Smart Innovative Factory

The training system for Industry 4.0

 CONTENTS

• Trends in Industry

• Introduction to Industry 4.0

• Technologies servicing
the businesses

• SIF-400 Overview
• SIF-400 Stations
• SIF-400 Software
• Optionals
• Sample configurations

• Questions Important note: all the information in this document such as drawings,
pictures, features, descriptions, etc., may change without previous notice.
 TRENDS IN INDUSTRY

Shall we analyse together?

VUCA ENVIRONMENT:
• Volatile
• Uncertain
• Complex
• Ambiguous

We need to adapt and

anticipate!
 TRENDS IN INDUSTRY

Technology

• New technology →
• New knowledge→
• New skill development→

DIGITALIZATION → NEW TALENT!

DATA INFORMATION

INSIGHTS DECISSION
 TRENDS IN INDUSTRY

Sustainability

“Sustainability is one of the

hottest trends in manufacturing
today and Industry 4.0 is
increasingly playing a pivotal
role in its proliferation”.
GLOBAL TALENT SHORTAGE

Source (2023):
https://go.manpowergroup.com/talent-shortage
 GLOBAL TALENT SHORTAGE

Source (2023):
https://go.manpowergroup.com/talent-shortage
 INTRODUCTION TO INDUSTRY 4.0

Some dates:
 INTRODUCTION TO INDUSTRY 4.0

Digitalization is changing our life….

…Work …Shopping …Communication

 INTRODUCTION TO INDUSTRY 4.0

The way people purchase and consume products has changed...

And factories need to be adapted to the new reality

 INTRODUCTION TO INDUSTRY 4.0

Customers request:
• Higher level of customization. Up to lot size 1
• Comfortable and easy purchase process 24/7 via internet
• To be informed during all the purchasing and delivery process
• Lower price and faster delivery time
• New products
 INTRODUCTION TO INDUSTRY 4.0

The business value of Industry 4.0. Main benefits:

• Efficiency
• Agility
• Innovation
• Customer experience
• Cost
• Revenues

Source: The Business Value of Industry 4.0 by Francisco Almada-Lobo, MESA Member and CEO of Critical Manufacturing
 INTRODUCTION TO INDUSTRY 4.0

Smart factory tries to satisfy customer’s needs with new technology.

 TECHNOLOGIES SERVICING THE BUSINESSES

LOTS OF NEW TECHNOLOGIES READY TO HELP THE VALUE CHAIN:

 INDUSTRIAL MANAGEMENT SYSTEMS– MES & ERP

Pyramid of automation:
 INDUSTRIAL MANAGEMENT SYSTEMS– MES & ERP
5 TOP ADVANTAGES

Capture costs more accurately

With MES, various costs such as labor, scrap, downtime, and maintenance are recorded in real-time from the shop floor.

Reduce waste, scrap, and overages

MES precisely analyzes production lines and finished products. Therefore this system detects any inconsistencies or
aberrations on these lines, immediately halting them to limit the number of bad parts and wasted material.

Decrease downtime
Through utilization of MES, your system generates realistic production schedules..

Reduce costs
It's possible to streamline operations logically once you get a better handle on the product, the material, time, and labor
required to complete the job.

Reduce inventory
Storing inventory surplus costs money. Besides the cost of producing overage, transporting, storing, and monitoring these
goods get expensive
 OPC-UA

STANDARD PROTOCOL TO
TRANSFER DATA BETWEEN
DEVICES AND PYRAMID
LAYERS
 IDENTIFICATION SYSTEMS

TRACEABILITY
Necessary information such as manufacturers, suppliers, and distributors is recorded. This
information is tracked in all processes from procurement of raw materials and parts to machining,
assembly, distribution, and sales to ensure that their histories can be traced.
IDENTIFICATION SYSTEMS
BAR CODE/ MATRIX/ QR
 IDENTIFICATION SYSTEMS
RFID (RADIO FREQUENCY IDENTIFICATION)
 IDENTIFICATION SYSTEMS
NFC (NEAR FIELD COMMUNICATION)
IDENTIFICATION SYSTEMS
 COLLABORATIVE ROBOTS

