Tag: smart factory

What is Industry 4.0? Explaining the difference with IoT
“Industry 4.0” is closely related to IoT and is said to be an important term that will influence the future direction of manufacturing in Japan. We will answer questions such as what is Industry 4.0, what kind of future does it paint, and how it is related to and different from IoT.

What is Industry 4.0?
Industry 4.0 (the fourth industrial revolution) is a national project which has established a domestic industry-government-academia collaboration system, and has also attracted attention in Japan with the advancement of IoT. At the heart of
this concept is the idea of the “smart factory” (thinking factory).

What is a smart factory in Industry 4.0?
A smart factory is a system in which all machinery and equipment within a factory are connected to the Internet, streamlining the manufacturing process and enabling the efficient large-scale production of small quantities of a wide variety of high-added-value products.
It is said that to make factories smarter, it is essential to network the engineering and supply chains using not only the Internet, but also IoT, big data, AI, industrial robots, etc. The essence of a smart factory is a factory that makes maximum use of advanced technologies such as IoT and robots and is connected by a network.

What is the goal of Industry 4.0?
What exactly does Industry 4.0 intend to achieve? The following three points are considered to be particularly important:
1. Realization of dynamic cell production
“Dynamic cell production” was devised as a way to realize large-scale production of a wide variety of low-volume, high-value-added products using smart factories. Dynamic cell production is said to be an evolved production method that combines the advantages of traditional “line production” and “cell production,” in which products are assembled by one person or a small team of workers.
In dynamic cell production, the line processes are classified into several types, and the robots responsible for assembly at each process exchange information in real time via a network with the cloud, higher-level systems, surrounding equipment, and on-site workers, and proceed with the optimized number and variety of production according to the situation.
2. Appealing to mass customization
By further advancing dynamic cell production, it will eventually be possible to produce products with individually different specifications. The manufacturing technique of producing products that reflect diverse customer needs in a timely manner, starting from “lot size 1,” and providing them to the market without increasing costs is called “mass customization.” This term is a combination of mass production, which means mass production, and customization, which means made-to-order production.
It is predicted that in the future, Industry 4.0 will see many smart factories being connected to each other, so that a country’s entire manufacturing industry will function as if it were one large smart factory.
Mass customization will be realized in the most ideal way in such a future environment. Each product with specifications changed according to needs will be produced quickly and smoothly by automatically selecting the most efficient line and process in the supply chain. It has been announced that this will enable everyone to obtain custom-made products quickly and at low prices.
3. Evolving manufacturing with cyber-physical systems (CPS)
Industry 4.0 aims to evolve manufacturing through “cyber-physical systems” that collect diverse data from the real world, or physical world, using sensor networks and other means, and process and analyze it using computer systems in cyberspace.
A sensor network is a network of interconnected sensors that measure data, while a cyber-physical system is a system or service that creates an efficient and advanced society by closely linking computing power in the real world and cyberspace.
For example, when a product manufactured through mass customization is delivered to a consumer, the product itself then acts as a data collection terminal, sending data on usage and consumer needs to the design and manufacturing site, creating a cycle.
Once such a cyber-physical system infrastructure is in place, it is expected that intelligent production systems will be built in which all data related to manufacturing, from design and development to production, will be accumulated and analyzed, and will operate autonomously to deliver products to consumers.

What is the difference between IoT and Industry 4.0?
IoT is translated as “Internet of Things”. IoT is a mechanism in which various things are connected to the Internet and take necessary actions by exchanging information. In IoT, things are basically connected to the Internet to exchange information.
On the other hand, in Industry 4.0, not only are things connected to the Internet, but things are also connected to each other. Furthermore, collections of things, or business processes, are also connected to each other and exchange information. These complex connections allow for autonomous and automatic operation while maintaining an optimized production system, which is the new form of manufacturing in Industry 4.0.

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July 30, 2024
Exploring IoT: Industry-Specific Success Stories and Fascinating Use Cases
When you hear the word ” IoT ,” it may seem like something from a faraway world, but in reality, there are many things that have already permeated our daily lives. In order to understand the future of IoT, it is necessary to know in what fields IoT is currently being used. In this article, we will introduce what IoT technology can do and various examples of how IoT is used in businesses and homes.
We also explain the benefits and points to note when introducing IoT, so please read until the end.

Basic knowledge of IoT
Before introducing specific use cases of IoT, let’s first deepen our understanding of what IoT is.
What is IoT?
IoT is an acronym for “Internet of Things,” and is translated into Japanese as “Internet of Things.” In other words, it is a system that connects various things around us to the Internet.
Until recently, it was common to connect to the Internet from a computer at home or work. However, with the spread of mobile devices such as smartphones and tablets, it has become easier to access the Internet from anywhere. Furthermore, “smart home appliances” such as televisions and air conditioners that can be connected to the Internet are appearing one after another, making it possible to operate devices remotely even when you are far away.
There are great expectations for technology that utilizes IoT, as it has the potential to make life even more convenient and enrich society. Against this background, the IoT market continues to grow year by year, and is expected to further expand in the future.

How IoT works
Various home appliances and equipment targeted by IoT are equipped with sensors, cameras, etc. These sensors and cameras sense and collect information such as the condition of objects and the surrounding environment, and transmit this data to people and objects via the Internet. The sensors installed vary depending on the device, such as light sensors, temperature sensors, and acceleration sensors.
Let’s take smartwatches as an easy-to-understand example. A smartwatch acquires information such as biometric data such as heart rate and blood pressure, as well as the number of steps taken, based on sensors attached to the watch and GPS. That data is then sent to your smartphone via the internet or stored in the cloud, where it accumulates. The data collected in this way is analyzed by AI, converted into easy-to-understand information such as graphs, and then presented to the user again.
Until now, when selling something, the functionality and price of the item itself were considered to be the main sales criteria to determine whether it would sell or not. However, by introducing IoT, manufacturers are now able to add new added value to existing products.

What can be achieved with IoT technology
By using IoT technology, you can do four main things.
The keyword for what can be done with IoT is “remote”.
Now, let’s introduce one by one what you can do using IoT technology.

Remote control
In recent years, many IoT home appliances have been released. Typical examples include lighting equipment and air conditioners. By using home smart devices and sensors, you can remotely control lights, air conditioners, home appliances, etc. It also helps prevent people from forgetting to turn off these devices, improving safety and efficiency. Remote control of IoT devices will make our lives more comfortable.
You can also use smartphone apps to boil a bath or cook rice from anywhere. In this way, remote control of IoT devices makes life more comfortable.
Furthermore, remote pairing allows devices that are physically separated to communicate with each other.
In the medical field, online medical treatment is conducted using “wearable devices” that can be worn on clothing or wrapped around the hand.
The unique feature is that patients can wear a wearable device to monitor their health status, such as their blood pressure, in real time. This has the advantage of being able to provide medical examinations and guidance in remote locations such as the patient’s home and the hospital.
In addition, at manufacturing sites, sensors and control equipment are paired with PCs in the factory for data communication, and real-time monitoring and equipment control are performed from remote locations.

Detecting the movement of objects from a distance
By utilizing IoT, it is also possible to detect and monitor the movement of things from a distance.
It is also possible to construct a remote monitoring system using cameras and sensors.
Various sensors have been developed, including sensors that detect people and movement, and sensors that detect temperature.
The following are examples of what can be done by combining such sensors and IoT technology.
- Activate the camera and take images only when someone passes by
- Send signals to other devices and play alarms, etc.
Autonomous driving, which applies the brakes when it detects a pedestrian, is also an example of the use of IoT technology to detect the movement of objects.

