Considering shifting your manufacturing into the cloud? Read the practical steps from Naveen Nadesan, ANCA Motion Global Marketing Manager, to make the most of the move.
Connectivity with the world is now something we take for granted in our everyday lives. We no longer need to be in the office to check emails, receive calls or even access our files. We can be anywhere in the world and, thanks to the cloud and mobile technology, still be connected. It’s a world of digital transformation that now applies to CNC machines.
New cloud-based management software, along with the Internet of Things – that is the networking of machines that send and receive data – are helping us design, test and produce parts no matter where we are, or where our facilities are. Pooling of live data in t he cloud means we can now optimise our processes in real time, even from the other side of the world.
Here are five ways the cloud will enhance CNC machines.
1. The cloud improves CNC machine productivity
“We need more of it and faster.” Ever heard that one? Cloud-based management of CNC machines can improve productivity through the removal of complex workflows, reduced costs for installation and manufacturing and the big one… automation.
Think also of the productivity gains that are possible when operation staff can access information and collaborate remotely as well as make updates in real time from multiple locations.
Automation on machines also means you can reduce the cost of doing business as manufacturers can run part batches ‘lights out’. This means that no matter where in the world you can be competitive – even in traditionally higher cost labour regions.
Cloud-based management of your machines gives you the ability to monitor them and production in real time and make faster, informed decisions about your capabilities.
This greater visibility provides insight into your supply chain and usage patterns including production levels, inventory, available capacity, quality levels and order status – without delay. This in turn will help you manage customer expectations around delivery.
3. Less downtime for more business continuity
How much time did you lose last year to unplanned machine downtime? CNC machines that are connected to the cloud provide constant data about their health and productivity. Sharing this information across the business can help identify production problems, including root causes, and also help predict machine failures before they happen.
The cloud is also your secure, offsite data backup. If and when something goes wrong there’s no need to worry about when the last manual back up was done – it’s automatically taken care of.
There is often a concern that the cloud may not provide the same IP protection as on-site data management. The truth is that the cloud may be less risky than your existing setup. Moving to the cloud means your business can access the policies and controls of your cloud host, without paying for the cost of maintaining facilities and hardware.
According to the World Intellectual Property Association, most IP data breaches occur internally as a result of access and privilege abuse. The cloud allows you to create levels of security and encryption to better protect your IP from internal abuse.
A proper cloud management suite can provide data encryption, automated software updates, automated backup and data centre grade security without the cost of having a full-time IT department.
5. Improved CNC Machine quality
Quality and precision are everything when it comes to high end CNC machined parts. Even small variances in performance can cause manufacturing disruption and costly recalls.
Cloud technology is helping tool manufacturers more easily develop customer scripting and maintain a high level of accuracy, even on large batches.
It also helps enable virtual simulation of tooling and modelling which can reduce waste and speed up trials.
Cloud-connectivity is the next big step for CNC machines. By taking the leap your business can reap the time, security, cost and productivity rewards, not to mention increasing visibility over operations no matter where you are in the world.
Thailand is gearing up for Industry 4.0. Here’s a look at the opportunities and strengths that the second largest economy in ASEAN has to offer, and its manufacturing outlook for this year.
Thailand is the second largest economy in Southeast Asia, consistently achieving robust economic growth driven by its strong fundamentals and diverse industries. Its GDP expanded by 2.4 percent in the third quarter of 2019, driven mainly by increases in private and government final consumption expenditure and investment, according to the Thailand Development Research Institute (TDRI). From January to September 2019, Thailand’s economy expanded by 2.5 percent overall, according to the Asian Development Bank (ADB).
The industrial sector represents between 35 percent and 40 percent of Thailand’s GDP, with manufacturing as its main component. Top manufacturing products include automobiles and electronics products. During the first three quarters of 2019, automotive parts and accessories, and computer, equipment and parts are the country’s top two exports, according data from the Ministry of Commerce.
Thailand’s exports to the United States has somewhat benefited from the trade diversion caused by the continuing trade tensions between China and the United States. According to data from the US Census Bureau, Thai exports to the United States reached $27.77 billion from January to October 2019, up by 4.23 percent compared to the same period in the previous year. This accounted for 5.3 percent of Thailand’s total exports during the period.
Many companies in China that export to United States have relocated to ASEAN to circumvent tariffs. Thailand is the second highest recipient of the relocation, with Japanese companies being the majority, particularly in automotive parts and electrical appliances.
The impact of these relocations to Thailand will be more evident in 2020 and is expected to be among the main drivers of the country’s economy, together with greater government spending.
Dr. Djitt Laowattana
Gearing Up for Industry 4.0
At present, there are a lot of investments from mainland China, South Korea, and Japan, coming to Thailand, according to Dr. Djitt Laowattana, Executive Advisor, Eastern Economic Corridor Office (EEC) of Thailand. And most of them are already Industry 4.0, he adds.
“But the local industry is still not acquainted to it. We are still lagging. We are at around Industry 2.5 or 3.0, so, it is a big change in the landscape of the local industry,” says Dr. Laowattana. Based on his recent study, he notes that the necessity for implementing and adopting robotics and automation is a reality now in Thailand.
“Before, when you install one robot, the breakeven is maybe around four or five years. But now, when you install one robot, the breakeven can just be around six or seven months. There’s no need to convince factories anymore,” Dr. Laowattana explains.
EEC Infra Projects in Progress
Dr. Laowattana is currently responsible for five clusters that will be set up in the EEC: Robotics, Aerospace, Medical/Health, Digital Hub, and Biofuels/Biochemicals. “I am responsible for the investment strategy and the human resource development at EEC. We projected that for the 10 clusters, within five years, Thailand will need about 475,000 workers for the industry,” says Dr. Laowattana.
