Integrating Industry 4.0 Solutions Into Your Coating Operation

Q: What are some of the new Industry 4.0 and automation technologies in the finishing industry, and how can I use them to improve my process?

A: Cloud-based remote troubleshooting

Traditionally, if equipment went down and the operator could not resolve the problem, you would have to wait hours, days, or even weeks for a service tech to diagnose the issue. But advancements in cloud-based connectivity can make this situation a thing of the past. On equipment with remote troubleshooting, so long as it’s connected to the internet through a wired, wireless, or even cellular connection, technical support can log in, in real-time, to complete almost all the same troubleshooting functions as if they were standing next to the unit, such as running diagnostics and performing test runs, to get you back up and running in minutes instead of days or weeks.

Real-time process control on ancillary equipment

Automated process control and monitoring have become more common on many of the major pieces of equipment in finishing systems. But more recent is the use of this technology on many types of ancillary equipment, such as agitators, regulators, valves, and pumps. By interconnecting the data from all devices alongside the equipment, a complete picture of your process can be viewed in real-time. And this data is then used by new smart systems to automatically adjust each component as necessary to optimize your process as conditions change. Rather than requiring an operator to change pressures and speeds as volumes, temperatures, or change humidity, changes can be completed automatically. The best systems are modular, allowing you to easily add new components as your process grows, without much of the time-consuming programming and integration required by legacy systems.

Predictive maintenance

Unexpected downtime due to unplanned maintenance or repairs is one of the biggest headaches for a plant. But this can be significantly reduced by equipment that automatically alerts when maintenance tasks are required. More advanced systems actively monitor uptime, operating conditions, and intensity of work to predict the optimal time to complete maintenance. The added benefit is not having to complete maintenance more often than necessary when the equipment is seeing a lower utilization rate, saving you money on labor and spare parts.

Q: I’d like to start using some of the new industrial web and cloud-based technologies in my plant, but how do I get around my management’s or IT’s concerns about data security and costs of integration?

A: Review the costs of IoT connectivity vs. traditional integration

One of the most significant benefits of the cloud-based revolution is reducing service costs relative to traditional systems integration, monitoring, and control. Rather than paying for a custom, ground-up solution for your specific process, you can now take advantage of the economies of scale a cloud-based system provides while still tailoring that service to your process needs. Many services have reasonable à la carte-based monthly or yearly pricing systems or are even complimentary with equipment purchase. When calculating your ROI potential for a service, include the most visible savings, such as material waste reduction, and the less obvious ones, such as reductions in rework due to improved process control.

Start small, focus on your most important KPI

It can be overwhelming to choose from the wide range of services and associated data intelligence available and even harder to make the business case for all of them. Instead, start by focusing on the most important KPI for your business or biggest headache. If it’s unplanned downtime, focus on equipment or a service that provides predictive maintenance. If it’s reducing material waste, focus on a service that tracks material usage, operator efficiency, and day-to-day or hour-by-hour variances. This will lead to a business case that resonates with management and, once implemented, will get decision-makers more comfortable with future service additions.

Balance monetary benefits against additional data security efforts

Persuading a stubborn IT department to change legacy processes may seem like a daunting task. But it can be successfully tackled by focusing on how the monetary benefits of the switch greatly outweigh the potential costs of new cloud-based security protocols. Work with the equipment or service provider to build an ROI calculation tailored to your process and goals. Being a first-mover in your industry can provide a major leg up over your competition, but if your company prefers a more conservative approach, focus on the successes similar cloud-adopting companies have generated to strengthen your business case.