Detect the status remotely
Using IoT, it is possible to detect conditions from a remote location, but even in this case, sensors are used.
For example, it uses temperature and humidity sensors to sound an alert when a certain value is exceeded.
Soil sensors also allow agriculture to monitor soil moisture, temperature, and nutrient levels.
Accelerometers that detect vibration, shock, and motion are used for structural monitoring of buildings, bridges, and vehicles.

Examples of IoT usage by industry
Now that we have a deeper understanding of IoT, let’s take a look at more specific use cases of IoT by industry. Convenient products and services with hidden potential are appearing one after another, including products that may become mainstream in the future.

Examples of use in the agricultural field
In the agricultural field, “smart agriculture,” which reduces the labor of agricultural work, is attracting attention. Smart agriculture is next-generation agriculture that uses cutting-edge technology that enables labor-saving and high-quality production. Specifically, sensors collect information on things like solar radiation and soil conditions, and calculate the timing of watering and fertilization, as well as the optimal amount of fertilizer.
In the agricultural industry, where labor shortages are becoming a major issue in the future due to the aging of workers and the lack of successors, there are high hopes for smart agriculture. By combining IoT with robot technology, it is possible to automatically water or spread fertilizer based on calculated data. It is not a dream to be able to automatically determine the harvest time, harvest, box and ship. It is expected that this technology will reduce the workload, improve productivity, and solve the problem of human resource shortages.

Examples of use in the medical field
One example of IoT being utilized in the medical field is wearable devices. This allows patients to wear a device connected to the Internet, which measures biological data such as body temperature, blood pressure, and pulse, and converts it into data.
If it becomes easier for medical institutions to collect detailed biological data on patients, it will help them make accurate diagnoses and provide appropriate treatment. When something abnormal is detected, it will help you make a quick diagnosis and take appropriate measures.
In recent years, there has been a serious shortage of doctors in the medical field, and the increasing burden placed on medical personnel has become a problem. IoT in medical institutions is an area of great interest from the perspective of improving the working environment for doctors. IoT specialized in medical care is called “IoMT (Internet of Medical Things),” and research and development is progressing to provide better medical services.

Examples of use in the logistics industry
In the logistics field, IoT is used for warehouse management, picking, delivery, etc. DX that uses the latest technologies such as IoT is called “Logistics 4.0” by the industry’s unique name.
For example, you may have heard of technology that uses robotics for picking tasks, automatically transporting shelves containing products to staff. This allows staff to quickly locate specific products without having to walk around a large warehouse. Furthermore, by attaching IC tags to the materials managed in the distribution warehouse, it is possible to manage the materials using drones flown into the sky.
In the area of delivery, a transportation management system called “TMS” has emerged that comprehensively manages transportation and delivery. This helps you plan efficient dispatches and accurately calculate freight and labor costs. Utilizing the GPS function, you can understand the location of each delivery vehicle in real time and guide drivers to the optimal route based on traffic congestion information. Additionally, you can manage delivery vehicle lease contracts and calculate expenses.
Due to the increased use of online shopping, the logistics industry is currently facing increased supply and complexity. It is also true that the burden on each worker is increasing, as the number of delivery drivers is decreasing due to the declining birthrate and aging of the population.

Examples of usage in the manufacturing industry
The manufacturing industry is an industry where work automation is progressing, with the introduction of industrial robots. With the advent of robots that can operate 24 hours a day, 365 days a year, productivity improvements and quality stabilization have been realized. IoT in the manufacturing industry is characterized by the collaboration of robotics with AI and M2M (machine-to-machine).
Introducing IoT to the manufacturing industry enables visualization, control, and automation. “Visualization” refers to visualizing the information collected by sensors. It collects information that is difficult to express, such as handwritten data and the amount of force applied during manufacturing, and visualizes it for easy analysis. “Control” uses the analysis results to help things operate efficiently. Furthermore, “automation” is the ability to automatically perform such control using AI and other means.
By introducing IoT into factories, we can also aim to create a ” smart factory ” (a thinking factory). A smart factory is a system that connects the systems and equipment in a factory to the Internet to visualize and automate various tasks. You can expect to improve productivity by understanding the operating status of your factory in detail and placing human resources in the appropriate locations. If you use a function to manage the status of equipment and issue an alert before it breaks down, you will be able to carry out maintenance and repairs as necessary and minimize the damage caused by equipment failure.

Familiar IoT usage examples
We have introduced examples of IoT usage in companies such as agriculture, medical care, and manufacturing, but now we will introduce more familiar usage examples of IoT that are closely related to daily life.

Multifunctional and versatile smart speaker
Multifunctional and versatile smart speakers are attracting attention as an example of IoT applications.
- Amazon’s Alexa
- Google’s “Google Assistant”
- Apple’s “Siri”
etc. are famous.
Smart speakers not only control IoT devices and home appliances, but also come with a variety of functions.
Additionally, more and more people are using smart speakers as part of their morning routine, as they can play music and provide audio information such as news, weather, traffic information, and stock prices.
You can also use your smart speaker to order products from online stores such as Amazon.

Smart locks are very popular among the dual-income generation.
Smart locks that utilize IoT are a convenient tool that is popular among the dual-income generation.
No more forgetting your house keys, forgetting to give them to family members, or worrying about losing your keys.
Depending on the product, it is also possible to manage car keys.
You can use the dedicated app to check the unlock history of your keys, and if there is unauthorized access, you will receive an alert notification, so you can also take security measures.

Refrigerator that lets you know how much stock is left
One of the home appliances that uses IoT is a refrigerator that allows you to see how much stock is left.
It has a built-in camera and weight sensor that monitors the remaining amount of food and drinks and sends this information through an app.
It is also possible to send an alert when food ingredients are nearing their expiry date.
You can also check the list of ingredients and drinks and create a shopping list by linking with the smartphone app.
Using IoT refrigerators not only contributes to reducing food waste, but also contributes to household finances.

Wearable underwear that shows your child’s health status
Wearable underwear that utilizes IoT has built-in sensors that measure body temperature, heart rate, breathing rate, etc.
This allows parents to monitor their children with peace of mind, even from a distance, as they can monitor their child’s health status in real time.
When an abnormality is detected, an alert notification will be sent via the smartphone app.
Furthermore, wearable underwear has been developed that is breathable, lightweight, and waterproof, making it comfortable to wear.
It seems that the day when it will be used for nursing care will be in the near future.

A GPS device that lets you know where your child is when they go to and from school.
One system that uses IoT to manage children going to and from school is a GPS device that children carry around with them.
It is useful for parents who want to check their child’s safety because they can know their child’s whereabouts in real time.
You can receive alerts from the app if you go outside of the range pre-set on your device.
This allows parents to quickly locate their children even if they do not return home or become lost.

Interesting IoT usage examples
So far, we have introduced typical IoT usage cases.
I’m sure there are many that you use or have heard of.
From here, we will introduce three interesting IoT usage cases that have become popular and have attracted attention.

MAMORIO
“MAMORIO” is an IoT device that can be used in conjunction with a smartphone to prevent the loss of items and confirm location information.
By attaching it to your keys, wallet, or your luggage, you can check your location information on your smartphone.
You can also always check where your pet is by attaching MAMORIO to your pet’s collar.
You can also set the app to notify you when your pet leaves a certain range.
You can also attach it to your car, so you can easily find it even in a large parking lot.