ROBOTS ARE NOT REPLACING PEOPLE, THEY ARE COLLABORATING WITH PEOPLE
 ARTIFICIAL VISION

HELPS DETECTING THE ERROR WHEN OCURRED

 ARTIFICIAL VISION

PICK AND PLACE APPLICATIONS

 HUMAN MACHINE INTERFACE (HMI)

MACHINES AND OPERATORS NEED TO “TALK”. NEED TO HAVE A BIDIRECTIONAL

DIALOGUE.
SMART DEVICES
IO- LINK
SMART DEVICES
IO- LINK
SMART DEVICES
IO- LINK
 SMART DEVICES
IO-LINK

Application example: Tire production with automatic parameter setting using IO-Link

If the color sensor reports a defect during production, it can be easily replaced. The new color sensor gets
its parameters from the PLC or a data server while the machine is still running.

previously with IO-Link

•Machine produces and then stops suddenly •Machine produces and reports color sensor
>-> Reason: Color sensor totally contaminated contaminated
•Changing tire color for example currently --> Automatic re-parameterizing based on
means stopping the machine, since the color degree of contamination and diagnostics
sensor cannot be reprogrammed during run message
time •Re-parameterizing of the color sensor (e.g.
•Color sensor fails during production and has for new tire color) possible while running
to be replaced --> Reduction in downtime
--> Parameter setting of the sensor in situ and •Simple error handling without re-
while machine is stopped parameterizing, since the PLC has the
parameter settings stored
 ELECTRIC ACTUATORS

PNEUMATICS TECHNOLOGY IS GREAT IF WE NEED TO GO FROM

“A “TO “B”.
WHAT IF WE NEED TO HAVE ACCESS TO MANY DIFFERENT
POSITIONS IN A FAST AND EASY WAY ?
 SAFETY

PRODUCTION ENVIROMENT NEEDS TO BE SAFE!

TECHNOLOGY IS HELPING TO REACH THAT TARGET!
 SAFETY

DEVICES AND STRATEGIES TO COMPLY WITH CE DIRECTIVES, OSHA, CSA, etc

REGULATIONS
 ENERGY EFFICIENCY

THE BEST WAY TO REDUCE COST AND KEEP OUR PLANET CLEAN!
 ETHERNET COMMUNICATIONS

MULTIPLE DEVICES AND SERVICES NEED A COMMON PROTOCOL TO

COMMUNICATE EACH OTHER.
 INTELIGENT AUTONOMOUS ROBOTS (IAV)

HELPING TRANSORTING PRODUCTS INSIDE THE PRODUCTION LINES AND

WAREHOUSES.
 SUMMARIZING

• WE HAVE EXISTING AND EMERGING TECHNOLOGIES AT OUR DISPOSAL.

• WE NEED TO MAKE A SMART USE OF THOSE TECHNOLOGIES, SO THAT WE

CAN ADD VALUE TO OUR CUSTOMERS BY IMPROVING OUR PROCESSES AND
SERVICES.

• INDUSTRY IS MOVING IN THIS DIRECTION. IT IS THE WAY TO BE COMPETITIVE.

• EDUCATION NEEDS TO FOLLOW THE TREND. INDUSTRY WILL NEED LOTS OF

OPERATORS, TECHNICIANS AND ENGINEERS WITH A NEW SET OF SKILLS.
 INDUSTRY 4.0 & EDUCATION

Industry 4.0 means a strategic investment for many Countries and Regions and
Education is a key point in this matter.

Intro I4.0

Are we ready for this new reality in Education?