While training and education are important to take advantage of these new manufacturing and technology developments, those already in the industry will also be able to enhance their knowledge on these new technologies through trade events and exhibitions, for instance, the Manufacturing Expo 2020, which is ASEAN’s leading machinery and technology event for manufacturing and supporting industries; as well as trade publications.
The Thai government has earmarked THB1.7 trillion for the development of the EEC. One key development is the upgrading of the U-Tapao International Airport into an “aviation hub”, which will include a maintenance, repair, and overhaul (MRO) centre.
The region currently has spearheaded three smart cities, which aims to be smart cites for logistics, financial hub and aerotropolis. According to Dr. Laowattana, when investors look at the EEC, they are not looking at it as a portal of Thailand, but as a portal for CLMV—Cambodia, Laos, Myanmar, and Vietnam.
“The FDI [foreign direct investment] is expected to be about THB4 trillion for the next five years,” says Dr. Laowattana. “Right now, the investments are about THB800 billion—of which, 58% is from China, followed by Japan. We are in a good track. With the investment of THB1.7 trillion for the infrastructure and expected FDI of about THB3 or THB4 trillion for the next five years [in the EEC], anybody can compute and collate that the GDP will be up 2 or 3 percent easily.”
Evolving Manufacturing Landscape
The necessity for implementing and adopting robotics and automation is a reality now in Thailand.
Thailand’s EEC aims to promote industries that are considered to be key driving forces for sustainable economic growth. And one key area of further development is the automotive manufacturing sector.
Thailand has developed from an assembler of automotive components into a top automotive manufacturing and export hub. It ships to more than 100 countries and has an established presence of almost all the world’s leading automotive manufacturers, assemblers and component makers.
In fact, by 2020, Thailand aims to manufacture 3.5 million units of vehicles to become one of the top performers in the global automotive market.
According to Dr. Laowattana, because Thailand’s automotive industry is huge, the challenge for new technologies such as hybrid and electric vehicles (HEVs) is the development of the supply chain around it. “But because this is a global trend, we cannot avoid it. Some of the part suppliers, we have to convert them to become precision parts manufacturers for the aerospace industry. When vehicles become EVs, the precision parts of the engine will be obsolete; so, the suppliers, manufacturers of precision parts, they have to move from the automotive to the aerospace,” Dr. Laowattana says. “My responsibility is to convert them to be the parts manufacturer for the aerospace industry. And there will be a major MRO set up in the EEC. MRO will be a critical component in the aerospace cluster.”
Regarding the transition to EVs, automotive leaders such as Toyota and Honda have already applied for investment incentives for EVs in Thailand. “It seems to me that they are finally doing it, while still maintaining the traditional automotive business. They are now trying to come up with prototypes to test whether EVs and hybrid vehicles will be practical in the Thai market.”
Thailand’s economic outlook is set to pick up this year because of improving state investment after the 2020 fiscal budget is disbursed, which is set to kick off in February. Another thing to note is the investments earmarked for the EEC. Likewise, private investments are also expected to rise despite myriad uncertainties, while exports are seen to improve. In addition, TDRI notes that household consumption is expected to grow at around 3 percent in 2020.
Productivity, in particular, is expected to improve in 2020. “New players are coming; in fact, we have one of the global leaders in robotics coming to Thailand,” says Dr. Laowattana. “I think the outlook for industrial automation will be better.”
Manufacturing Expo 2020, to be held 24–27 June at BITEC, Bangkok, is set to write a new chapter in manufacturing.
Such optimistic outlook bodes well for technology suppliers to Thailand’s high-tech industries, including automotive manufacturing. As Thailand gears up to enter the Industry 4.0 area, system suppliers and equipment makers will find a lot of opportunities to help Thai manufacturers upgrade their manufacturing capabilities, further improve their efficiencies and quality, and take their production to the next level.
As the world changes significantly and the manufacturing industry enters a new era where every single production process is being connected together with Internet of Things (IoT), robotics, and big data solutions, Manufacturing Expo 2020, to be held 24–27 June at BITEC, Bangkok, is set to write a new chapter in manufacturing by gathering the newest manufacturing technology innovations and solutions from 2,400 brands from 46 countries. The event aims to highlight the latest breakthroughs and changes happening in the manufacturing industry, and be the industry’s platform to further empower manufacturing development in Thailand.
Market outlook 2020: The year 2019 has been quite a challenging year for the manufacturing industry, with geopolitical tensions impacting investment decisions and shifts in manufacturing centres, and trends such as e-mobility, Industry 4.0, and additive manufacturing creating industrial transformation. In this Outlook 2020 special, six industry leaders share their thoughts on what to expect in 2020, how the industry will develop, new opportunities and market drivers, and how to navigate through the challenges and issues from these dynamics.
HEXAGON MANUFACTURING INTELLIGENCE
Lim Boon Choon, President, Asia Pacific, Hexagon Manufacturing Intelligence
The year 2019 was a time of economic uncertainty in global manufacturing. But the Asia Pacific region is well placed to capitalise on new opportunities in 2020, as increasing adoption of disruptive technologies shows organisations are facing market challenges by pursuing innovation-driven competitiveness. The growing recognition of the efficiency and operational excellence to be gained from digitised metrology offers long-term, sustainable investment and expansion in the Asia Pacific market.
The Growth of the Smart Factory
Increasingly connected enterprises will be a continuing trend throughout 2020 and beyond. The digital transformation of quality is a central part of this smart factory vision. Approaches to metrology data are maturing, and companies are focused on gaining actionable insights from real-time data. Growing demand for data analysis software is expected, and the adoption of platforms offering advanced big data and Industrial Internet of Things (IIoT) capabilities will enable far more predictive and proactive manufacturing.