Foop
foop is a smart device that will change the way you grow vegetables.
It automatically manages the environmental conditions necessary for growing vegetables, such as light, water, and temperature, and supports the growth of vegetables.
You can operate it from your smartphone and check the progress of training and environmental conditions in real time, so you can go to work or travel with peace of mind.
It also automatically sets the optimal growing program for the type of vegetable.
The stylish design allows you to grow vegetables even in limited space such as in urban areas.

Crunchy machine
“Kari Kari Machine” is a service that supports pet meal management using IoT devices.
The Karikari Machine allows you to set the amount of food according to your pet’s weight and age, and can also record the amount eaten. It is also possible to adjust the amount of food by remote control.
You can accurately manage your pet’s diet even when you are away.
Additionally, if your pet overeats while you are away, you will receive a notification on your smartphone, so you can take immediate action.

Benefits of IoT for businesses
From here, for those who are positively considering the introduction of IoT, we will introduce the benefits that the use of IoT brings to companies.

Enables improved quality and productivity
By utilizing IoT, quality and productivity can be improved in many industries such as manufacturing, logistics, agriculture, and construction.
For quality improvement, IoT devices can be used to monitor product quality in real time.
If a quality abnormality occurs, by setting up an alert to be sent, you can prevent the occurrence of defective products at an early stage and ensure quality.
When it comes to improving productivity, IoT devices can be used to streamline work processes and reduce production line downtime.

Can reduce the number of workers
By utilizing IoT, it may be possible to reduce the number of workers required for some tasks.
Particularly at manufacturing sites, IoT sensors can be used to predict machine failures and perform necessary maintenance in advance, reducing the number of maintenance workers.
In some cases, automating tasks can free up your time for other tasks.

Know the issues to consider when introducing IoT
Although we have introduced the benefits of using IoT, there are also issues to consider when implementing it.
We will explain the five issues in an easy-to-understand manner.

Radio wave trouble
Radio wave troubles are an issue when introducing IoT.
Communication may become unstable due to radio wave interference, external noise, radio wave shielding, etc.
Radio wave problems may be resolved by taking measures such as selecting an appropriate installation location, setting the frequency band, and selecting the antenna.
It is also an effective method to obtain support from engineers who have technical knowledge about IoT device communication specifications and radio wave troubles.

Power supply trouble
Power supply problems are a major issue when introducing IoT.
Since power needs to be constantly supplied, power supply problems can affect the entire IoT system.
- Problems where power is not supplied to IoT devices due to power outages due to earthquakes, disasters, etc.
- An issue where an abnormality occurs in the power supply circuit, causing IoT devices to malfunction.
To solve these problems, it is necessary to have a backup power supply, such as an uninterruptible power supply or battery.

Securing human resources familiar with IoT
One of the issues to consider when introducing IoT is securing knowledgeable human resources.
Implementing an IoT system requires a wide range of knowledge, including hardware, software, cloud, and data analysis.
However, depending on the industry, there is a limited number of experienced human resources available for IoT technology, so it may be difficult to secure human resources.
IoT technology is evolving rapidly, so it is important to always learn the latest knowledge.
It is also necessary to utilize support from experts such as consulting firms, and to develop human resources in-house by utilizing online learning, training, seminars, etc.

Security trouble
Security measures are important when introducing IoT.
Unauthorized access to an IoT system may result in damage such as system misuse or leakage of personal information.
- Encrypt data to prevent information leaks
- Achieve secure authentication using multi-factor authentication
- Update regularly and fix vulnerabilities
- Continuously implement security measures such as introducing security monitoring tools
When it comes to security, the measures mentioned above are key.
Privacy trouble
When introducing IoT, it is also important to pay attention to privacy.
Since users’ actions and situations are recorded and analyzed, there is a possibility that this may violate the Personal Information Protection Act.
It is also necessary to take measures to prevent data leaks such as personal information leaks.
- Building a system that complies with laws and regulations regarding personal information protection
- Implement security measures such as data encryption and access control
- When collecting personal information, keep it to the minimum necessary and clarify the purpose of use.
Privacy measures, like security measures, require the above consideration from the system construction stage.

Summary
This time, we have introduced some well-known and interesting IoT usage cases.
Incorporating IoT products at home can lead to improved quality of life, such as reducing the burden of housework and reducing anxiety for families with children.
While the introduction of IoT in companies has security and privacy issues, there are many benefits such as reduced labor costs, increased efficiency, improved productivity, and improved safety.

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June 29, 2024
Exploring IoT: Industry-Specific Success Stories and Fascinating Use Cases
When you hear the word ” IoT ,” it may seem like something from a faraway world, but in reality, there are many things that have already permeated our daily lives. In order to understand the future of IoT, it is necessary to know in what fields IoT is currently being used. In this article, we will introduce what IoT technology can do and various examples of how IoT is used in businesses and homes.
We also explain the benefits and points to note when introducing IoT, so please read until the end.

Basic knowledge of IoT
Before introducing specific use cases of IoT, let’s first deepen our understanding of what IoT is.
What is IoT?
IoT is an acronym for “Internet of Things,” and is translated into Japanese as “Internet of Things.” In other words, it is a system that connects various things around us to the Internet.
Until recently, it was common to connect to the Internet from a computer at home or work. However, with the spread of mobile devices such as smartphones and tablets, it has become easier to access the Internet from anywhere. Furthermore, “smart home appliances” such as televisions and air conditioners that can be connected to the Internet are appearing one after another, making it possible to operate devices remotely even when you are far away.
There are great expectations for technology that utilizes IoT, as it has the potential to make life even more convenient and enrich society. Against this background, the IoT market continues to grow year by year, and is expected to further expand in the future.

How IoT works
Various home appliances and equipment targeted by IoT are equipped with sensors, cameras, etc. These sensors and cameras sense and collect information such as the condition of objects and the surrounding environment, and transmit this data to people and objects via the Internet. The sensors installed vary depending on the device, such as light sensors, temperature sensors, and acceleration sensors.
Let’s take smartwatches as an easy-to-understand example. A smartwatch acquires information such as biometric data such as heart rate and blood pressure, as well as the number of steps taken, based on sensors attached to the watch and GPS. That data is then sent to your smartphone via the internet or stored in the cloud, where it accumulates. The data collected in this way is analyzed by AI, converted into easy-to-understand information such as graphs, and then presented to the user again.
Until now, when selling something, the functionality and price of the item itself were considered to be the main sales criteria to determine whether it would sell or not. However, by introducing IoT, manufacturers are now able to add new added value to existing products.

What can be achieved with IoT technology
By using IoT technology, you can do four main things.
The keyword for what can be done with IoT is “remote”.
Now, let’s introduce one by one what you can do using IoT technology.

Remote control
In recent years, many IoT home appliances have been released. Typical examples include lighting equipment and air conditioners. By using home smart devices and sensors, you can remotely control lights, air conditioners, home appliances, etc. It also helps prevent people from forgetting to turn off these devices, improving safety and efficiency. Remote control of IoT devices will make our lives more comfortable.
You can also use smartphone apps to boil a bath or cook rice from anywhere. In this way, remote control of IoT devices makes life more comfortable.
Furthermore, remote pairing allows devices that are physically separated to communicate with each other.
In the medical field, online medical treatment is conducted using “wearable devices” that can be worn on clothing or wrapped around the hand.
The unique feature is that patients can wear a wearable device to monitor their health status, such as their blood pressure, in real time. This has the advantage of being able to provide medical examinations and guidance in remote locations such as the patient’s home and the hospital.
In addition, at manufacturing sites, sensors and control equipment are paired with PCs in the factory for data communication, and real-time monitoring and equipment control are performed from remote locations.

