Industry 4.0, digital factory, digital production, smart factory – the terms vary, but there is a common approach behind them: industrial companies need to digitalize their existing production approaches. Fast. Cost-efficiently. Securely. We take your production into the digital age.
The digital and smart factory is a central concept in modern industrial production, characterized by the integration of digital technologies such as the Internet of Things (IoT), artificial intelligence (AI), robotics/automation and big data analytics. The networking of machines and systems is essential to enable a continuous flow of data and to successfully realize the idea of more efficient and flexible production.
Four questions to Stephan Lausterer, Head of Software Core Engineering & Product Development
Digital twins and virtual commissioning are key technologies in the field of industrial automation. At Manz, we support our customers in using these technologies effectively for digital transformation. We help manufacturing companies realize the benefits of virtual commissioning by creating a digital twin and using it to perform the commissioning of equipment and systems virtually first. This method minimizes the risk of downtime and errors during actual commissioning, as potential problems can be identified and resolved at the virtual stage.
Artificial intelligence (AI) and machine learning play a key role in the digitalization of production facilities by enabling intelligent and efficient analysis of large amounts of data.
AI and machine learning are used to recognize patterns and trends in production data, enabling more accurate prediction of maintenance needs, production downtime and quality control. In connected manufacturing, AI systems use data from sensors and machines to gain real-time insights into the production process and optimize decision-making processes. Machine learning is also used to optimize production processes and resource utilization by continuously learning from the collected data and adapting to changing conditions.
This leads to greater efficiency, lower operating costs, and improved end products. AI and machine-learning play a key role in making production smarter, more flexible and more efficient.
We use artificial intelligence to improve the visual inspection of manufactured parts and to determine quality from sensor data and other data collected during production. A particular focus is on the quality control of laser processes.
We use artificial intelligence to optimize and automatically adjust process parameters and analyze the impact of various production parameters on the OEE of machines and production lines.
We use AI for condition monitoring and predictive maintenance, i.e. to predict when a machine needs maintenance or when a component should be replaced. And thanks to anomaly detection, changes in the machine's condition are detected before production downtime occurs.
Our AI applications help to reduce energy consumption and operate systems efficiently.
The smartPRODUCTIONKIT is the central software platform for monitoring and evaluating production data as well as the database and control center for our AI-based innovations. The platform integrates data from process modules from various manufacturers and makes it possible to evaluate this data both in real time and retrospectively. The former is particularly relevant in order to be able to react in good time to process-related events, e.g. axle position dependencies – a truly unique selling point.
One of the main functions of the smartPRODUCTIONKIT is to increase the availability of production systems and improve product quality at the same time. The system collects and stores machine and production data via the standardized OPC UA interface, which means that the smartPRODUCTIONKIT can also be used to monitor and evaluate production steps in process modules that are not from Manz. With its open development environment, the smartPRODUCTIONKIT software platform can be continuously expanded with new applications and functions. Users can use the solution both cloud-based and edge-based.
The smartPRODUCTIONKIT is available in 3 different versions, which differ in functionality and available dashboards. The packages are designed in such a way that a later update to a package with a higher level is possible, e.g. to get more functions and possibilities.
| Package Comparison | sPK Frame | PK Basic | sPK Pro |
|---|---|---|---|
| Production Overview
Line Overview Generic |
|
✓ ✓ ✓ - - |
|
|
Machine View |
- |
✓ |
✓ |
|
Move & Maintain |
- |
✓ |
✓ |
|
Management View |
- |
- |
✓ |
|
Production View |
- |
- |
✓ |
|
Customer-specific Dashboards |
- |
Project Order |
Project Order |
The smartPRODUCTIONKIT aggregates, visualizes, and processes data from process modules from different manufacturers. The integration of the smartPRODUCTIONKIT for data analysis significantly increases the availability of systems and production quality. The platform enables data evaluation both in real time and retrospectively, which supports advanced IIoT applications such as predictive maintenance. This holistic solution therefore offers significant added value in the modern manufacturing environment.
The smartPRODUCTIONKIT can collect and analyze almost all types of production data, including detailed process cycle data and data for real-time tracking and tracing of parts and workpiece carriers throughout the entire production process.
The system securely and reliably integrates Manz machines into the production process via the industry standard OPC UA interface and is also suitable for integrating third-party machines.
The installation and operation of the smartPRODUCTIONKIT is extremely simple and ideal for medium-sized companies. The pricing model is geared towards machines, quantities, and customer benefits. Our customers can put the smartPRODUCTIONKIT through its paces free of charge during a test phase.
The cybersecurity measures of the smartPRODUCTIONKIT follow a standard established at Manz that is based on IEC 62443 and the recommendations of the VDMA. The smartPRODUCTIONKIT's data interfaces are protected by certificates and passwords, as are the databases. Our customers can choose whether they want to use their data exclusively internally or grant Manz access to this data to help optimize their systems.
Our customers use the smartPRODUCTIONKIT to optimize production efficiency, reduce downtime and maintenance costs, improve product quality and consistency, and increase operational transparency and decision-making, among other things.
