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In a recent project, B&R optimized the production of industrial PCs. With an online configuration tool, B&R's customers can let the PC fully meet their requirements. After confirming the feasibility of the configuration, the ERP system automatically generates a bill of materials with a unique serial number.
Figure 1: Egglesberg Advanced 4.0 Factory in B&R
250 billion possibilities "Mathematically speaking, there are more than 250 billion different hardware configurations available for customers to choose from," said Gerald Haas, head of global industrial management at B&R. This has not considered the software selection. Most orders are concentrated in the two to three ranges. "This way we set up is not related to order quantity," Haas said. "We can produce one-off things equally effectively, 1,000 bags."
The ERP system has planned an optimal order processing plan to ensure the smooth flow of logistics.
Figure 2: The B&R production area is fully networked. The ERP system directly controls the retrieval system of warehousing and three-dimensional warehouses, and automatically optimizes product logistics.
Parts from the warehouse are sent just in time. This is one of the advantages of the B&R Smart Factory. The factory in Eggelsberg is fully networked - whether horizontal or vertical.
The unified network "What we provide is unique in that we don't use specific networks for different levels of connectivity," said Haas. "We used to connect every machine, every building automation component and ERP system is a unified network." This is the way to provide ERP systems with the ability to control automatic storage and retrieval in a three-dimensional warehouse. The ERP system classifies the items in the three-dimensional warehouse according to the current production and planned production, and reminds the order when the inventory decreases.
When the PC orders arrive at the worker's assembly station, the necessary parts have arrived. Workers follow the on-screen instructions and light signals to complete the assembly of each PC. The design of the assembly table is ergonomic and the height of the table can be easily adjusted according to the height of the worker.
During the assembly process and after the assembly is completed, each PC must be tested repeatedly. Tests include whether the installation is correct and whether the CPU and RAM meet the performance and stress tests. The ERP system will release the PC for shipment only if all tests are completed successfully. "After all, every product that our customers receive should run without error," explained Peter Gucher, general manager of B&R.
Figure 3: Only B&R Industrial PCs that have undergone rigorous functional testing and stress testing are allowed to ship.
Seamless tracking "Functional testing is nothing else," Gucher said. "It's just that we give each product a unique and complete traceability." At any time, every step in the production, every test and every important part can be performed track. This traceability covers the entire life cycle of the product. Even in the next few years, relying solely on the PC serial number, you can find out every functional test that the product has done and clearly identify every part that the product contains.
Figure 4: Each component must undergo a functional test. After several years, simply enter the serial number to view the test results and all relevant production parameters.
"This means providing our customers with certainty beyond the standard," explains Gucher. On the website, B&R provides a service channel where customers can search technical data and order-related information simply by entering the product serial number. Including version information, delivery time, warranty status, etc. "In this way, we can help our customers save a lot of time and energy," Gucher added.
Figure 5: Peter Gucher (General Manager, left) and Gerald Haas (Head of International Industrial Management) are proud of the B&R Smart Factory.
Real-time dynamic communication across the network factory covers all aspects. "Our X20 module is a good example," Haas said. Today, 200 types of modules are produced from various production lines. When the module arrives at the fully automatic operator station for assembly, testing and labelling, the real-time SAP inquiry function will decide which kind of test is required. Immediately, the machine begins to operate on the received instructions. The reason that is feasible is precisely because each product can be confirmed by a unique serial number.
If a R&D engineer records in SAP that the next module has received a specific confirmation, it happens that this type of module happens to reach the labeling station, and the confirmation mark will be accurately printed on the housing by laser. "This is the subtlety of smart factory technology," Haas said. Of course, fully networked smart products will generate the necessary sharing data. In large systems, the speed of data collection can reach GB or even TB levels. "Automatic data processing and analysis are crucial for effective decision-making," Gucher said. This is why B&R chose its own APROL process control system to collect and evaluate all production data.
Obtain OEE parameters at any time In the APROL system, you can view various parameters at any time, such as overall equipment efficiency (OEE), and you can even compare between production lines, shifts, or work days. "Using APROL, we can always monitor energy consumption." Haas added, "When an issue arises, it can be corrected immediately."
Figure 6: The B&R APROL process control system can send parameters in real time, such as Overall Equipment Effectiveness (OEE)
B&R also raised maintenance standards. With the condition monitoring tool in the folder, B&R can determine the best time for maintenance. This not only avoids waste due to premature replacement of parts, but also avoids the risk of long waiting times and machine damage. If the key parameters are out of the set range, the employee will receive an automatic e-mail notification and will intervene before the aging component fails and initiate unplanned downtime maintenance.
Industry 4.0 as usual
"For Begalis, the networked smart factory was implemented in 2006," said Haas. "This factory meets the integration of production intelligence and service described in Industry 4.0. 4.0 is a new term, but everything is as usual for us."
B&R itself is the advanced technology power represented by Industry 4.0. Therefore, the new concept is not a concept to us.
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[Chinese instrument network enterprise vane] The flourishing industry 4.0 now has been applied to B&R's own production equipment for nearly a decade. The smart factory in Eggelsberg, Upper Austria, was fully completed in 2006 and has been continuously upgraded.