Case study Kundenorientierte digitale Dienste

Factory automation tool Yoshi raises operator engagement and shop-floor efficiency

Factory automation has revolutionized manufacturing by streamlining production processes and reducing human error. Integrating automation technology, mainly through sophisticated industrial automation systems, enhances precision, consistency, and overall operational effectiveness, enabling businesses to track productivity, increase production rates, and reduce errors. This technological advancement allows companies to meet customer demands and achieve growth.

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What is Factory Automation?

Factory automation refers to integrating advanced technology and machinery to streamline production processes in a factory setting. This involves using various automation systems, such as industrial robots, programmable logic controllers (PLCs), and computer-aided design (CAD) software, to enhance efficiency, productivity, and quality. Flexible automation enhances productivity by allowing quick changeovers and handling varied products without batching, facilitated by reprogramming that occurs offline from the production equipment. By minimizing human intervention, factory automation reduces errors and ensures consistency in production processes. This optimization lowers operational costs and significantly improves product quality, making it a vital component of modern manufacturing.

Skills and services Proekspert provided in factory automation systems

Analysis, UX/UI design, ERP integration and software development: MS SQL, Azure, ASP.NET, ERP-integration, Angular
As a service: Analysis, UX/UI design, ERP-integration and software development
To ensure quality: Unit testing, manual testing

Client challenge in production processes

OSHINO Electronics Estonia, a full-service electronics contract manufacturing company, was looking for a way to increase its electronics assembly efficiency and motivate its operators to improve teamwork.

Solution at a glance

The software tool Yoshi was created by combining OSHINO’s electronics assembly manufacturing experience and Proekspert’s software design and development skills. This tool is integral to a factory automation system, enhancing manufacturing processes through advanced data acquisition and cloud connectivity.

Yoshi enables:

Real-time monitoring of current performance
Visualization of data and comparison to company averages, anonymous leaderboards, and personalized reviews
Detailed insights into performance metrics
Error occurrence logs
Product assembly times

Benefits of Implementing Yoshi

Implementing Yoshi, a cutting-edge factory automation system, brings many benefits to manufacturing processes. By automating production lines, businesses can significantly enhance efficiency, reduce operational costs, and boost overall productivity. Yoshi’s advanced automation technology enables real-time monitoring and control of production processes, allowing for the swift identification and resolution of issues. This proactive approach improves quality, reduces waste, and increases customer satisfaction.

Moreover, Yoshi’s automation software empowers businesses to optimize their production processes, resulting in lower energy consumption and better resource management. The system’s ability to provide detailed insights into production metrics helps make informed decisions, further driving efficiency and continuous improvement. Additionally, Yoshi fosters greater operator engagement by simplifying complex tasks and providing intuitive interfaces, making it easier for operators to adapt and excel in their roles.

Implementing Factory Automation with Yoshi

Assessing Production Processes

Before implementing Yoshi, conducting a thorough assessment of current production processes is crucial. This involves analyzing production lines, equipment, and workflows to pinpoint areas where automation can impact most. By understanding the existing state of production processes, businesses can identify bottlenecks, inefficiencies, and opportunities for improvement. This foundational step ensures that the transition to automation is smooth and that Yoshi is deployed to maximize its benefits.

Choosing the Right Automation Tools

Selecting the appropriate automation tools is vital for the success of any factory automation project. Yoshi offers a comprehensive range of automation tools, including industrial robots, programmable automation, and process automation solutions. Each tool is designed to address specific aspects of the production process. For instance, industrial robots can handle repetitive tasks precisely, while programmable automation allows for flexibility in production runs. Process automation tools help maintain optimal production conditions by managing variables such as temperature and pressure. By carefully choosing the right tools for their specific production needs, businesses can ensure that automation is implemented effectively and efficiently, enhancing productivity and quality.

Results

Increased employee engagement and shop-floor efficiency

1. The tool increased the engagement of shop floor operators by 100%.

2. The ability to self-organize increased.

3. Operators may now start and report their work with minimal interaction required (without extensive reporting and/or paper pushing).