Detecting the movement of objects from a distance
By utilizing IoT, it is also possible to detect and monitor the movement of things from a distance.
It is also possible to construct a remote monitoring system using cameras and sensors.
Various sensors have been developed, including sensors that detect people and movement, and sensors that detect temperature.
The following are examples of what can be done by combining such sensors and IoT technology.
- Activate the camera and take images only when someone passes by
- Send signals to other devices and play alarms, etc.
Autonomous driving, which applies the brakes when it detects a pedestrian, is also an example of the use of IoT technology to detect the movement of objects.

Detect the status remotely
Using IoT, it is possible to detect conditions from a remote location, but even in this case, sensors are used.
For example, it uses temperature and humidity sensors to sound an alert when a certain value is exceeded.
Soil sensors also allow agriculture to monitor soil moisture, temperature, and nutrient levels.
Accelerometers that detect vibration, shock, and motion are used for structural monitoring of buildings, bridges, and vehicles.

Examples of IoT usage by industry
Now that we have a deeper understanding of IoT, let’s take a look at more specific use cases of IoT by industry. Convenient products and services with hidden potential are appearing one after another, including products that may become mainstream in the future.

Examples of use in the agricultural field
In the agricultural field, “smart agriculture,” which reduces the labor of agricultural work, is attracting attention. Smart agriculture is next-generation agriculture that uses cutting-edge technology that enables labor-saving and high-quality production. Specifically, sensors collect information on things like solar radiation and soil conditions, and calculate the timing of watering and fertilization, as well as the optimal amount of fertilizer.
In the agricultural industry, where labor shortages are becoming a major issue in the future due to the aging of workers and the lack of successors, there are high hopes for smart agriculture. By combining IoT with robot technology, it is possible to automatically water or spread fertilizer based on calculated data. It is not a dream to be able to automatically determine the harvest time, harvest, box and ship. It is expected that this technology will reduce the workload, improve productivity, and solve the problem of human resource shortages.

Examples of use in the medical field
One example of IoT being utilized in the medical field is wearable devices. This allows patients to wear a device connected to the Internet, which measures biological data such as body temperature, blood pressure, and pulse, and converts it into data.
If it becomes easier for medical institutions to collect detailed biological data on patients, it will help them make accurate diagnoses and provide appropriate treatment. When something abnormal is detected, it will help you make a quick diagnosis and take appropriate measures.
In recent years, there has been a serious shortage of doctors in the medical field, and the increasing burden placed on medical personnel has become a problem. IoT in medical institutions is an area of great interest from the perspective of improving the working environment for doctors. IoT specialized in medical care is called “IoMT (Internet of Medical Things),” and research and development is progressing to provide better medical services.

Examples of use in the logistics industry
In the logistics field, IoT is used for warehouse management, picking, delivery, etc. DX that uses the latest technologies such as IoT is called “Logistics 4.0” by the industry’s unique name.
For example, you may have heard of technology that uses robotics for picking tasks, automatically transporting shelves containing products to staff. This allows staff to quickly locate specific products without having to walk around a large warehouse. Furthermore, by attaching IC tags to the materials managed in the distribution warehouse, it is possible to manage the materials using drones flown into the sky.
In the area of delivery, a transportation management system called “TMS” has emerged that comprehensively manages transportation and delivery. This helps you plan efficient dispatches and accurately calculate freight and labor costs. Utilizing the GPS function, you can understand the location of each delivery vehicle in real time and guide drivers to the optimal route based on traffic congestion information. Additionally, you can manage delivery vehicle lease contracts and calculate expenses.
Due to the increased use of online shopping, the logistics industry is currently facing increased supply and complexity. It is also true that the burden on each worker is increasing, as the number of delivery drivers is decreasing due to the declining birthrate and aging of the population.

Examples of usage in the manufacturing industry
The manufacturing industry is an industry where work automation is progressing, with the introduction of industrial robots. With the advent of robots that can operate 24 hours a day, 365 days a year, productivity improvements and quality stabilization have been realized. IoT in the manufacturing industry is characterized by the collaboration of robotics with AI and M2M (machine-to-machine).
Introducing IoT to the manufacturing industry enables visualization, control, and automation. “Visualization” refers to visualizing the information collected by sensors. It collects information that is difficult to express, such as handwritten data and the amount of force applied during manufacturing, and visualizes it for easy analysis. “Control” uses the analysis results to help things operate efficiently. Furthermore, “automation” is the ability to automatically perform such control using AI and other means.
By introducing IoT into factories, we can also aim to create a ” smart factory ” (a thinking factory). A smart factory is a system that connects the systems and equipment in a factory to the Internet to visualize and automate various tasks. You can expect to improve productivity by understanding the operating status of your factory in detail and placing human resources in the appropriate locations. If you use a function to manage the status of equipment and issue an alert before it breaks down, you will be able to carry out maintenance and repairs as necessary and minimize the damage caused by equipment failure.

Familiar IoT usage examples
We have introduced examples of IoT usage in companies such as agriculture, medical care, and manufacturing, but now we will introduce more familiar usage examples of IoT that are closely related to daily life.

Multifunctional and versatile smart speaker
Multifunctional and versatile smart speakers are attracting attention as an example of IoT applications.
- Amazon’s Alexa
- Google’s “Google Assistant”
- Apple’s “Siri”
etc. are famous.
Smart speakers not only control IoT devices and home appliances, but also come with a variety of functions.
Additionally, more and more people are using smart speakers as part of their morning routine, as they can play music and provide audio information such as news, weather, traffic information, and stock prices.
You can also use your smart speaker to order products from online stores such as Amazon.

Smart locks are very popular among the dual-income generation.
Smart locks that utilize IoT are a convenient tool that is popular among the dual-income generation.
No more forgetting your house keys, forgetting to give them to family members, or worrying about losing your keys.
Depending on the product, it is also possible to manage car keys.
You can use the dedicated app to check the unlock history of your keys, and if there is unauthorized access, you will receive an alert notification, so you can also take security measures.

Refrigerator that lets you know how much stock is left
One of the home appliances that uses IoT is a refrigerator that allows you to see how much stock is left.
It has a built-in camera and weight sensor that monitors the remaining amount of food and drinks and sends this information through an app.
It is also possible to send an alert when food ingredients are nearing their expiry date.
You can also check the list of ingredients and drinks and create a shopping list by linking with the smartphone app.
Using IoT refrigerators not only contributes to reducing food waste, but also contributes to household finances.

Wearable underwear that shows your child’s health status
Wearable underwear that utilizes IoT has built-in sensors that measure body temperature, heart rate, breathing rate, etc.
This allows parents to monitor their children with peace of mind, even from a distance, as they can monitor their child’s health status in real time.
When an abnormality is detected, an alert notification will be sent via the smartphone app.
Furthermore, wearable underwear has been developed that is breathable, lightweight, and waterproof, making it comfortable to wear.
It seems that the day when it will be used for nursing care will be in the near future.