Across the region, new business models will emerge with the prevalence of cloud computing, connecting quality systems to machines throughout end-to-end processes and across factories. Streamlining the analysis and communication of metrology data is essential to breakdown operational silos and drive growth by enhancing product customisation capabilities and throughput.
The trend of automating metrology operations will continue to grow with the increasing adoption of robotics, measuring cells, and automated part loading, enabling manufacturers to scale up their autonomous capabilities. And as manufacturers look to increase their application flexibility, demand for non-contact 3D scanning technology will increase.
Driving Additive Manufacturing Capabilities
Additive manufacturing, also known as industrial 3D printing, is still emerging in sectors such as medical, transportation and logistics, construction, aviation, automotive, and shipping. But according to research from Thyssenkrupp, 3D printing is expected to create $100 billion in value in the ASEAN region by 2025. Quality will play a central role in expanding this developing process, with technologies such as 3D scanning and computed tomography (CT) for measuring internal geometries. Additive manufacturing is a key area of strategic importance for Hexagon. The recent acquisition of CT software provider Volume Graphics adds advanced measurement capabilities to Hexagon’s already comprehensive solution portfolio in the additive space, which also includes software for generative design and additive process simulation.
The expected widespread adoption of smart technologies suggests 2020 will mark a major step forward on the industry 4.0 journey.
Meir Noybauer, Business Development Manager, ISCAR
Throughout the year 2020, the industry as we know it will shift towards smart factories with IoT (Internet of Things) cyber connectivity, and AI (artificial intelligence) and robotics technologies, that will most likely be developed in the main industrial hubs as part of the fourth industrial revolution (Industry 4.0).
Additive Manufacturing and other advanced manufacturing technologies will continue to grow and replace conventional methods for machining automotive, aerospace and energy parts, and facilitate new opportunities for complicated part designs that were previously unrealizable.
The global search for clean energy and low-emission mobility is leaning towards newer and harder materials, which challenge ISCAR to develop advanced machining technologies, such as SiAlON ceramics and super alloy materials, while using high and ultra-high coolant pressure to boost productivities to higher levels never seen before.
The medical sector will be one of the emerging industry segments, with sophisticated implants using advanced materials and machining technologies jointly developed by ISCAR engineers and leading medical implant companies throughout Europe, the US and Eastern Asia.
The automotive segment will continue to be a global industry leader, while transitioning from conventional combustion to small hybrid-high efficiency engines and electric e-drive cars and implementing other clean mobile technologies, specifically for electric charging infrastructures which have not yet been applied in many countries.
Stefano Corradini, Group Director, Sales & Marketing, Marposs
The year 2020 appears to be one of the most challenging years of the last decade, both in the Asia Pacific and worldwide.
The combination of trade wars and their impact on several geographic areas and market sectors, social turmoil in various countries, and many technological changes as consequence of increased environmental concerns, may have a significant negative effect on the general economic situation.
Automotive Manufacturing Evolution
Being a significant part of Marposs business somehow related to the automotive sector, we see the evolution from internal combustion engine (ICE) to electromobility as one of the biggest driver of the economic uncertainty. We prefer, anyway, to see this as an opportunity to offer our existing and new customers an extended panel of solutions, which are moving from our traditional measuring sector to a broader concept including several type of testing equipment (mainly leak test using different type of tracer gas extended also to fuel cells), as well as inspection applications (non-destructive, vision, and similar), and control systems to monitor the whole manufacturing process of the core components of the NEVs/BEVs (new/battery energy vehicles), such as battery cells, modules and packs, battery trays, and electric drive units (EDU) including electric motors; and end of line testing.
We are willing to become a preferred partner of BEV manufacturers and suppliers as we have been for decades for traditional combustion engines, offering them our technical know-how, our innovation culture, and our worldwide organization for sales and after sales.
Steve Bell, General Manager, ASEAN, Renishaw (Singapore) Pte Ltd
Smart manufacturing technologies increase visibility and transparency to manufacturing operations, allowing manufacturers to get the overall picture of their productivity and competitiveness, to make faster changes in response to market-based threats or opportunities. This requires a range of intelligent process control solutions throughout the factory, to ensure high standards of repeatability. The key is going digital—connecting physical manufacturing processes with the digital technology to make decisions about process improvement on the shop floor, or on mobile devices.
Flexible and Customised
Additive manufacturing plays a major role in the Industry 4.0 revolution, allowing manufacturers the flexibility to build highly customised parts. Renishaw’s additive manufacturing technologies continue to evolve, aiming to provide users the flexibility to use, change and manage different metal materials, enables users to adapt to meet market demand and configure processes to achieve optimal performance.
Focus on Automotive Industry
Ensuring businesses are equipped and ready to navigate the evolving automotive manufacturing landscape, Renishaw’s manufacturing solutions provide the speed, flexibility, and ease of use to help companies adapt their production capabilities for the evolving electric future. From multi-sensor rapid scanning of machined castings to material analysis of fuel cells, we will continue to support customers on the road from internal combustion engine (ICE) to electric vehicles (EV).
SIEMENS DIGITAL INDUSTRIES SOFTWARE
Alex Teo, Managing Director, Southeast Asia, Siemens Digital Industries Software
The maturity of manufacturing supply chains in Asia has undoubtedly exerted pressure on the metalworking industry to be more competitive than ever. Demand for steel in Asia is expected to rise by an average of 1.5 percent in 2020, and will likely see effects such as rising operating costs necessitating the move for businesses to look for technology driven solutions to relieve some of these operational strains. In particular, Southeast Asia is an exciting region for growth, with markets such as Malaysia, Vietnam, and Singapore making strides in realising their Industry 4.0 visions through digitalisation. In 2020, we also launched a Technical Competency Hub in Penang, the first in the region, which serves as a platform for Siemens to help companies, especially SMEs, begin their digitalisation journey in order to meet the needs of the new economy.