 INDUSTRY 4.0 & EDUCATION

In this context, SMC International Training is launching to the market a new training
system: SIF-400

Smart Innovative Factory

 SIF-400 OVERVIEW

Factory purpose:

TO EMULATE AN AUTOMATED SMART FACTORY INCLUDING THE TECHNOLOGY

INVOLVED WITH INDUSTRY 4.0, ADVANCED MANUFACTURING CONCEPTS AND
CONNECTED ENTERPRISE REALITY.
 SIF-400 OVERVIEW

Main features:

• Connected via internet / LAN

• Industrial Internet of things
• Big data & Smart data acquisition
• Horizontal and vertical system integration
SKILLS
• Plug and play DEVELOPMENT

• Modular
• Flexible
• Energy efficient
 SIF-400 OVERVIEW

WHAT CAN BE DONE IN OUR SMART FACTORY?

TO PRODUCE
• Unitary canisters: the client orders X canisters, assigning each of them one recipe.
• Packs of canisters: the client orders X packs containing specific canisters.

TO DISPATCH:
• Unitary canisters.
• Pack of canisters.
• Pallet of packs.
 SIF-400 OVERVIEW

THE PRODUCTS:
• Multiple different type of products delivered attending to:
▪ Type of container: square and round container
▪ Type of content: solid, liquid and customized
▪ Configuration of content: color, weight, density, level of content, mixture %…
▪ Number of containers in a pack.
▪ Number of packs in a pallet

More different products that you can imagine!!!

 SIF-400 OVERVIEW

Conceptual lay-out:

From SIF-406 From SIF-407

To SIF-408 To SIF-408

1 - Assembly 3 - Logistics
2 - Production 4- Assistant
 SIF-400 OVERVIEW

Lay-out blocks:
• Assembly

• Production

• Logistics

• Assistant
 SIF-400 OVERVIEW

SIF-400 - Cyber Physical System

• Software for process tracking, data acquisition,

management and control of the system.
 SIF-400 OVERVIEW

SIF-400 Station: base arquitecture

• Extruded aluminium base structure.

• Stainless steel front with on-off switch and emergency stop button.
• Composite made lateral surface.
• Integrated conveyor belts
• Remote energy consumption emitter
• Size - foot print: 1230x1000 mm
 SIF-400 OVERVIEW

SIF-400 Station: base control

SYSTEM

STATION
 SIF-400 OVERVIEW

SIF-400 I4.0 technologies:

Industry 4.0
Technologies
 SIF-400 OVERVIEW

I4.0 Technologies:

• Industrial controllers ● ● ● ● ● ●
• OPC-UA ● ● ● ● ● ●
• RFID/BCR/QR/NFC ● ● ● ● ● ●
• Ethernet communications ● ● ● ● ● ●
• Distributed I/Os ● ● ● ● ● ●
• HMI ● ● ● ● ● ●
• Web services ● ● ● ● ● ●
• MES / ERP ● ● ● ● ● ●
• Energy efficiency ● ● ● ● ● ●
 SIF-400 OVERVIEW

I4.0 Technologies:

• Electric actuators ● ● ● ● ● ●
• I/O link sensors & actuators ● ● ● ● ● ●
• Artificial vision ● ● ● ● ● ●
• Collaborative robot ● ● ● ● ● ●
• SCARA robot ● ● ● ● ● ●
• Safety ● ● ● ● ● ●
• Augmented reality ● ● ● ● ● ●
• Autonomous Mobile Robot ● ● ● ● ● ●
 SIF-400 STATIONS

Stations & I4.0 technologies:

• RFID/BCR/QR/NFC
• Electric actuators
• Industrial Controller
• OPC UA
• HMI
• Ethernet communications
• Distributed I/Os
• Energy Efficiency

AVAILABLE IN ALL THE STATIONS

FROM SIF-401 TO SIF-413!
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-401 – Canister and pallet feeding

• I4.0 specific technologies:

▪ RFID
▪ Electric actuators
▪ Energy Data Receptor (EDR) and WIFI AP*
*This kit can be also placed in SIF-406/SIF-409