A GPS device that lets you know where your child is when they go to and from school.
One system that uses IoT to manage children going to and from school is a GPS device that children carry around with them.
It is useful for parents who want to check their child’s safety because they can know their child’s whereabouts in real time.
You can receive alerts from the app if you go outside of the range pre-set on your device.
This allows parents to quickly locate their children even if they do not return home or become lost.

Interesting IoT usage examples
So far, we have introduced typical IoT usage cases.
I’m sure there are many that you use or have heard of.
From here, we will introduce three interesting IoT usage cases that have become popular and have attracted attention.

MAMORIO
“MAMORIO” is an IoT device that can be used in conjunction with a smartphone to prevent the loss of items and confirm location information.
By attaching it to your keys, wallet, or your luggage, you can check your location information on your smartphone.
You can also always check where your pet is by attaching MAMORIO to your pet’s collar.
You can also set the app to notify you when your pet leaves a certain range.
You can also attach it to your car, so you can easily find it even in a large parking lot.

Foop
foop is a smart device that will change the way you grow vegetables.
It automatically manages the environmental conditions necessary for growing vegetables, such as light, water, and temperature, and supports the growth of vegetables.
You can operate it from your smartphone and check the progress of training and environmental conditions in real time, so you can go to work or travel with peace of mind.
It also automatically sets the optimal growing program for the type of vegetable.
The stylish design allows you to grow vegetables even in limited space such as in urban areas.

Crunchy machine
“Kari Kari Machine” is a service that supports pet meal management using IoT devices.
The Karikari Machine allows you to set the amount of food according to your pet’s weight and age, and can also record the amount eaten. It is also possible to adjust the amount of food by remote control.
You can accurately manage your pet’s diet even when you are away.
Additionally, if your pet overeats while you are away, you will receive a notification on your smartphone, so you can take immediate action.

Benefits of IoT for businesses
From here, for those who are positively considering the introduction of IoT, we will introduce the benefits that the use of IoT brings to companies.

Enables improved quality and productivity
By utilizing IoT, quality and productivity can be improved in many industries such as manufacturing, logistics, agriculture, and construction.
For quality improvement, IoT devices can be used to monitor product quality in real time.
If a quality abnormality occurs, by setting up an alert to be sent, you can prevent the occurrence of defective products at an early stage and ensure quality.
When it comes to improving productivity, IoT devices can be used to streamline work processes and reduce production line downtime.

Can reduce the number of workers
By utilizing IoT, it may be possible to reduce the number of workers required for some tasks.
Particularly at manufacturing sites, IoT sensors can be used to predict machine failures and perform necessary maintenance in advance, reducing the number of maintenance workers.
In some cases, automating tasks can free up your time for other tasks.

Know the issues to consider when introducing IoT
Although we have introduced the benefits of using IoT, there are also issues to consider when implementing it.
We will explain the five issues in an easy-to-understand manner.

Radio wave trouble
Radio wave troubles are an issue when introducing IoT.
Communication may become unstable due to radio wave interference, external noise, radio wave shielding, etc.
Radio wave problems may be resolved by taking measures such as selecting an appropriate installation location, setting the frequency band, and selecting the antenna.
It is also an effective method to obtain support from engineers who have technical knowledge about IoT device communication specifications and radio wave troubles.

Power supply trouble
Power supply problems are a major issue when introducing IoT.
Since power needs to be constantly supplied, power supply problems can affect the entire IoT system.
- Problems where power is not supplied to IoT devices due to power outages due to earthquakes, disasters, etc.
- An issue where an abnormality occurs in the power supply circuit, causing IoT devices to malfunction.
To solve these problems, it is necessary to have a backup power supply, such as an uninterruptible power supply or battery.

Securing human resources familiar with IoT
One of the issues to consider when introducing IoT is securing knowledgeable human resources.
Implementing an IoT system requires a wide range of knowledge, including hardware, software, cloud, and data analysis.
However, depending on the industry, there is a limited number of experienced human resources available for IoT technology, so it may be difficult to secure human resources.
IoT technology is evolving rapidly, so it is important to always learn the latest knowledge.
It is also necessary to utilize support from experts such as consulting firms, and to develop human resources in-house by utilizing online learning, training, seminars, etc.

Security trouble
Security measures are important when introducing IoT.
Unauthorized access to an IoT system may result in damage such as system misuse or leakage of personal information.
- Encrypt data to prevent information leaks
- Achieve secure authentication using multi-factor authentication
- Update regularly and fix vulnerabilities
- Continuously implement security measures such as introducing security monitoring tools
When it comes to security, the measures mentioned above are key.
Privacy trouble
When introducing IoT, it is also important to pay attention to privacy.
Since users’ actions and situations are recorded and analyzed, there is a possibility that this may violate the Personal Information Protection Act.
It is also necessary to take measures to prevent data leaks such as personal information leaks.
- Building a system that complies with laws and regulations regarding personal information protection
- Implement security measures such as data encryption and access control
- When collecting personal information, keep it to the minimum necessary and clarify the purpose of use.
Privacy measures, like security measures, require the above consideration from the system construction stage.

Summary
This time, we have introduced some well-known and interesting IoT usage cases.
Incorporating IoT products at home can lead to improved quality of life, such as reducing the burden of housework and reducing anxiety for families with children.
While the introduction of IoT in companies has security and privacy issues, there are many benefits such as reduced labor costs, increased efficiency, improved productivity, and improved safety.

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June 29, 2024
What is a smart factory? Explaining the advantages, disadvantages, issues, and examples!
Smart factories that make full use of IT technologies such as IoT and AI have the potential to be useful in situations such as failure prediction, defective product detection, human resource development, and energy conservation. Smart factories are one of the effective solutions to the challenges facing manufacturers in terms of factory operations. However, implementing it requires manufacturing knowledge and digital know-how. In order to introduce it, other issues such as initial cost and security must be resolved.
In this article, we will discuss the advantages and disadvantages, challenges, and tips for implementing smart factories.

What is a smart factory?
A smart factory is a factory that connects various equipment such as machine tools and production lines to a network to improve the efficiency of information management and optimize operations.
Traditional factory operations typically relied on skilled labor, highly technical staff, and experienced managers. However, factories, which support the backbone of the manufacturing industry, must constantly respond to a variety of issues. It is true that humans have limits when it comes to tackling issues such as failure detection, defective product detection, productivity improvement, and energy optimization.
Currently, in addition to the sophistication of equipment, the situation is constantly changing, such as the introduction of FA equipment (factory automation equipment) that supports automation, the spread of IoT, which refers to the Internet of Things, and the practical use of AI (artificial intelligence). . It is no exaggeration to say that all operations related to factory operations are supported by IT. It is now possible to quickly link product quality and condition, factory equipment operating status, and line information, dramatically improving capabilities.
As a result, the number of options for achieving the traditional issues of labor saving and productivity improvement has increased. With the introduction of smart factories, it is becoming easier to address pressing issues such as dealing with labor shortages and saving energy.

[Advantages] 5 reasons why you should work on a smart factory

This chapter introduces five benefits that can be gained by implementing a smart factory.

