Industry Analysis
Digital technologies are increasingly being customized to serve the needs across multiple industries with maximum application being witnessed in automotive, healthcare, aerospace and defense, chemical and consumer goods.
The automotive industry is witnessing rapid digital adoption with benefits including faster time-to-market and lower costs. The A&D industry has one of the highest rates of digital adoption owing to the sheer complexity of its value chain. Digitalization in healthcare is centered around medical devices and pharmaceuticals. Even though, the chemical and consumer goods industries are late bloomers, they are now not only transforming production but also creating smart supply chains and new business models.
Source: McKinsey
Reduction in Maintenance Costs Range ( %)
10% to --------------------------------------
40%
Digital disruption recently started in the consumer goods industry
Diaper Manufacturer uses Predictive Maintenace
A diaper manufacturer had been replacing cutting blades at fixed intervals regardless of their working condition. This sometimes resulted in blades being replaced too soon or too late, which either increased costs or affected productivity.
To address this problem, the company installed sensors in its machines which could detect microfibers and other debris which indicated blade dullness. This data was then uploaded onto the cloud and fed into customized algorithms to determine the best time for replacement of the blade.
According to McKinsey estimates, the application of predictive analytics by consumer goods companies has decreased maintenance costs by 10%-40%.
Source: McKinsey
Industry 4.0 Technology Used
Predictive Maintenance
Predictive Maintenance
The constant capture of the system parameters to predict future failures. Cutting-edge data analysis (machine learning) can be used to accurately predict imminent damage.
Condition Monitoring
Condition Monitoring
Regular/permanent capture of the system status using sensor technology and measuring systems, such as endoscopy, thermography, and vibration measurement.
Companies manufacturing consumer goods have been digitizing their marketing, sales and customer service efforts for some time now. However their supply chain and production areas have only recently started to experience digital disruption with the use of data analytics and other digital tools which have made the manufacturing process leaner and more efficient.
Big data analytics, connected devices and cloud computing have had the maximum impact in improving supply chain management. A company’s data on sales and operations, machine performance, training materials, delivery schedules and so on, which was earlier fragmented and siloed, led to problems such as late deliveries and equipment downtimes.
However the consolidation of all this data into digital hubs powered by cloud computing, has led to enhanced collaboration across all levels of the value chain, thereby making the entire manufacturing process more efficient.
McKinsey case studies put the use of data analytics in various stages of the consumer goods manufacturing process in perspective.
Projected annual investment 1 in industry 4.0 till 2020 in billion US$
Electronics
243
% of annual revenue per year until 2020
7%
Engineer & Construction
195
% of annual revenue per year until 2020
5%
Industrial manufacturing
177
% of annual revenue per year until 2020
5%
Transportation & logistics
97
% of annual revenue per year until 2020
5%
Automotive
65
% of annual revenue per year until 2020
5%
Metals
55
% of annual revenue per year until 2020
4%
Chemical
45
% of annual revenue per year until 2020
5%
Aerospace,defence & security
15
% of annual revenue per year until 2020
5%
Forest, paper & packaging
15
% of annual revenue per year until 2020
4%
Digital disruption recently started in the consumer goods
Maintenance has become much more important in recent years, particularly as increasingly dynamic and complex production processes and technological opportunities have emerged. It is also an important but – in many sectors – still underused lever for optimizing value creation . Being able to avoid unplanned production stoppages results directly in increased availability. A whole range of options for doing just that are being discussed in both science and industry. As a pioneer in drive technology, SEW-EURODRIVE is already turning visions into reality.
In future, the information and data captured in drive systems will be visualized in a clear, user-friendly way (e.g. trend charts) and processed by cutting-edge analysis workflows (keyword: machine learning). This drive technology monitoring and analysis portfolio is being developed at SEW-EURODRIVE under the name DriveRadar ® . The concept aims to make it easy for users working with SEW components and system solutions – even when working remotely – to always keep precise track of how a system is actually behaving when in use and whether maintenance work is needed. DriveRadar ® gives operators of these systems the opportunity to unlock considerable added value and tap into potential for optimization . For example, it can provide greater transparency for the operational conditions of an analyzed drive, boost the availability of an entire system, make it easier to plan maintenance work, reduce the need to hold spare parts in stock, and create opportunities to optimize processes.
DriveRadar ® will also be available for many SEW components and system solutions in the future and help operators to avoid downtimes and improve workflows . Characteristic features from all relevant components can be used to derive straightforward recommendations . As an expert contact, the company offers its customers valuable support in the form of a global service network and a modular service portfolio that can be tailored to specific requirements. Recommendations can be put straight into action.
Collecting and evaluating data and predicting events.
SEW-EURODRIVE concept:
The aim of DriveRadar® is to determine the state of products, machines, and systems by using existing data that is collected by the drive systems from SEW‑EURODRIVE during operation. Cutting-edge data analysis (machine learning) can be used to accurately predict imminent damage using a digital twin. This means, DriveRadar® can prevent unforeseen failures and interferences in operation, detect wear, and minimize downtimes.
Predictive analytics:
Constant capture of the system parameters to predict future failures
Concept from SEW‑EURODRIVE: Detection of anomalies, diagnosis, prognosis ( digital twin )
Objective: Predictive maintenance by means of permanent collection of data evaluated by using machine learning procedures.
Condition monitoring:
Regular/permanent capture of the system status using sensor technology and measuring systems, such as endoscopy, thermography, and vibration measurement
Objective: Condition-oriented maintenance using current system status.
MOVITRANS® Powering Options
MOVITRANS® is a sophisticated, no-contact inductive charging system that provides constant power to your AGVs. Due to it’s contactless, friction-free nature, MOVITRANS® requires zero maintenance and will accommodate a wide array of complex motion plans and can be supplied in multiple variants including; continuous charging loop, short recharging lands, or spot charges along the travel path.
Although the installation of MOVITRANS® requires minor alterations to your facility’s floor, the trade-off will work in your favour. Prior to installation, careful planning of your throughput process will be identified, and our MAXOLTUION® team of engineers will create a customized, highly efficient, motion plan using our sophisticated simulation software.
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MAXO-MS-TVO15 (Load Handling Device)
The MAXO-MS TVO15 AGV is programmed to connect with our unloading/loading station autonomously. The unloading/loading station is highly efficient and utilizes SEW-Eurodrive’s low voltage power rollers (ECDriveS®).
The two-part integrated loading station is a demonstration of our system solutions customization competencies. Each industry will have its own set of customization requirements for payload management, and our team of engineers are ready to solve any pain points within your facility’s motion plans. Our base loading stations are engineered for the modern era with an emphasis on compact form factor, low profile design, scalable modularity, and customization.
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ECDrivesS® Power Rollers
ECDriveS® are low voltage power rollers, and idlers that available in PVC coated Stainless steel and the Galvanized steel. The roller conveyors are linked using a ribbed timing belt, or an O-ring belt. The 24-volt control heads are used to partition the conveyor’s system into multiple conveyor segments with multiple speed variations based on the sensors and the zone settings.
The control heads that regulate the speed and the speed zones are neatly hidden within the frame of the AGV, resulting in a compact form factor. The conveyor set can be divided into different speed zones and vary the speed of the load being transferred between each zone.
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