Smart Factory: First Steps

Industry 4.0IoTAutomation

Practical guide to begin the digital transformation of production, starting with concrete and scalable projects that guarantee a measurable return on investment.

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Elements

  • Industrial Wi-Fi network with complete coverage
  • Basic sensors for temperature, vibration, and energy consumption
  • IoT gateway for data collection
  • Centralized monitoring system
  • Redundant internet connection

Core Technologies

  • IoT platform for data collection and visualization
  • Basic SCADA system for process control
  • Data analysis software for predictive maintenance
  • Real-time operational dashboard
  • Automatic notification system

Results

  • 15-20% reduction in unplanned machine downtime
  • 10-15% decrease in energy consumption
  • 20% increase in operational efficiency (OEE)
  • Measurable ROI in 12-18 months
  • Solid foundation for future expansions

    • Gradual Implementation Approach

    The journey begins by selecting a pilot production line where the first IoT sensors are installed. These are connected to a central gateway that collects data and sends it to a cloud platform. The dashboard allows real-time monitoring of key parameters and preventive alerts. Analysis of the collected data enables pattern identification and anticipation of potential problems, optimizing maintenance and reducing machine downtime.

    Change Management

    Project success depends on the active involvement of line operators and technical staff. It starts with basic training on new technologies and clear procedures for using new tools. Operators are involved in defining alarm thresholds and customizing dashboards, leveraging their field experience. The first positive results on the pilot line create the demonstrative effect needed to expand the project to other production areas.

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