The introduction of new technologies on the shop floor has been growing for years and in different ways. More robust and high-capacity machines arrived with great force in Brazil in recent years, but the change that currently drives production optimization is much more subtle than previously perceived.
This is the advent of integrated systems, mobile devices, and the connection between machine and computer, which is creating the concept of the smart factory worldwide. Fundamental for the survival and competitiveness of Brazilian industry, this concept brings a major challenge for business owners. After all, what should one invest in to be more assertive, and what are the trends that will truly have a positive impact on the business?
Data systems on the shop floor
To answer this question, it is important to globally analyze the technologies that are consolidating. One of them is the Internet of Things (IoT), which refers to the use of connected devices and machines. With this type of solution, the factory consolidates data collected during the production process into its system, aiding continuous improvement. We can mention, for example, sensors that point out production rates and can highlight poor distribution of resources and machinery.
A structural adjustment based on these data can significantly reduce team transition time within the factory, as well as improve the distribution of resources such as raw materials and electric energy. IoT is also applied through the automation of vehicles and robots that distribute supplies in the industrial routine. It can also be seen in sensors that collect machine information through presence, volume, or temperature and send this data directly to the companies’ ERPs.
Still regarding the concept of smart factories, automation in production scheduling is a major challenge and, at the same time, an opportunity for gains at various levels. This can be considered an increasingly tangible investment for Brazilian industries, with medium-term gains. This includes APS software, which stands for Advanced Planning and Scheduling.
These are systems that allow detailed production planning, taking into account various variables of the company’s routine. With the support of collected data, they considerably reduce structure idle time, overloads, and delivery delays. In practice, this means reduced product delivery times at the end of the chain, preventive equipment maintenance, and a consequent reduction in costs for unscheduled repairs.
How to stand out in the market?
The advantages and gains of smart factories go far beyond theories and research. They are based on data: according to the Brazilian Industrial Development Agency, cost reduction in Brazilian industry through the adoption of the smart factories and Industry 4.0 concept can reach R$ 73 billion per year.
An example of how this savings occurs can be seen by analyzing the speed and precision of production planning solutions, which can execute a company’s one-year production plan in just 30 minutes.
Even though the gains of technology for the shop floor are becoming increasingly evident, many companies still do not shift their management toward this new global scenario. According to the National Confederation of Industry (CNI), only 1.6% of Brazilian businesses are already adapted to the automation landscape that is advancing considerably in developed countries.
Low adoption highlights the opportunity to grow in competitiveness and market representativeness for those already investing in automation. More than just cutting costs, these companies that are already adjusting their factories to the 4.0 concept can differentiate themselves through fast, high-quality, and cost-effective deliveries. They gain market share while those who fail to invest end up left behind. It is the Blue Ocean of the shop floor, which in a short time will not just be a differentiation, but a necessity for survival in an increasingly competitive, automated, and connected market.
Signed by: Aloisio Arbegaus — Commercial Director at Teclógica