Using digital twins, manufacturers will be able to explore more economical and structurally enhanced materials. By leveraging physics-based simulations, supported by data analytics in an entirely virtual environment, the expansion of production capacity in Asia can be further encouraged. This means that manufacturers can optimise their choice of materials by testing and analysing combinations of different metals and alloys digitally before using additive manufacturing technologies such as powder bed fusion to produce these components faster and more reliably, reducing the need and cost for real prototypes.
Siemens’ end-to-end additive manufacturing solutions cover CAD/CAM/CAE models that enable product design and simulation of production processes and planning, preparation, and verification of the print jobs. Simulation and 3D modelling allow for advanced complexity of design and quality, ultimately resulting in fewer distortions and errors. The goal is flawless execution when parts come out of a factory, ready for certification. The full additive challenge covers the entire value chain: product design, production process, and performance.
Using customisable solutions for pressing, transporting, positioning and press safety, in combination with simulation for the entire spectrum of metal forming, businesses can proactively advance with components working seamlessly together. This collaboration increases the cost-effectiveness of all production processes in all sectors, reducing energy costs.
The economic environment for the international and German machine tool industry remains difficult now and in the coming months. After eight years of high economic activity in the international machine tool industry, global demand for capital goods has calmed considerably after the fourth quarter of 2018. The reasons for this have already been identified and discussed many times. The economic distortions, in particular the trade war between the United States and China, are boosting the already sharp drop in demand. The increasing protectionism at all levels is affecting world trade and international supply chains. Finally, the structural shift in the automotive industry towards new drive technologies is causing further problems. It is still questionable at what pace and extent development is progressing and which technologies will be used in the future. The entire scenario is unsettling the industry worldwide. Companies have become very cautious, and they are shifting their investments.
Because of these, incoming orders in the international machine tool industry fell sharply in all regions in the first nine months of 2019. According to initial estimates, orders worldwide fell by 21 percent. Asia declined by 24 percent, while Europe lost 19 percent of its orders. Contracts in America, which is particularly the United States, held up best, if we can say so. They went down 18 percent in comparison to the previous year. In Germany, with its high dependence on exports, incoming orders fell by 23 percent by October in 2019, the most recent available data. This applies equally to domestic and foreign orders.
Markets to Stabilise
Oxford Economics, the VDW’s forecasting partner, expects this trend to stabilise in the best case scenario for 2020. At 2.5 percent, global economic output is expected to be slightly below the increase in 2019. With 2.1 percent, industrial production will grow more strongly than the current year. This also applies to investments. Stabilisation is also expected for the whole German economy. Industrial production, which is expected to shrink in 2019, is likely to turn slightly up again. This means that incoming orders in the machine tool industry will probably go through the bottom in the course of the coming year.
Machine tool consumption, a late indicator, will remain negative in all regions. Asia is the exception. Manufacturers can draw new hope from the fact that the election results in Great Britain have now provided certainty about the island’s exit date from the European Union. Then, the negotiations on a tariff agreement can begin and hopefully lead to a good end. There is also movement in the trade conflict between the United States and China. Should a consensus be reached, the world economy will reach new momentum as well.
As we move into 2020, we take a look back at the most popular Industry 4.0/Automation and Additive Manufacturing articles for 2019. For your enjoyment, here is the list of the top 10 Industry 4.0 and top five most read Additive Manufacturing articles over the past year.
The second edition of ITAP 2019 – A HANNOVER MESSE event, held from October 22 to 24 at the Singapore EXPO & MAX Atria attracted a record of over 18,000 industry practitioners from 77 countries—a 20 percent increase from last year—of which 27 percent were C-Level attendees.
A total of 350 exhibitors from 30 countries were featured at the event, an increase of 32 percent from last year. Industrial Transformation ASIA-PACIFIC 2019 also played host to eight national pavilions, a 60 percent increase from 2018.
With 13 landmark MOUs signed, ITAP 2019 proves to be Asia Pacific’s pre-eminent platform once again, bringing thought leaders, industry partners and policy makers together to generate ideas—enabling a growing ecosystem of Industry 4.0 (I4.0) practitioners to overcome challenges and future-proof their businesses.
A showcase of actionable I4.0 solutions to start, scale and sustain
One hundred more exhibitors were featured this year taking the total to 350 exhibitors across five exhibition segments: Additive Manufacturing; Digital Factory; Integrated Energy; Industrial Automation; and Smart Logistics. Integrated Energy, a new segment, presented 18 exhibitors who showcased innovative sustainable solutions to improve energy efficiency in factories.
Sunil Wahi, Senior Sales Director, Head of Supply Chain Applications, Asia Pacific, Oracle, said, “The exchange and dialogue that Oracle have had with the ecosystem at this event have been phenomenal. ITAP 2019 has allowed us to have meaningful conversations with CXOs about where to start on their I4.0 journey and how they could leverage the cloud applications that Oracle has to offer.”
Fueling high-level international engagements
There were more international representations this year with 3,255 unique foreign attendees (18 percent of total attendees in 2019 and a 67 percent increase from last year), 200 hosted buyers from the region (67 percent increase from last year), 47 regional delegations and eight national pavilions.
The Russian Federation presented an impressive pavilion showcasing I4.0 solutions from 70 high-tech companies and electronic products across several sectors: industrial automation; digital factory; medical technologies; integrated energy; aerospace; artificial intelligence; cybersecurity; and electronics. There were close to 700 meetings with potential partners from Asia Pacific.