Enhanced operational efficiency through manufacturing automation

Manufacturing automation automated the planning, operating, and reporting by making all operations entirely paperless.

Improved predictive capabilities, error prevention, and quality

1. Planning- and resource allocation capabilities increased tens of times.

2. Production managers may identify recurring production errors within manufacturing shifts.

Read the longer version of the case study here: Factory automation tool allows to focus on a job and raise the engagement through gamification

The Role of Operator Engagement in Factory Automation

Operator engagement is a required factor in the successful implementation of factory automation. Involving operators in the automation process ensures they are comfortable with new technologies and workflows, leading to higher adoption rates and reduced training times. Yoshi’s automation software is designed with user-friendliness, making it easy for operators to monitor and control production processes. This intuitive design empowers operators, giving them the confidence to manage automated systems effectively.

By providing operators with the right tools and comprehensive training, businesses can unlock the full potential of factory automation. Engaged operators are likelier to embrace new technologies, contribute to continuous improvement efforts, and drive productivity. Yoshi enhances operational efficiency and fosters a collaborative and motivated workforce, which is essential for sustaining long-term success in a rapidly evolving manufacturing landscape.

Types of Automation in Manufacturing

In factory manufacturing, several types of automation are employed to meet different production needs:

Fixed Automation: Ideal for high-volume production of a single product, fixed automation utilizes specialized machines and equipment designed for specific tasks. This type of automation is characterized by its high initial cost and inflexibility but offers low variable costs and high production rates.
Programmable Automation: Suitable for low-volume production of various products, programmable automation leverages PLCs and CAD software to control production processes. This flexibility allows manufacturers to quickly reprogram equipment to accommodate different products, making it a versatile solution for dynamic production environments.
Flexible Automation: Designed to produce various products in small batches, flexible automation employs industrial robots and computer-controlled machines that can be easily reprogrammed. This adaptability makes it ideal for manufacturers switching between different products without significant downtime.
Process Automation: Focused on controlling and optimizing industrial processes, process automation involves managing variables such as temperature, pressure, and flow. This type of automation is crucial for industries where precise control of production conditions is essential for product quality.
Industrial Automation Encompasses a wide range of systems, including manufacturing execution systems (MES), enterprise resource planning (ERP), and supply chain management (SCM). These systems work together to optimize overall industrial operations, ensuring seamless integration and efficiency across the production line.

The Future of Factory Automation

Emerging technologies such as artificial intelligence (AI), machine learning (ML), and the Internet of Things (IoT) are poised to revolutionize the future of factory automation. These advancements will enable factories to become more intelligent, flexible, and interconnected, driving significant efficiency, productivity, and quality improvements.

Increased Use of Industrial Robots: As technology advances, industrial robots are expected to become more prevalent in factories, performing complex tasks such as assembly, welding, and inspection with greater precision and speed.
Greater Use of Automation Software: Automation software will be increasingly vital in optimizing factory operations. These software solutions can enhance production planning, resource allocation, and quality control by leveraging advanced algorithms and real-time data.
Increased Focus on Cybersecurity: With the growing connectivity of factory systems, cybersecurity will become a critical concern. Factories will need to implement robust measures to protect against cyber threats and ensure the integrity of their operations.
Greater Emphasis on Continuous Improvement: Factories will need to adopt a culture of continuous improvement, utilizing data analytics and other tools to identify areas for optimization and enhance product quality. This ongoing commitment to improvement will be essential for competitiveness in a rapidly evolving market.

Future-proof your business with digitalization

Factory automation is critical to modern manufacturing, enabling factories to improve efficiency, productivity, and quality.

By understanding the different types of automation used in manufacturing and the trends shaping the future of factory automation, factories can optimize their operations and stay competitive in a rapidly changing market.

Proekspert’s specialists are familiar with digital technologies and have years of experience in software development for industrial automatics. We help manufacturers implement factory digitalization to improve plant operations and create a future-proof digital enterprise.

As technology evolves, factories must adapt and innovate to remain competitive, and automation will play a vital role in this process.

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