MAY 20239MANUFACTURING TECHNOLOGY INSIGHTSinclude quality, size and footprint, commissioning complexity, dependency on packing format, ergonomics, scalability, robustness and more. Then based on the hierarchy, we define and prioritize manufacturing principles, such as· Clean and simple production flow· Dedicated areas for kitting, assembly, testing and more· Separate aisles for trucks and stackers· Continuous flow with a minimum of buffers Flexible and robust manufacturing Traditionally a manufacturing process is built up on a line basis. However, to build robustness, the smart factory is built up of multiple standalone cells, which perform defined tasks. These cells are then connected intelligently to ensure a logical workflow where the drive passes through several cells during its assembly. At every step there is more than one alternative route, so that in the event of a delay at one cell, the manufacturing path progresses to an alternative cell which can perform the same manufacturing step. The flexibility and many degrees of freedom that the flexible cell concept implies, means the process can quickly become very complex from a production planning point of view. Therefore, each manufacturing facility must choose its own compromise between flexibility and simplicity and cost-effectiveness: the more flexibility, the more complexity. Simplicity can still be a virtue and there is every reason to implement just enough redundancy and process robustness to ensure a reliable manufacturing capacity, but no more. To optimize this balance between flexibility, simplicity and cost, the factory runs simulations to estimate losses and gains prior to establishing the equipment in real life. The simulations provide the information base required to make the decision on the level of complexity required to achieve a robust process. In practice, the new factory is built up one cell at a time, scaling up to meet higher demand over time. Artificial intelligence controls the network of machines to achieve optimal flexibility.Bringing even more robots into the factoryIn the past we have only automated our PCB production and certain sub-assemblies in manufacturing using robots. Now, we are going through an automation transformation of the whole global supply chain. We have started the journey with the highest-volume items, and with assembly and test areas.Many vital contributorsThere are many contributors to successful smart manufacturing, and we have discussed several of them here. As you would expect, connectivity, communication and artificial intelligence are important elements. The less visible elements are compromise and alignment between product design and manufacturing processes, a matrix approach to process robustness to ensure a reliable manufacturing capacity, and optimal packaging of both components and finished products. All these contributions play a special role in smart manufacturing ­ each of them vital ­to create products of world-class quality and reliability.In the future, robotics is a vital element of our plans. We aim to make step-changes in safety, quality, cost, and delivery for the benefit of our customers and staff. These goals fit perfectly into our ambition of maintaining our world-class position inflexible supply chain operations. DfAA is a clear example of the close collaboration required between R&D and the factory
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