A learning journey with customisable I4.0 solutions
This year saw 2,700 guided tour participants (29 percent increase from last year) who actively learnt more about old vs new technologies. The show’s signature Learning Journey approach included the highly anticipated new space, Collaboration Lab, a co-creation and demonstration area for solution providers and manufacturers to discuss test-bedding and retrofitting solutions for a stepped approach towards progressive adoption of I4.0 solutions.
Together with other curated platforms that enhanced the intersection of industries to exchange and explore new ideas, the show facilitated 1,100 business matchings (41 percent increase from last year) and saw the launch of 30 new products with significant MOUs signed among industry players.
James Boey, Executive Director of SingEx Exhibitions said, “We set out last year to curate a platform that would inspire learning, deepen understanding of I4.0 solutions and spark collaborations among industry giants, SMEs and startups. This year, with the introduction of new content and more opportunities for business matching and collaborations, the event exceeded our expectations. With 67 percent more regional delegations, 13 MOUs sealed and 30 new product launches, it is evident that Asia Pacific is already undergoing change, and Industrial Transformation ASIA-PACIFIC is central to this transformation where practitioners gain knowledge, make valuable connections and adopt best practices for better implementation of I4.0 solutions. The strong attendance of ASEAN delegations from Brunei, Cambodia, Indonesia, Malaysia and the Philippines was testament to the significance of the show in meeting current market demands.”
Next year’s ITAP will be held 20 to 22 October 2020.
With Industry 4.0 and the rise of the Internet of Things (IoT), the heavy industries of manufacturing, construction, transportation and utilities are becoming ever more connected. Gartner forecasts that 25 billion connected things will be in use by 2021, capturing huge amounts of data information, including videos, images – all with the help of AI.
In order to do that, organisations are required to have the ability to understand data. In other words, they need to be data literate.
If organisations are to develop data literacy, the opportunity present is significant. Qlik’s Data Literacy Index states that if companies improve corporate data literacy levels, their enterprise value may increase between three and five percent, which equates to a staggering $324 to $534 million.
TOP INDUSTRY 4.0/AUTOMATION ARTICLES FOR THE MONTH
However, improving data literacy might be challenging for businesses operating in heavy industries. Leaders in the manufacturing, resources and construction, transportation and utilities industries admitted that they lack confidence in their organisation’s data literacy. In fact, businesses are falling short when it comes to data literacy. It is reported that although 78 percent of the global workforce are willing to invest more time and energy into improving their data skill set, only 34 percent of firms are currently providing data literacy training and just 17 percent “significantly encourage” employees to become more comfortable with data.
Part of the issue may be the value which leaders in heavy industries place on data literacy, or the lack thereof. Despite the ongoing conversation of Industry 4.0 and the increasing use of IoT, less than half of business leaders from the sector believe that data literacy is relevant to their industry.
This might be unlikely to change soon – just under a third of business leaders surveyed think data literacy is a very important factor when hiring, suggesting that it is not of priority for all.
This might seem like a contradiction – to have smart factories, meters, wind turbines, and connected housing; yet, limited desire to understand the data that all these innovations generate. One of the current issues is that, whilst leaders recognise the value of connecting production lines, processes and hardware, many are only looking at each part in isolation. So, for instance, that might mean investing in sensors to monitor heavy goods vehicles for maintenance, and separating the technology used for tracking locations, without thinking of how the two can work together. In effect, this creates data silos, where the lack of a complete view amounts to extracting a limited value.
The research results confirm this challenge, with few leaders expecting employees to be data literate – only 14 percent of heavy industry respondents significantly encourage their workforces to be comfortable with data, and less than a third (32 percent) provide data literacy training. Most tellingly, just a quarter of the sector communicated that they are willing to extend a higher salary to employees who are data literate.
That said, there are some areas which the heavy industries are focusing on. While the heavy industries reported a lower usage of data decision making than other sectors in the Index, they outperformed the cross-industry average when it came to data analysis. 37 percent of heavy industry respondents reported that data analysis influences the corporate performance measurement and demand forecasting, 11 percent ahead of the average. A deeper dive into heavy industries finds that 73 percent of engineers use data analytics, well ahead of banking (54 percent), the commercial sector (56 percent) or services (58 percent).
Is this light at the end of the tunnel, or merely a silver lining? With data analytics often being the first step in cohesive data comprehension, I hope the former over the latter. As with any industry, there are examples of manufacturers, utilities companies and logistics businesses understanding the power of data or rejecting it completely. Most sit somewhere in the middle, perhaps wrestling with contrasts and contradictions within their own organisation.
What is clear, though, is that ongoing investments are being made in technology to unlock new opportunities. In spite of that, true success will be out of reach without an increase of data literacy level. If these remain low, companies in the heavy industries run the risk of losing valuable ground on competitors and struggling to thrive in this data-driven era.
Article by Jeremy Sim – Senior Director, Industry Solutions, Global Manufacturing & HighTech and Retail
Manufacturing business growth has continued to rise over the past year, but at a much slower rate than the previous 12 months. Despite challenging market conditions and the difficulty in recruiting and retaining skilled staff, there has been a marginal one percent rise in the number of businesses reporting growth. These findings are survey results unveiled today from the annual Global Growth Index by Epicor Software Corporation—a global provider of industry-specific enterprise software to promote business growth.
For those companies who have experienced growth, maintaining it hasn’t been easy over the past year. Fifty-three percent admit it has been challenging, whilst a fifth (23 percent) have found it stressful. Thirty-five percent of businesses cite market conditions as having a negative impact on growth, and 32 percent feel that staff skills and experience have also played a detrimental part in maintaining growth.
