In the last posting, I wrote about the possible issues in the production procedures of common factories. How can smart factories solve these problems?
Let’s see what they can do.
- LG CNS Smart Factory for Efficient Production (1):
LG CNS’s smart development procedure
Problems in each stage can be taken care of with LG CNS’s smart factory system. I’d like to show you how, in detail.
- Managing Methods in each step
1) Ordering components/half-finished products
– Since the current state of the production is monitored after ordering components/half-finished products in real time, the production plan can be modified whenever there’s an issue.
2) Quality Check
– Instead of finding faulty items and taking care of them after the fact, the smart system checks the results of quality tests which were performed at the factory in which the items were made.
– The level of the sampling test is determined according to the level of the quality of each provider in order to minimize the inspection time
3) Moving to Production Line
– The smart storage system assures that components/half-finished products will be ready when production needs to begin by automatically managing the items in storage.
– Since the quantity of the components/half-finished products is monitored in real time, the plan can be measured properly based on the exact quantity when the production plan is changed.
4) Producing Finished Goods
A. The intelligent production system checks the operation rate of each machine in real time, and the intelligent moving system moves the parts to the right machine in order to keep production flowing smoothly and efficiently.
B. Unexpected breakdowns are prevented as each machine’s condition is automatically recorded and it notifies the manager when parts need to be replaced (based on real usage, not a simple time period).
C. The system collects the data on machines’ temperature/humidity and the products in real time, in order to prevent the production of faulty products by automatically changing the machines’ settings when there are signs of problems. The exterior of the products is checked with visual testing equipment (finding formulaic patterns through a camera) to make sure there aren’t any products with scratches or soldering problems.
D. The system keeps the network on when the machine is not operating, and the power (electricity, gas, etc.) is provided only when the machine is about to operate in order to save energy.
5) Final Quality Check
– The department in charge is notified of unexpected errors and they’re recorded on the system in order to prevent further problems.
– In order to prevent additional errors, the settings of the production system are changed automatically.
6) Storing and Shipping
– The warehouse is operated automatically and puts the products which will be shipped out first closest to the shipping area.
– The inventory is checked in real time and is moved onto trucks automatically when it’s time to be shipped out.
Necessary for the best productivity
Factories with the best productivity are what all companies want. Lowering expenses and improving quality make a factory a strong competitor, so many companies try to optimize their production and renovate their factory’s operating systems.
‘LG CNS smart factory’ was developed to enhance the effects of such efforts. It designs a factory with optimal process according to the industry and equipment which cooperates under an integrated controlling method through specialized solutions. As we learned earlier, since the entire production and moving system are intelligent in smart factories, they work independently while improving their own quality and preventing breakdowns. These systems also check if every operation in the factory is progressing on schedule, what the level of quality is, how well the equipment is operating, and if there is any stagnancy in production due to breakdowns, and then sends such data to the managers in charge.
With a smart factory, not only can we focus on developing a better product but we can also give the customer more satisfaction.
Written by Kyeong-Ho Cho, Smart Factory Solution Team