Smart Factories - trexDCAS

Smart Factory ;

In Smart Factory, each product can be followed up with an ID at the end of production (barcode, RFID, sensor, not marking on the product) Product traceability must be monitored instantaneously as software. Process data which can be accessed instantaneously in the parameters of the tools used in production (machine, robot, human, instrument) (tension, temperature, speed, pressure, energy consumption) should be kept in the statistical database. Software and hardware must be installed to remotely manage the production tools (machine, robot, human, instrument). Process data and data analysis of the output data produced should be used to make decisions or suggestion systems. Software that optimizes the production efficiency by using the process data from the production tools and the data from the system that evaluates the product quality should be used. Estimation systems should be established by creating scenarios and models with production data. Systems should be installed that can predict potential failures of production tools (sensors, forecasting software, statistical information associated with the manufacturer’s database). When the means of production give error, malfunction, maintenance need information, the related unit should be automatically transmitted.

Production;

The production plan should be automatically updated according to the conditions of the resources (human, material, machine, equipment, mold) to be used in production in accordance with the purposes for that time. Systems that minimize setup times should be installed when the product switches to the product. The production plan can be optimized according to the use of energy-intensive production tools (paint, drying) at times when energy is cheap. An accurate production plan should be made by estimating the past production data. The production plan should be optimized and simulated to optimize it. Production performance data should be shared instantly during operation.

Robotics;

The automation system should be installed, and the automation system should support the product type conversions. There should be robots and sensors that measure the quality of production. Robots must be mobile in multiple factories or departments. Robots working with personnel should improve the ergonomics of the working environment. (To make cargo movements easier, to do more delicate work.) To do non-complex work with robots Robots should be used for monotonous works for people. Robots should be used in dangerous work.

Social business network;

In-house communication network Applications that provide business-to-business interactions between departments should be used to receive instant support services.

Virtual Education;

Applications such as virtual reality, participatory training for new recruiters. Planning and monitoring the trainings needed according to personnel competencies. Staff competencies need to be transparent and participatory.

Electronic Performance Panels;

  • Current situation in production
  • KPIs Monitoring of improvement projects in computer environment

Mobile Performance Indicators;

  • Instant monitoring of KPIs
  • Monitoring of equipment conditions
  • Monitoring performance indicators
  • Previous job Next job Current job performance monitoring
  • Monitoring of work orders
  • Observation of Production Technical Drawings

Integrated Product Development;

  • Platform for integrated business cooperation with suppliers
  • Production costs instantaneous calculation
  • Collection of product data up to customer delivery and product crash
  • Bidirectional communication between the production phase and the design phase

Data Focused Quality Control;

  • Registration of quality parameters measured during production
  • Optimize using data analytics
  • Self-instantaneous optimizing systems based on quality data.
  • The quality parameters are recorded instantly by sensors via cameras.

Estimator Maintenance;

  • Instantaneous check of the machines through sensors
  • Forecasting the fault by using information from these sensors
  • Planning and monitoring machine maintenance plans
  • Immediate notification of related units and optimization of plans in case of failure
  • Ability to make visual, written, interactive intervention when the fault requires external support
  • Ensure that the failure and resolution of the problem archiving are not repeated and can be investigated for similar problems.

Transparent Supply Chain;

  • Instant and business alliance between MES and ERP
  • Instant business alliance between MES and PLM
  • The standards of the works to be made by the suppliers are defined and updated
  • EDI system must be established and widespread
  • Effective use of ERP in all processes
  • Instant sharing of supplies stocks by supplier and processing

Intelligent Warehouse;

  • Warehouse order preparation automation is the system from which the raft will be taken and which product in the raft where the shelf will be taken
  • Technologies that provide the accuracy of the status of the store instantly (RFID, Barcode, Image)
  • Estimation analysis of material consumption and stock quantities

Digital Factory Logistics;

  • Completion of processes (approval, monitoring, request) in computer environment.
  • Road, load optimization of vehicles used in logistics (truck, truck)
  • Automation for the calculation of transport times of materials
  • Data collection and optimization systems for material movement optimization

Automatic Stock Renewal;

  • Production of raw materials and semi-finished products by automation
  • Automatic ordering by the system to the suppliers
  • Optimization of in-process stocks
  • The supply system is compatible with rapid product changes

Cloud Services;

  • Creation of all merged process data and opening up for sharing of users in the cloud system
  • Data storage system tools that can do big data analysis

Digital Factory Design;

  • Factory simulation

3D simulations;

  • Simulations of resource consumption requirements (energy, fuel, air, water, space)
  • Production plan simulation

3D Printers (Articulated Manufacturing);

  • Use 3D printer for spare parts manufacturing
  • Prototype production
  • In the production of tools and auxiliary tools