Political volatility and uncertainty also continue to be a common cause for concern across the globe. Fifty-five percent of respondents cited the China-US trade dispute as likely to have a negative impact on future business growth. A quarter of businesses (26 percent) stated that the uncertainty surrounding Brexit is also still a big threat.
“The manufacturing industry plays an integral role in our global economy and people forget that it is responsible for delivering important products we use every day,” said Epicor CEO, Steve Murphy. “As such, the health of the manufacturing industry is something we should all be concerned about. While it’s good news to see that growth in this industry is still taking place, we need to keep a close eye on what factors are contributing to this growth and what factors are causing a lag. The information in the Global Growth Index empowers businesses so they can make strategic plans that will best position them for the future.”
The table below shows the Global Growth Index results for 2019 across six key indicators, compared with figures from 2018 and 2017. Percentages represent the median average number of businesses that have reported growth in each of the key growth metrics.
Growth performance indicator
% reporting growth
Exports and overseas sales
Average % recorded across all six attributes
Index (year one=base 100)
“Investing in the right technology, such as enterprise resource planning (ERP) solutions, can help businesses better plan for change by improving visibility and insights into current operational workflows. This can help alleviate stress and enable people to deal with challenges more effectively, by providing the flexibility, agility, and adaptability needed to respond to market conditions and customer demands. Technology can also have a positive influence on other factors including work ethic and staff recruitment and retention,” concluded Reid Paquin, research director, IDC.
In an interview with Asia Pacific Metalworking Equipment News, Uwe-Armin Ruttkamp of Siemens Digital Industries talked about how digitalisation is helping machine builders and users, the utilisation of data to improve manufacturing processes, as well as how umati will help push the metalworking industry forward. Article by Stephen Las Marias.
One of the highlights of Siemens’ booth at EMO Hannover 2019 is the latest generation of its Sinumerik One, the first digital native CNC aimed at driving the digital transformation in the machine tool industry. Siemens has also extended its Industrial Edge offerings for Sinumerik Edge to include more new applications to help machine tool users improve workpiece and process quality, increase machine availability, and further optimise machine processes.
With Sinumerik One, machine tool manufacturers can virtually map their entire development processes, significantly reducing the product development phase and time to market for new machines. This helps machine builders significantly reduce the duration of actual commissioning. Its virtual model opens up new possibilities for manufacturers and operators—machine concepts and functions can be discussed even before real hardware is available.
Sinumerik One enables machine users the programming of workpieces in the virtual environment and the setup and operation of machines completely on the PC. Employee training can also be carried out using the digital twin instead of the actual machine. These hardware and software innovations help machine builders and operators speed up processing steps significantly.
In an interview with Asia Pacific Metalworking Equipment News, Uwe-Armin Ruttkamp, Head of Machine Tool Systems, Motion Control Business Unit, Siemens Digital Industries, talked more about the benefits of these new technologies and how digitalisation is helping machine builders and users. He also discussed the utilisation of data to improve manufacturing processes, as well as how umati will help push the metalworking industry forward.
When we look at the current potential for these technologies and all that they involve, are they more suited to advanced markets such as Europe or the US?
Uwe-Armin Ruttkamp (UR): I wouldn’t say so. You have all kinds of industries also in Asian countries. Not everything is low-cost and price-driven; they are also technology driven, especially aerospace, automotive industries, or the upcoming additive manufacturing.
So, there’s a lot of technologies driving the industries. In addition to this, labour is not staying on this low-cost level—in Asian countries, people want to earn more money as well—so saving time, and saving cost by saving time, is also an issue for Asian countries.
How does this technology play out in the smart factory concept?
UR: It plays perfectly into that concept, because with our Digital Enterprise (DE) Portfolio we offer a holistic end-to-end solution including industrial software and automation that allows the use of a seamless value chain. This value chain consists of five steps for the machine user, and five steps for the machine builder. If you build a machine, you start with a concept, mechanics, you go to electrical design, you go to engineering, you go to commissioning, and sometimes, it also needs service.
For the machine user, there are also several steps needed to build a part. Get the machine on the shop floor, create a part, build the part, check it for quality, and ship it. And this complete concept is the basis for running a smart factory.
In a lot of these steps, Sinumerik One brings great benefits. For example, in machine engineering, people in the offices can engineer the machine. You don’t need to have a test rack next to your desk, and you don’t need to go to the shop floor to test the applications. You can do it all in the virtual world. That’s one perfect example of an Industry 4.0 application that people will get from our Sinumerik One concept.
How do you see digital twins being implemented by customers in Asia?
UR: I see a lot of customers thinking about it. We talk to many customers, including those in Asia. We, for example, are customers of our customers. We have factories ourselves. And we only buy machines where we can get a digital twin beforehand. We make it a prerequisite for purchasing a machine, that it comes with a digital twin. And I believe in future many other users are going to do the same. The benefits are huge. You can train the people, who are going to operate the machine, before the machine is even delivered. And even more, you can also do the run-ins, do the first test of the programs, and know the cycle time of the production, before the machine is delivered.
Does siemens have a benchmark so that when machine users’ data are analysed, they will determine whether they are doing okay or they are falling short?
UR: We offer from our service department a digitalisation check. Together with our customers we examine their factories and give them advise what digitalisation measures are in place to get to another productivity level. It’s a consulting approach not a benchmark.
More and more people are talking about the lights out factory. how are you helping customers go into that level of manufacturing?