Can solve the shortage of human resources
Japan is experiencing a declining birthrate and aging population, and it is predicted that there will be a chronic labor shortage in the future. In the manufacturing industry, it is necessary to create an environment where even the elderly can work comfortably and to recruit human resources.
Labor savings can be achieved by automating tasks that were previously done manually. Furthermore, by having robots perform tasks that require physical strength, it will be easier to create an environment in which skilled seniors can work comfortably. It is predicted that the declining birthrate and aging population will continue in the future, so the introduction of smart factories can be expected to be effective in the long term.
Can promote work style reform
The introduction of smart factories will also lead to the promotion of work style reform . As the needs of workers continue to diversify and the working population continues to decline due to the declining birthrate and aging population, work style reforms are being promoted with the aim of reducing working hours and improving productivity in order to solve these issues. I am.
Its introduction can be expected to improve productivity and improve management efficiency in many manufacturing companies, which may lead to the promotion of work style reforms. Since it responds to the diversifying needs of workers, it can be said that it can be expected to improve employee satisfaction.
Technology can be inherited for a long time
Japan’s manufacturing industry has continued to make strides with its high technological capabilities, but the current situation is that technology has not been passed down. By using smart factories, you can collect know-how and skills as data. By using the collected data to create manuals and standardize work, it becomes easier to transfer technology smoothly.
By making it easier to inherit technology, there is also the benefit of smoother business succession, allowing advanced technology to be passed on to the next generation. Another feature is that by digitizing know-how and experience, it becomes easier to share it with the next generation.
You can promote your efforts towards SDGs.
This will also help promote your efforts towards the SDGs. SDGs (Sustainable Development Goals) are sustainable development goals that were unanimously adopted at the United Nations Summit in 2015. Since the Japanese government and many companies are also working on this, it is one of the elements that we would like to use as material for our appeal.
Smart factories can be said to be a response to the SDGs because they can monitor energy usage and prevent wasteful energy use.
Leads to cost reduction
Working towards smart factories will lead to cost reductions. Since defects in factory equipment can be identified, defective products can be reduced, and material costs can be expected to be reduced.
In addition, it will be possible to visualize the status of the production line and link data such as customer data, which will reduce the burden on employees and reduce labor costs.
By introducing this system, you can expect cost reductions, including material costs and labor costs.

[Disadvantages] Issues that arise when working on smart factories and how to deal with them

While smart factories have many benefits, they can also come with challenges. From here, we will explain the four main issues and how to deal with them.

Securing digital human resources
It is important to secure digital human resources in order to work on smart factories. Since knowledge and know-how in introducing and utilizing digital technology are required, human resources cannot be developed immediately. Furthermore, since know-how in manufacturing technology is required, it is common to proceed with training by introducing experts, IT vendors, etc.
Japan is experiencing a declining birthrate and aging population, making it more difficult than ever to secure human resources. Therefore, there are many cases where smart factories cannot be introduced due to a lack of human resources.
Enhanced security
Strengthening security is important in these efforts. It is common to handle large amounts of data, but this data is often important confidential information for companies, and if it is leaked, it will cause great damage.
In recent years, external threats such as unauthorized access and malware infection have increased the risk of data leaks. Therefore, a strong security model is essential for operating a smart factory.
Network system capacity issues
For deployment, network system capacity criteria must be met. If an IoT system does not have a certain amount of network system capacity, it will not be possible to collect huge amounts of data and improve efficiency and automation.
Additionally, slow system communication speeds may lead to response delays and performance deterioration. However, understanding the required capacity requires someone knowledgeable in cost-benefit analysis of IoT systems.
Securing initial costs
In order to introduce a smart factory, it is necessary to introduce various equipment such as systems, AI, IoT sensors, cloud servers, and IoT gateways. Therefore, the high initial cost for introduction is a major issue.
The cost of installation varies depending on the environment construction, the cost of necessary equipment, and the company providing the service. Therefore, it is important to clarify costs before implementation. It is important to note that smart factories require not only initial costs but also maintenance costs and other costs.

Issues that can be solved with smart factories
Factories that support the manufacturing industry face a variety of challenges. For example, troubleshooting, defective product countermeasures, lack of skilled workers, and energy conservation measures are issues that must be steadily addressed in any factory.
Due to the globalization of business and the diversification of consumer needs, customer demands have expanded to include delivery times, costs, and quality. Additionally, the competition for talented human resources is expanding beyond industry boundaries, making it increasingly difficult to secure human resources to support businesses. Under such circumstances, we must also face the problem of an aging workforce. Stable succession of technology is also an urgent issue.
Smart factories are expected to play a supporting role in solving these problems faced by the manufacturing industry.
Prediction of failure
Failure prediction is the use of IoT to monitor the status of equipment and other factory equipment, predict the probability of failure in advance, or detect areas where abnormalities are currently occurring.
In many cases, factory line monitoring is already being carried out in a typical factory. However, there are many cases where data cannot be measured because the equipment is outdated, or even if the data itself can be measured without any problems, it is difficult to manage the data because the data format is different. In such cases, the problem is that it takes a lot of effort to accurately understand the operating status and prepare for failures.
Making factories smart can solve these challenges. For example, by installing sensors equipped with IoT functions on devices, data can be aggregated regardless of whether they are new or old. By consolidating data in one place, you can centrally manage operating status. Management becomes more efficient by making it easier to understand operating rates and operating conditions, and the accuracy of failure prediction can be improved by utilizing centralized data.

Detecting defective products using image recognition
Image recognition technology is also useful for finding defective products. Traditionally, defective products have been detected through manual inspection. However, this method not only requires a lot of effort, but also has the issue of not being able to train human resources who can perform the inspection and eliminate the risk of human error. Additionally, installing equipment to detect defective products requires a large amount of cost. Dealing with defective products can be said to have continued to be a major problem for factory operations.
Using current image recognition technology, it is possible to solve these problems related to defective products. Deep learning in AI automatically detects specific patterns when a large amount of image data is loaded. By repeating this process, we have seen results such as a dramatic improvement in the accuracy of discovering patterns from image data.
This technology can also be applied to detect defective products in factories. If quality inspection is digitized, AI will be able to automatically learn from the data, and it will also be able to accumulate information on situations where defective products are likely to occur, which will be of great help in analyzing the causes.

Human resource development through remote support using VR
VR (virtual reality) technology, which enables remote operation and management, is also useful for human resource development.
Securing and developing human resources is an urgent issue for the entire manufacturing industry and factory operations. As Japan as a whole progresses toward a declining birthrate and aging population, the proportion of young people in the labor force is decreasing, and the number of middle-aged and older workers is increasing. Under such circumstances, a labor shortage has occurred, and work style reforms are being promoted to reduce working hours. Factories are faced with the challenge of how to pass on the skills of veterans and how to make effective use of their time to develop the next generation of human resources.
VR, also known as “virtual reality,” is a technology that uses goggle-type devices, cameras, and remote systems to monitor and experience the situation as if you were actually there, even if you are not there. As a related technology, a technology called “ mixed reality ” has also emerged, which allows a person wearing a goggle-type device to simultaneously see another image in addition to the reality they are currently seeing.
This has made it possible for veteran employees in remote locations to instruct new employees on tasks and provide manuals through goggles. By using the VR system, it is becoming possible to efficiently develop human resources.

Optimizing factory energy with sensors
Smart factories are also suitable for energy conservation throughout the factory. Currently, the importance of environmental awareness is being emphasized worldwide, as exemplified by terms such as “SDGs” (Sustainable Development Goals) and “ESG management” (management that takes into account the environment, society, and governance). I am. The manufacturing industry, which uses a lot of energy, is also being forced to take a clear response.
In a smart factory, the operating status and energy usage status of the factory can be visualized by utilizing IoT sensors. By managing numerically, it is possible to use energy efficiently and save energy.