• Other relevant features:

▪ Plug and play feeders
▪ Flexible canister feeders configuration
▪ Energy efficiency measurement devices.
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-402 – Canister filling - solid

• I4.0 specific technologies:

▪ RFID
▪ Electric actuators
▪ I/O link sensors & actuators

• Other relevant features:

▪ Plug and play feeders
▪ Flexible canister feeders configuration
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-403 – Canister filling - liquid

• I4.0 specific technologies:

▪ RFID
▪ I/O link sensors & actuators

• Other relevant features:

▪ Regulation of analog variables: flow rate and level
▪ Impulse oil lubricator (ALIP)
▪ Ultrasonic sensor
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-404 – Canister filling - customized

• I4.0 specific technologies:

▪ RFID
▪ Electric actuators

• Other relevant features:

▪ Flexible canister storage configuration
▪ Flexible canister feeders
▪ Canisters may be filled with any product that may fit
inside.
▪ Allows the user to produce externally an item to be
included in the canister.
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-405 – Canister capping

• I4.0 specific technologies:

▪ RFID
▪ Electric actuators
▪ Artificial vision

• Other relevant features:

▪ Plug and play feeders
▪ Cover’s stock in real time
▪ Pneumatic gap checker
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-406 – Canister storage

• I4.0 specific technologies:

▪ RFID
▪ Electric actuators
▪ Energy Data Receptor (EDR) and WIFI
AP*
*This kit can be also placed in SIF-406/SIF-409

• Other relevant features:

▪ Intelligent warehouse management possibility
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-407 – Canister labelling and dispatching

• I4.0 specific technologies:

▪ RFID
▪ Electric actuators
▪ I/O link sensors & actuators
▪ Artificial vision system (QR)

• Other relevant features:

▪ Matrix code: QR
▪ Serial devices: printer
▪ Output for finished and correct canisters.
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-408 – Canister packing

• I4.0 specific technologies:

▪ RFID/BCR
▪ Electric actuators
▪ Collaborative robot

• Other relevant features:

▪ Plug and play feeders
▪ State lamp with sensor for visual inspection
▪ Bar code reader - BCR
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-409 – Packs storage

• I4.0 specific technologies:

▪ BCR
▪ Electric actuators
▪ Energy Data Receptor (EDR) and WIFI AP*
*This kit can be also placed in SIF-406/SIF-409

• Other relevant features:

▪ Bar code reader - BCR
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-410 – Packs palletizing

• I4.0 specific technologies:

▪ BCR
▪ SCARA robot
▪ Safety

• Other relevant features:

▪ Bar Code Reader – BCR
▪ Packaging process
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-411 – Pallet of packs marking

• I4.0 specific technologies:

▪ BCR/NFC
▪ Inkjet marking

• Other relevant features:

▪ Connection between NFC label and software DDBB.
▪ Bar Code Reader – BCR
▪ NFC reader
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-412 – Pallet of packs expedition

• I4.0 specific technologies:

▪ BCR/NFC
▪ NFC user application

• Other relevant features:

▪ State lamp for visualization
▪ 3 different delivery methods
▪ Bar Code Reader – BCR
▪ NFC reader
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-413 – Recycling

• I4.0 specific technologies:

▪ Wireless devices
▪ Augmented reality application

• Other relevant features:

▪ Vibration feeding system
▪ Chromatic sensors
▪ Blowing application
▪ Raw material plug and play feeders
 SIF-400 STATIONS

Stations & I4.0 technologies: SIF-414 – IAV – Autonomous Mobile Robot

• I4.0 specific technologies:

▪ Autonomous Mobile Robot

• Other relevant features:

▪ Interface via tablet.
▪ Robot location and navigation.
▪ 60 Kg payload.