UR: Lights out factories are not new. When you go into an automotive factory, for example they produce the same part over and over, it is relatively an automated production. So, what they have done, of course, is to use a CAD/CAM chain, which, out from the design of the piece, create the program to build the piece, download it into the machine, and run it. Of course, this is something we support with our DE portfolio. You can put a program into the machine remotely, and then run it automatically. But of course, it requires in-feed of the materials and taking out the material and the pieces produced. But then again, you need automation, and the complete tool chain and software, like NX for example, or TeamCenter, to have a data backbone for all the production information about the part. But there are other companies focusing on job shops, so they produce many different parts every day according to customer specifications. For them it does not make sense run a fully automated line. So, a lights-out factory for them is not possible.
One of the highlights of emo 2019 is umati. How are you supporting this initiative?
UR: We support it 100 percent. We are part of the initiative and helped it to get to the point where we are today. At Siemens our solution to serve a universal interface for machine tools is based on our industrial edge concept. Edge computing is the perfect solution for this. For example, one wants to have a central dashboard, which shows the amount of cooling liquid used per hour. Cooling liquid per hour is not stored as one piece of information in all the machines in the same way. You need to have some sort of programming that knows where that data is stored in the machine and sends it out in a uniform way. Our Siemens industrial edge concept is perfectly suited for this, because OPC-UA is built into our edge devices. This allows the machines to communicate the data provided based on OPC-UA, and the user can program a little piece of code into it to acquire the data out of the machine.
The specifications for umati is still being finalised. during its early development, what were the challenges that you experienced, and are they still a challenge now?
UR: From a technical perspective, it’s not difficult, because it is OPC-UA, and it is a definition of data. It is basically a companion stem based on OPC-UA. The difficult part was to get an agreement among all parties which data they want to support, or which use cases they want to support. Once umati defines which piece of information has to be programmed, it’s done. It’s relatively simple.
Here’s a look at how cloud computing is transforming metalworking. Article by John Young, EU Automation.
Metalworking has played a pivotal role in the evolution of mankind, so much so that there are entire periods of history named after metals. While the Iron and Bronze Ages are behind us, society is framed by a whole other frontier of technology — The Information Age. But can the legacy of metalworking and the evolution of digitalisation work in unison?
Despite its deep-rooted history, metal fabrication remains an essential process in modern manufacturing. Rising urbanisation and industrialisation, burgeoning automotive and aerospace industries and new advancements in metal forming are just some of the many reasons why metalworking faces increased demand and expanding production.
As the Internet of Things (IoT) hits the shop floor, insight into its vast network of communicating machinery is accompanied by an ever-increasing access to the internet. The more machines ‘talk’, the more information they produce and as we enter the dawn of a data-driven era, managing this information is integral to its value.
Up in the Air
Also called ‘The Cloud’, cloud computing refers to software applications that run on remote servers instead of a user’s onsite IT infrastructure. The on-demand computing resource is gaining significant traction across industries that are looking to easily manage and access their data from anywhere in the world.
Regions all over the world are beginning to adopt the technology—and the Asia-Pacific region is no exception to the trend. In fact, the APAC region has been keen to reap the benefits of cloud computing across many of its industries.
Established in 2010, the Asia Cloud Computing Association (ACCA) represents the stakeholders of Asia’s cloud computing ecosystem and works to accelerate the growth of the technology across the region. According to ACCA’s 2018 Cloud Readiness Index (CRI), Singapore is APAC’s most cloud-ready region and, alongside Hong Kong, is a global leader in cloud readiness. Far ahead of larger economies such as the United Kingdom, Germany and the United States, Singapore represents the APAC region’s swift adoption of the technology.
Blue Skies Beyond
Effective implementation of cloud computing goes beyond connecting your shop floor devices to the sky—it means connecting your shop floor to the rest of the business. With one accurate record on hand, employees, suppliers and partners can all refer to a single source of reliable information to increase consistency.
The innate scalability of cloud computing means that manufacturers can easily accommodate changes and growth to their projects. Resources can be leveraged on a pay-as-you-go or on-demand basis, which gives access to additional assets when required and without the need to invest in an expensive network of internal infrastructure.
Cloud computing can also accommodate product development with ease by facilitating collaboration with engineers and other members of the product development team much earlier in the design process, reducing the time frame from conception to launch.
Pass the Test
Quality often overtakes quantity in metal working, as errors can jeopardise both the function and appearance of products. One hurdle that manufacturers in the metal industry need to overcome is passivity.
Stainless steel doesn’t rust—in theory. Stainless steel is often corrosion resistant, but that doesn’t mean that it is completely impervious to rusting. To combat corrosion, the metal undergoes a treatment process known as passivation, which involves using an acidic solution to remove the free iron from the metal’s surface.
Once the surface iron is removed, the other components of the alloy—namely chromium and nickel—are left behind as a surface layer over the steel. Once these elements react with air, they form a protective oxide layer that prevents the steel from rusting.
More frequently, customers are asking for a passivity guarantee to ensure the quality of their steel. But measuring, verifying and reporting on an invisible layer of protective coating can be difficult, time-consuming and expensive. During testing, a section of steel that has undergone the same treatment as the end product is sent for verification from an independent lab.
However, concluding that the results from this sample are the same as those of the finished component is little more than an assumption—leaving manufacturers with little choice but to hope that the product passes the test. What’s more, receiving the test results can take hours, which could delay shipping if correction is required.
Cloud computing can provide a solution. With the help of a wireless tester, smartphone and cloud-based technology, data can be captured and reported from any location. Not only can IoT-enabled remote testing speed up the passivity process, but uploading the results to the cloud means that they can be shared with other departments and customers in an instant.
One surface technology company has already developed a cloud-based solution to streamline passivity testing. Walter Surface Technologies helps machine shops and fabricators leverage IoT technology with its cloud-based passivation app, which allows technicians to chart oxidation levels of stainless steel to measure its passivation state and seamlessly communicate it with the company’s customers.