Methods and tips for realizing a smart factory

Simply introducing a smart factory does not guarantee success. This chapter introduces methods to ensure smooth operation after installation.
Thoroughly visualize and accumulate data
In order to realize a smart factory, it is important to thoroughly visualize and accumulate data. Until now, in the manufacturing industry, it was common to manually manage data related to quality control and production. However, handwritten data cannot be shared in real time.
Therefore, by digitizing the necessary data, it becomes possible to visualize and accumulate it in real time.
Deploy tools for efficient analysis
For efficient analysis, it is a good idea to introduce tools. It is necessary not only to collect data, but also to analyze and utilize it. However, manually analyzing data is time-consuming and difficult.
Therefore, it is important to introduce tools that automatically create graphs to visualize data, accumulate data, and analyze it from various angles.
Set automation as the end goal
Furthermore, it is important to set automation as the end goal. Ultimately, the purpose of introducing a smart factory is to collect and accumulate data and automate the process for efficient analysis.
This allows you to generate effective data without spending time and effort on data collection and analysis. This data can be effectively utilized for future factory operations and marketing measures.

Initiatives for smart factories that are progressing around the world
Efforts toward smart factories are progressing in countries around the world.
The government of Germany, a manufacturing powerhouse in Europe, is advocating ” Industry 4.0 .” The government is promoting the development of the manufacturing industry through advanced technologies such as the IoT as an industrial revolution. The underlying idea is that the development of IoT will reduce costs and improve productivity, leading to new economic development and social structural change.
For example, as smart factories become more sophisticated, machines will not only be able to carry out human commands, but factory equipment will also be able to guide the way towards finished products themselves. The development of smart factories that can complete products without human instructions is underway.
In China, the national leadership is proposing an industrial policy called “Made in China 2025.” 23 items in 10 fields have been set to advance the manufacturing industry, including next-generation information technology (semiconductors and 5G) and new energy vehicles. We are working to strengthen our manufacturing industry with the aim of joining the world’s manufacturing powerhouses by 2025.
India also advocated “Make in India,” and announced a policy to develop the Indian manufacturing industry through foreign investment. Among these, the development of manufacturing infrastructure has been emphasized, and efforts have been made to comprehensively upgrade the manufacturing industry, including smart factories.
Summary

A smart factory is a factory that utilizes network connectivity and introduces digital technology to equipment and equipment within the factory. By creating a smart factory, you can improve productivity, eliminate labor shortages, and perform efficient data analysis.

Follow us on Facebook for updates and exclusive content! Click here: Each Techy
June 28, 2024
What is a smart factory? Explaining the advantages, disadvantages, issues, and examples!
Smart factories that make full use of IT technologies such as IoT and AI have the potential to be useful in situations such as failure prediction, defective product detection, human resource development, and energy conservation. Smart factories are one of the effective solutions to the challenges facing manufacturers in terms of factory operations. However, implementing it requires manufacturing knowledge and digital know-how. In order to introduce it, other issues such as initial cost and security must be resolved.
In this article, we will discuss the advantages and disadvantages, challenges, and tips for implementing smart factories.

What is a smart factory?
A smart factory is a factory that connects various equipment such as machine tools and production lines to a network to improve the efficiency of information management and optimize operations.
Traditional factory operations typically relied on skilled labor, highly technical staff, and experienced managers. However, factories, which support the backbone of the manufacturing industry, must constantly respond to a variety of issues. It is true that humans have limits when it comes to tackling issues such as failure detection, defective product detection, productivity improvement, and energy optimization.
Currently, in addition to the sophistication of equipment, the situation is constantly changing, such as the introduction of FA equipment (factory automation equipment) that supports automation, the spread of IoT, which refers to the Internet of Things, and the practical use of AI (artificial intelligence). . It is no exaggeration to say that all operations related to factory operations are supported by IT. It is now possible to quickly link product quality and condition, factory equipment operating status, and line information, dramatically improving capabilities.
As a result, the number of options for achieving the traditional issues of labor saving and productivity improvement has increased. With the introduction of smart factories, it is becoming easier to address pressing issues such as dealing with labor shortages and saving energy.

[Advantages] 5 reasons why you should work on a smart factory

This chapter introduces five benefits that can be gained by implementing a smart factory.

Can solve the shortage of human resources
Japan is experiencing a declining birthrate and aging population, and it is predicted that there will be a chronic labor shortage in the future. In the manufacturing industry, it is necessary to create an environment where even the elderly can work comfortably and to recruit human resources.
Labor savings can be achieved by automating tasks that were previously done manually. Furthermore, by having robots perform tasks that require physical strength, it will be easier to create an environment in which skilled seniors can work comfortably. It is predicted that the declining birthrate and aging population will continue in the future, so the introduction of smart factories can be expected to be effective in the long term.
Can promote work style reform
The introduction of smart factories will also lead to the promotion of work style reform . As the needs of workers continue to diversify and the working population continues to decline due to the declining birthrate and aging population, work style reforms are being promoted with the aim of reducing working hours and improving productivity in order to solve these issues. I am.
Its introduction can be expected to improve productivity and improve management efficiency in many manufacturing companies, which may lead to the promotion of work style reforms. Since it responds to the diversifying needs of workers, it can be said that it can be expected to improve employee satisfaction.
Technology can be inherited for a long time
Japan’s manufacturing industry has continued to make strides with its high technological capabilities, but the current situation is that technology has not been passed down. By using smart factories, you can collect know-how and skills as data. By using the collected data to create manuals and standardize work, it becomes easier to transfer technology smoothly.
By making it easier to inherit technology, there is also the benefit of smoother business succession, allowing advanced technology to be passed on to the next generation. Another feature is that by digitizing know-how and experience, it becomes easier to share it with the next generation.
You can promote your efforts towards SDGs.
This will also help promote your efforts towards the SDGs. SDGs (Sustainable Development Goals) are sustainable development goals that were unanimously adopted at the United Nations Summit in 2015. Since the Japanese government and many companies are also working on this, it is one of the elements that we would like to use as material for our appeal.
Smart factories can be said to be a response to the SDGs because they can monitor energy usage and prevent wasteful energy use.
Leads to cost reduction
Working towards smart factories will lead to cost reductions. Since defects in factory equipment can be identified, defective products can be reduced, and material costs can be expected to be reduced.
In addition, it will be possible to visualize the status of the production line and link data such as customer data, which will reduce the burden on employees and reduce labor costs.
By introducing this system, you can expect cost reductions, including material costs and labor costs.

[Disadvantages] Issues that arise when working on smart factories and how to deal with them

While smart factories have many benefits, they can also come with challenges. From here, we will explain the four main issues and how to deal with them.

