With the continuous development of robotics and factory automation technology, the manufacturing industry needs to master and utilize these technological advances. It is also necessary to understand the impact of Industry 4.0 on data center and power protection departments.
According to the survey, the implementation of “Industry 4.0†will increase the UK manufacturing industry's revenue by 455 billion pounds, and will create 175,000 jobs while reducing CO2 emissions by 4.5%. Accenture's research shows that globally, by 2030, the Industrial Internet of Things (IoT) could create more than $14 trillion in value, equivalent to the UK, France, Germany, Italy, Spain, Canada, the Netherlands, and Belgium. The sum of gross national product.
When people feel the sheer size of these numbers, it's not surprising that most UK manufacturers are keen to embrace the possibilities offered by automation, artificial intelligence, machine learning and robotics.
The factory's shop floor has installed hundreds of machines, from industrial plant production lines to air conditioning units, as well as power-saving uninterruptible power supplies (UPS) systems. Each of these devices is equipped with a myriad of sensors that generate large amounts of data and enable them to interact with each other.
Combining these constantly flowing data with intelligent real-time analysis and insight, the results are obvious. Reducing processing defects, improving production quality, improving efficiency, optimizing the supply chain, better maintenance, and better work can save some time and cost.
As with any industrial revolution, it will bring some problems and concerns. Nearly one-third of job opportunities (30%) are said to be threatened by the rise of robots, although the reality may see the loss of many traditional jobs, not large-scale unemployment.
In the data center and key power protection industries, there are also many major issues that need to be addressed, namely how companies can handle the large amounts of data created by smart factories and IoT connected devices. A machine's performance log can generate about 5GB of data per week. A typical smart factory generates about 5PB of data per week, which is equivalent to the capacity of more than 300,000 16GB iPhones.
Big data, big opportunityTo allow manufacturers to fully exploit the potential of Industry 4.0, they must combine the data of their connected devices with artificial intelligence, processing and analysis. Traditional factories produce goods, while smart factories produce goods and numbers, which must go hand in hand to achieve productivity and efficiency.
These big data advantages are extensive in the factory floor and can be used in a variety of business areas, from product quality and inventory control to supply chain optimization, and improve health and safety. Data generated by a smartly connected UPS can be input into decisions made by artificial intelligence that affect the plant's power consumption, energy efficiency, and mechanical maintenance regime.
30% of the manufacturer's annual revenue may be lost due to defects in the production process. By analyzing real-time data from production line sensors, many quality issues are discovered and corrected as soon as they occur.
Technology giant Intel uses data analytics to help predict device failures in their microchips. The result is a 50% reduction in maintenance time, a 25% increase in production, a 20% reduction in spare parts costs, and a total savings of $3 million. On the other hand, in order to produce this positive result, 5TB of machine data needs to be processed every hour!
Another key area in which the impact of industrial Internet of Things (IIoT) equipment has a major impact is machine maintenance. Industrial equipment is often repaired on a fixed schedule (ie monthly or yearly), regardless of its operating conditions. By analyzing the performance statistics generated by the machine, preventive maintenance can be performed as needed rather than time, reducing labor waste and reducing the risk of unexpected failures.
Whether it's assessing damage or deterioration during transportation to optimize packaging materials, research consumer trends and buyer behavior in real time to inform production output, or monitor key performance indicators (such as absenteeism or work injuries) to improve internal processes, connect equipment, Data analysis affects all aspects of industrial life.
Manufacturers collect valuable insights into many of the built-in sensors even after selling the product to end users for a long time. How do the data indicate how the project is used? Is its performance affected by the surrounding environment? What is the most utilized feature of the customer? Its valuable insights are fed back into the ongoing product development process.
The rise of robots - or should it be cooperative robots?Of course, whenever discussions about Industry 4.0 and smart factories are held, people's conversations will soon turn to robots. Robotic Process Automation (RPA) has played a huge role in driving manufacturing efficiency.
The advent of robots has automateed many of the tasks that humans perform boring, manual, and even unsafe. These tasks can be done better, faster, and more accurately than humans. Unlike humans, robots don't feel tired at the end of the shift, so productivity levels are always high.
In terms of robot applications, the UK is still behind many countries. Statistics from the International Robotics Association show that there are only 33 robots per 10,000 people in the UK, far behind Japan (213 units per 10,000 people), Germany (170 units per 10,000 people), and Sweden (154 units per 10,000 people). The Boston Consulting Group predicts that by 2025, robots will perform a quarter of manufacturing tasks (currently 10%), and these mainstream thinking and these ratios will need to change.
Advances in computing power and networking technology mean that today's robots are "smarter" than their predecessors, not just the functions they can perform, but also their adaptability. Although early robots performed the same function over and over again, modern robots can adjust movements, learn lessons, and even collaborate in real time, all thanks to the robots and the amount of data they produce.
In future factories, it will not be an alternative between humans or robots. Robots and workers will work together on the factory floor. In fact, by 2020, manufacturers expect 60% of factory workers to work with robots, or with automated assistive technologies such as artificial intelligence.
What is the impact of Industry 4.0 on the data center?The data center was once a measure of purely data storage. But people know that the Industrial Internet of Things makes everything more dynamic and fluid. In smart factories across the country, data is being captured, analyzed and processed in real time.
Additional processing capacity and additional power is required for additional processing. Of course, it provides an excellent opportunity for the data center industry, but it also raises a question for managers and operators about how they make the most of capital.
Can an enterprise's data center handle the 5GB of data that a single smart machine will create each week? maybe. But what about 100 machines? What about 1000 machines? How many devices and sensors will the factory floor be installed? How will companies balance the need for additional power to keep up with demand without scaling up? People will face the classic problem of “doing more with lessâ€.
A small micro data center with a modular approach is enabling data processing facilities to be built on-site or as close as possible to the user's location. This edge calculation is essential because it enables manufacturers to run real-time analytics without having to send large amounts of data all the way to the cloud and back to processing.
The modular data center provides operators with a range of “extended paymentâ€. The rise of modular UPS also provides similar power protection requirements. As Industry 4.0 promotes the development of data centers, the need for reliable and robust continuous power supply becomes even more urgent.
The transformerless modular UPS provides higher power density in a smaller space and operates more efficiently under all electrical loads, thus saving more power and eliminating the need for a large power supply to maintain cooling.
Data center managers will wisely review their current power protection features. If their UPS models are old, bulky, and less efficient, upgrading to a modern modular UPS would be a smart move to ensure adequate preparation for the needs of smart factories.
Of course, for some manufacturers, especially those with multiple sites distributed across multiple locations, whether using a field data center or cloud computing, some centralized data storage is still required.
The increased level of automation also raises questions about the many basic factors typically required to run a plant or data center. If the plant or data center facilities have reached an unmanned stage, do they need lighting or heating? This creates opportunities to save a lot of energy and costs.
Today's consumers are more demanding than ever. They like personalized or customized products, and they almost always need to buy them on the fly. Of course, they also hope that these unique products can be widely used and are as low-cost as mass-produced products.
The rise of machine learning and Industry 4.0 has the potential to kick-start the manufacturing industry's “advantages†of custom-made products that are manufactured on-demand locally, without ordering production around the world.
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