos clave de la etapa de planificación. Los prototipos 3D de armarios eléctricos brindan una visualización sencilla del diseño mientras se encuentran en un estado virtual y pueden capturar los cambios del cliente antes de cortar el metal, lo que reduce el costo y acelera la fabricación.

Sus clientes exigirán una mayor responsabilidad y conexión en el futuro. La documentación es un ejemplo de cómo evolucionará esto.

La documentación en papel que acompaña a la maquinaria ha ocasionado problemas importantes. El riesgo de daño o pérdida es alto y el coste del mantenimiento es engorroso e ineficaz.

El software de ingeniería centrado en bases de datos como EPLAN archiva proyectos en un formato que puede revisarse según las necesidades. La documentación digital permanece con el producto a lo largo de su ciclo de vida y opera en tiempo real con información actualizada, como sustituciones de piezas, actualizaciones y complementos. La documentación también se puede importar a un dispositivo móvil para acceder mientras se trabaja in situ con la máquina.

 

Estas son solo algunas de las formas en que IIoT está cambiando la dinámica a la vez que proporciona formas innovadoras para crear un mejor producto y brindar un valor añadido a su relación con sus clientes.

Este es el futuro de la producción, y es el momento de prepararse para ello.

 

 

El movimiento Fábrica Inteligente

Aunque el término de Fábrica Inteligente o Smart Factory solo ha existido durante algunos años, EPLAN ha estado proporcionando la infraestructura clave necesaria para el movimiento durante más de tres décadas. Además de la plataforma EPLAN, que ayuda a las fábricas a adentrarse en la Fábrica Inteligente, también ofrecemos servicios de consultoría.

Nuestros consultores pueden identificar los puntos de reducción de costes y las mayores oportunidades de eficiencia a lo largo de su proceso de ingeniería. Al trabajar con su personal, podemos desarrollar una solución que proporcione más integración y procesos optimizados, mejorando así el flujo de trabajo de su empresa.

 

Procesos de Ingeniería: Los procesos de ingeniería están cambiando rápidamente. Le brindamos soluciones con las que puede enfrentar estos desafíos, hoy y en el futuro.

Implementación: Le ofrecemos una introducción profesional y directa con la Plataforma EPLAN con nuestros servicios de implementación. Para que empiece lo antes posible a mejorar la eficiencia de ingeniería eléctrica.

Estandarización: La estandarización y la documentación son directamente proporcionales a la calidad, coste y tiempo invertidos.

Automatización: Los procesos de trabajo repetitivos se pueden optimizar y automatizar.  EPLAN puede simplificar los procesos de diseño eléctrico altamente repetitivos.

Gestión de Proyectos Profesional: Para proyectos complejos, uno de nuestros consultores técnicos le ayudará, adaptándose a sus necesidades.

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