Securing digital human resources
It is important to secure digital human resources in order to work on smart factories. Since knowledge and know-how in introducing and utilizing digital technology are required, human resources cannot be developed immediately. Furthermore, since know-how in manufacturing technology is required, it is common to proceed with training by introducing experts, IT vendors, etc.
Japan is experiencing a declining birthrate and aging population, making it more difficult than ever to secure human resources. Therefore, there are many cases where smart factories cannot be introduced due to a lack of human resources.
Enhanced security
Strengthening security is important in these efforts. It is common to handle large amounts of data, but this data is often important confidential information for companies, and if it is leaked, it will cause great damage.
In recent years, external threats such as unauthorized access and malware infection have increased the risk of data leaks. Therefore, a strong security model is essential for operating a smart factory.
Network system capacity issues
For deployment, network system capacity criteria must be met. If an IoT system does not have a certain amount of network system capacity, it will not be possible to collect huge amounts of data and improve efficiency and automation.
Additionally, slow system communication speeds may lead to response delays and performance deterioration. However, understanding the required capacity requires someone knowledgeable in cost-benefit analysis of IoT systems.
Securing initial costs
In order to introduce a smart factory, it is necessary to introduce various equipment such as systems, AI, IoT sensors, cloud servers, and IoT gateways. Therefore, the high initial cost for introduction is a major issue.
The cost of installation varies depending on the environment construction, the cost of necessary equipment, and the company providing the service. Therefore, it is important to clarify costs before implementation. It is important to note that smart factories require not only initial costs but also maintenance costs and other costs.

Issues that can be solved with smart factories
Factories that support the manufacturing industry face a variety of challenges. For example, troubleshooting, defective product countermeasures, lack of skilled workers, and energy conservation measures are issues that must be steadily addressed in any factory.
Due to the globalization of business and the diversification of consumer needs, customer demands have expanded to include delivery times, costs, and quality. Additionally, the competition for talented human resources is expanding beyond industry boundaries, making it increasingly difficult to secure human resources to support businesses. Under such circumstances, we must also face the problem of an aging workforce. Stable succession of technology is also an urgent issue.
Smart factories are expected to play a supporting role in solving these problems faced by the manufacturing industry.
Prediction of failure
Failure prediction is the use of IoT to monitor the status of equipment and other factory equipment, predict the probability of failure in advance, or detect areas where abnormalities are currently occurring.
In many cases, factory line monitoring is already being carried out in a typical factory. However, there are many cases where data cannot be measured because the equipment is outdated, or even if the data itself can be measured without any problems, it is difficult to manage the data because the data format is different. In such cases, the problem is that it takes a lot of effort to accurately understand the operating status and prepare for failures.
Making factories smart can solve these challenges. For example, by installing sensors equipped with IoT functions on devices, data can be aggregated regardless of whether they are new or old. By consolidating data in one place, you can centrally manage operating status. Management becomes more efficient by making it easier to understand operating rates and operating conditions, and the accuracy of failure prediction can be improved by utilizing centralized data.

Detecting defective products using image recognition
Image recognition technology is also useful for finding defective products. Traditionally, defective products have been detected through manual inspection. However, this method not only requires a lot of effort, but also has the issue of not being able to train human resources who can perform the inspection and eliminate the risk of human error. Additionally, installing equipment to detect defective products requires a large amount of cost. Dealing with defective products can be said to have continued to be a major problem for factory operations.
Using current image recognition technology, it is possible to solve these problems related to defective products. Deep learning in AI automatically detects specific patterns when a large amount of image data is loaded. By repeating this process, we have seen results such as a dramatic improvement in the accuracy of discovering patterns from image data.
This technology can also be applied to detect defective products in factories. If quality inspection is digitized, AI will be able to automatically learn from the data, and it will also be able to accumulate information on situations where defective products are likely to occur, which will be of great help in analyzing the causes.

Human resource development through remote support using VR
VR (virtual reality) technology, which enables remote operation and management, is also useful for human resource development.
Securing and developing human resources is an urgent issue for the entire manufacturing industry and factory operations. As Japan as a whole progresses toward a declining birthrate and aging population, the proportion of young people in the labor force is decreasing, and the number of middle-aged and older workers is increasing. Under such circumstances, a labor shortage has occurred, and work style reforms are being promoted to reduce working hours. Factories are faced with the challenge of how to pass on the skills of veterans and how to make effective use of their time to develop the next generation of human resources.
VR, also known as “virtual reality,” is a technology that uses goggle-type devices, cameras, and remote systems to monitor and experience the situation as if you were actually there, even if you are not there. As a related technology, a technology called “ mixed reality ” has also emerged, which allows a person wearing a goggle-type device to simultaneously see another image in addition to the reality they are currently seeing.
This has made it possible for veteran employees in remote locations to instruct new employees on tasks and provide manuals through goggles. By using the VR system, it is becoming possible to efficiently develop human resources.

Optimizing factory energy with sensors
Smart factories are also suitable for energy conservation throughout the factory. Currently, the importance of environmental awareness is being emphasized worldwide, as exemplified by terms such as “SDGs” (Sustainable Development Goals) and “ESG management” (management that takes into account the environment, society, and governance). I am. The manufacturing industry, which uses a lot of energy, is also being forced to take a clear response.
In a smart factory, the operating status and energy usage status of the factory can be visualized by utilizing IoT sensors. By managing numerically, it is possible to use energy efficiently and save energy.

Methods and tips for realizing a smart factory

Simply introducing a smart factory does not guarantee success. This chapter introduces methods to ensure smooth operation after installation.
Thoroughly visualize and accumulate data
In order to realize a smart factory, it is important to thoroughly visualize and accumulate data. Until now, in the manufacturing industry, it was common to manually manage data related to quality control and production. However, handwritten data cannot be shared in real time.
Therefore, by digitizing the necessary data, it becomes possible to visualize and accumulate it in real time.
Deploy tools for efficient analysis
For efficient analysis, it is a good idea to introduce tools. It is necessary not only to collect data, but also to analyze and utilize it. However, manually analyzing data is time-consuming and difficult.
Therefore, it is important to introduce tools that automatically create graphs to visualize data, accumulate data, and analyze it from various angles.
Set automation as the end goal
Furthermore, it is important to set automation as the end goal. Ultimately, the purpose of introducing a smart factory is to collect and accumulate data and automate the process for efficient analysis.
This allows you to generate effective data without spending time and effort on data collection and analysis. This data can be effectively utilized for future factory operations and marketing measures.

Initiatives for smart factories that are progressing around the world
Efforts toward smart factories are progressing in countries around the world.
The government of Germany, a manufacturing powerhouse in Europe, is advocating ” Industry 4.0 .” The government is promoting the development of the manufacturing industry through advanced technologies such as the IoT as an industrial revolution. The underlying idea is that the development of IoT will reduce costs and improve productivity, leading to new economic development and social structural change.
For example, as smart factories become more sophisticated, machines will not only be able to carry out human commands, but factory equipment will also be able to guide the way towards finished products themselves. The development of smart factories that can complete products without human instructions is underway.
In China, the national leadership is proposing an industrial policy called “Made in China 2025.” 23 items in 10 fields have been set to advance the manufacturing industry, including next-generation information technology (semiconductors and 5G) and new energy vehicles. We are working to strengthen our manufacturing industry with the aim of joining the world’s manufacturing powerhouses by 2025.
India also advocated “Make in India,” and announced a policy to develop the Indian manufacturing industry through foreign investment. Among these, the development of manufacturing infrastructure has been emphasized, and efforts have been made to comprehensively upgrade the manufacturing industry, including smart factories.
Summary

A smart factory is a factory that utilizes network connectivity and introduces digital technology to equipment and equipment within the factory. By creating a smart factory, you can improve productivity, eliminate labor shortages, and perform efficient data analysis.

Follow us on Facebook for updates and exclusive content! Click here: Each Techy
June 28, 2024