Perhaps one of the best uses of the cloud is as part of asset maintenance. Sensors that collect data on the health of equipment can send this information to the cloud for analysis. There, a streaming data processor transmits the sensor data to storage, otherwise known as a data lake.
The data is still raw at this point, so may contain irrelevant items. To turn the data into insightful information, it is sent to the big data warehouse where it is analysed with machine learning algorithms. These algorithms reveal correlations in datasets and detect any abnormal patterns.
This data collected can then be fed back into planned predictive maintenance (PPM) schemes and remote monitoring of equipment. Unlike reactive maintenance, which involves waiting for a piece of machinery to break, PPM can be used ahead of time to prevent breakdowns and downtime.
For example, a brake press used to bend sheet metal into complex shapes requires accurate control for precise bending. To maintain a high level of product quality, it is crucial that all the machines’ components are in perfect working order.
Let’s say a motor in the brake press is running at an abnormally high temperature. Data in the cloud would be able to flag this abnormality to prompt plant managers to get in touch with a parts supplier such as EU Automation before a breakdown occurs, drastically reducing the amount of associated downtime.
The days of the Bronze Age are long gone—but there’s no questioning that we’re in the golden age of digital manufacturing. Cloud computing boasts several benefits that allow the technology to deliver a scalable and insightful solution to a variety of industries. Metalworking may be one of society’s most ancient processes, but cloud-based solutions can help breathe life into the sector by monitoring its core processes, improving product quality and providing workers with actionable insight to increase efficiency.
Stay ahead and relevant with Industrial Transformation ASIA-PACIFIC ITAP 2019 – A HANNOVER MESSE event, held from October 22 to 24 at Singapore EXPO & MAX Atria, brings together a growing ecosystem of Industry 4.0 (I4.0) practitioners and connects attendees to all aspects of their I4.0 needs, from learning and networking to problem-solving and retrofitting.
With trade tensions, slowing Chinese economic growth, and an uncertain Eurozone casting a shadow on a strained global economy, there is no better time than now for businesses to progress with transformation efforts and leverage available initiatives to enhance competitiveness through innovation, productivity growth and internationalisation.
ITAP 2019 SMEs in Asia-Pacific will not only hear from thought leaders, but will also be treated to an immersive experience through a showcase of actionable I4.0 solutions for companies looking to future-proof their businesses. Mr. Heng Swee Keat, Singapore’s Deputy Prime Minister and Minister for Finance, will be the Guest-of-Honour at the event’s Opening Ceremony.
Simon Lim, Executive Director for Manufacturing & Engineering, Enterprise Singapore said, “Industrial Transformation ASIA-PACIFIC ITAP 2019 brings together leading manufacturers and solution providers to exchange best practices, discover new technologies and catalyse partnerships in I4.0. Singapore has a strong manufacturing industry, which has enterprises in both manufacturing and the provision of manufacturing expertise and solutions. They are excited to be participating in the event, contributing to the exchange of best practices and technology in the industry. Enterprise Singapore is working closely with these enterprises to facilitate partnerships and support their move towards building smart factories of the future.”
Organised by SingEx Exhibitions and international partner, Deutsche Messe, Industrial Transformation ASIA-PACIFIC won the “Best Exhibition Organiser” award at the Singapore Tourism Awards for last year’s edition. The ITAP 2019 seminal event serves as a catalyst for the development of I4.0 thinking from awareness to driving adoption.
“With the comprehensive personalised learning opportunities provided for attendees, the show will help them – especially beginners and early adopters – find the right fit of I4.0 solutions with their stage of business development. SMEs, in particular, will find a support system where industry players can provide customisable and cost-effective solutions to help them optimise manufacturing processes or reinvent business models that satisfy client demands; and expand into new markets to grow their customer base,” shared Aloysius Arlando, CEO, SingEx Holdings. “We have also developed a digital engagement platform to help companies and practitioners learn, network and collaborate beyond the show.”
“The manufacturing industry today faces very different challenges compared to only a few years ago,” said Dr. Jochen Köckler, CEO, Deutsche Messe AG. “For example, customers want individualised products and same-day delivery at lower prices. In order to remain competitive in the global marketplace, companies need to embrace digitalisation. Industrial Transformation ASIA-PACIFIC brings together users and providers of all sizes to actively shape the Fourth Industrial Revolution in Singapore and the surrounding region.”
An immersive learning journey
Designed as a personalised learning journey with LIVE demonstrations, the “Gateway to Industry 4.0” is a curated gallery powered by TÜV SÜD on the evolution of I4.0. It aims to inspire delegates on how to implement I4.0 concepts by contrasting old-technology exhibits versus the new, showcasing the transformation and outcomes of practical applications demonstrating real benefits. Two new areas of interest are:
Collaboration Lab – Co-creation and demonstration areas for solution providers and manufacturers to discuss test-bedding and retrofitting solutions for a stepped approach towards progressive adoption of I4.0.
Robotics Experimental Zone – Future Lab featuring an innovative robotics display and interactive exhibits. Deepen the understanding on robotics application via talks, presentation sessions and workshops, and ideal for System Integrators, Product companies, Roboticist & Technologists, Procurement Engineers, I4.0 solution providers, Regional Robotics and automation stakeholders.
Other curated platforms that have been added to maintain momentum for I4.0 learning include: Over 60 Sandbox sessions providing practical learnings based on industry-specific challenges; a Research and Technology Zone to activate business collaborations through open innovations with technology providers and seekers; over 100 Guided Tours with 8 tracks covering 12 industries; and island-wide Technical Tours to leading R&D centres.