AMR
 SIF-400 STATIONS

SIF-400: The process

SIF-400
Process
 SIF-400 SOFTWARE

SIFMES-400
• This software allows user’s of SIF-400 to control and manage the system as well as tracking
and store all the process data.
• In a connected enterprise reality, customers, factory and suppliers are connected thanks to
some of the functions of this software: From customer’s order to delivery.
 SIF-400 SOFTWARE

SIFMES-400

• 14 different functions are implemented in 4 different blocks of the software.

• Functions/apps of the software:

▪ Order ▪ Logistics
▪ Scheduler ▪ Data base tool
▪ Dispatcher ▪ Maintenance management
▪ Material movement ▪ Energy management
▪ Data collector ▪ Performance analytics
▪ Inventory management ▪ Statistical Process Control
▪ Disturbances ▪ Tracking
 SIF-400 SOFTWARE

SIFMES-400
 SIF-400 SOFTWARE

SIFMES-400

Management: production orders, scheduler, dispatcher, stocks, logistics,

customers, maintenance, database and data analytics…

Movements: physical and logical lay-out, reset and movements tracking…

Visualization: system status and alarms: maintenance, energy, analytics and

statistical process control…

Administration: Database, role administration and disturbances (instructor)…

 SIF-400 SOFTWARE

Function Management Movements Supervision Administration

Order ■
Scheduler ■
Dispatcher ■
Material Mov. ■
Maintenance M. ■ ■
Energy M. ■ ■
Data Collector ■
P. Analytics ■ ■
SPC ■ ■
Tracking ■
Inventory ■
Logistics ■
DDBB ■
Disturbances ■
 SIF-400 SOFTWARE

SIFMES-400: Sample: Material Movement - Physical & Logical layout

• Physical layout means the stations that we have on the floor.
• Logical layout can be CHANGED via software.

THIS ALLOWS THE USER A FULL FLEXIBILITY WITHOUT CHANGING

THE PHYSICAL LAYOUT!
 SIF-400 SOFTWARE

SIFMES-400: Sample: Big Data - Predictive Maintenance

• Simulated data is collected from different components and plotted based on a clustering
algorithm as a method of identifying behaviour.
• This dataset allows to study different existing techniques based on different algorithms such as
machine learning, supervised learning and unsupervised learning.

SIFMES-400
 SIF-400 OPTIONAL

CYBER SECURITY KIT for SIF-400

Designed to acquire basic knowledge of fundamental industrial cybersecurity concepts and develop
related competencies to achieve the following objectives:
• Know how the information exchange systems of interconnected machines works.
• Recognising different IT threats and implementing security countermeasures
• Define and design offensive security audits on an OT (Operational Technologies) environment,
exploiting existing vulnerabilities to identify and protect different attack vectors.
 SIF-400 OPTIONAL

What is SMCTwin-400?
Online emulation platform in which you can:
- Develop and control your digital twins
- Work with some of those created for SMC International Training's didactic equipment.

Benefits

✓ Safe experimentation of the

system's behaviour.
✓ Monitoring all electrical and
pneumatic values, etc..
 SIF-400 OPTIONAL

✓ Replicate the stations so that students will be able to create PLC/HMI programs and connect them to the
digital twin and check the result.

Virtual PLC

SMCTWIN-400 SMCTwin-
Virtual HMI 400
 DOCUMENTATION

PEDAGOGICAL DOCUMENTATION:
• IMM: Instructions and maintenance manual
• User’s manual Do you want to have a
look?
• Operation manual: manual and integrated mode
• Software operation manual
• Exercise manual: Technologies
• Exercise scenarios from SIFMES-400
 SAMPLE CONFIGURATIONS

Full configuration:
• x12 process stations
• x1 recycling station
• x1 Autonomous Indoor Vehicle
 SAMPLE CONFIGURATIONS

9 stations configuration: assembly and logistics

 SAMPLE CONFIGURATIONS

7 stations configuration: logistics

 SAMPLE CONFIGURATIONS

5 stations configuration: assembly

QUESTIONS
Thanks for your attention!

www.smctraining.com