22 Nov How is the implementation of Industry 4.0 evolving at Rieusset?

In a previous post, we talked about what Industry 4.0 is, in which of our processes it affects us and how important it is.

Continuing with this exercise in transparency that characterizes us, we would like to explain where we are and how we will continue with our roadmap. The goal is to tackle the different implementation phases of Industry 4.0 that we defined in the initial scenario.

With regard to the pillars that we defined previously, in this post we will talk about those that are related more to technology.

What are we working on?

As you will have seen if you are following our blog, we started working on the collection of data and its analysis. We believed that this should be the starting point. The reason is simple. Surely you have heard the famous phrase, “what cannot be measured, cannot be improved”. Well, capturing this data is essential in order to be able to generate a good database and from this, make a good analysis. As a result of this exercise, we will be clear on where to allocate resources efficiently. Later we will talk about how we select our projects.

For this reason, we updated the data collection of our production processes through the introduction of QPlant. Additionally, we wanted to analyze our consumption. This was monitored through SCADA but could not be processed. So we started a new project: “SCADA data capture”. The objective was to cross-reference both databases to determine the consumption of electricity, gas, water and nitrogen that we have in each of the manufacturing orders. The result has been a table where, in percentage terms, we see the references that represent a higher cost for us. From there we have generated an action plan to deal with these higher-than-average consumptions.

Another point on which we have focused has been trying to reduce the carbon footprint generated by our company. For this reason, we are committed to responsible consumption of electrical energy, and for some time now we have only received it from clean sources. With the aim of reducing this consumption, we have started a project to switch to smart, energy-efficient lighting. The fact that our facilities are operative 24 hours a day and have large storage areas for raw material (RM) and semi-finished material (SF) means that we have a large area that is illuminated for long periods of time but has low staff occupancy. Therefore, all the flood lights will be replaced by ones that have motion sensors. In this way we plan to reduce lighting consumption by 70%. We have baptized this project with the name of “Smart Lighting”.

Continuing along the same line of energy saving, we have started a consumption reduction project. This was initially planned to be carried out in the medium term, but due to the increase in the cost of all energies, we have prioritized it and have set up a multidisciplinary work team to tackle all the inefficient consumption that is generated. Therefore, the “Consumption Reduction” project has generated a series of procedures and tests as well as modifications to some equipment in order to optimize these consumptions.

What do we have to work on in the medium term?

Apart from the projects listed above, we are starting conversations with different companies to work on two very ambitious projects that will allow us to advance considerably in terms of the implementation of cutting-edge technology in our company, such as:

• Collaborative robots in the packaging and palletization processes of the final product
• Implementation of autonomous mobile robots (AMR)

The first of these focuses on the installation of collaborative robots in the phases of label boxing or unloading machine reels. These are routine load movement operations, in some cases heavy, without any added value. In this way we can allocate more resources to controlling the process and to making better quality inspection. Furthermore, we will improve working conditions by largely eliminating repetitive movements and avoiding accidents caused by handling heavy loads.

The second one is part of a longer-term project, which is the complete redistribution of the layout of the plant. We know that the implementation of autonomous vehicles requires a significant adaptation process both of the areas through which they pass and of the personnel who interact with them. That is why we want to start working with this technology so that we can later scale it to all areas. In the same way that we have commented with the previous project, simply moving material is an operation without added value which we want to eliminate. This first phase will focus on the initial and final part of the process, which are the distribution of raw material (RM) to the points of consumption and the collection of the finished product (FP) to be located in the final warehouse.

Where are we aiming?

Technological advances in the industry are increasingly opening new doors for us and address needs that we did not have covered. One point which started to interest us is the application of augmented reality. The range of possibilities it offers is extremely wide and two of the points where we believe it can be very useful is in the possibility of carrying out guided maintenance or giving precise training on different points of the machines. In industrial environments where the emphasis is increasingly on lean manufacturing, being able to solve any breakdown more quickly or carry out preventive maintenance plans in a more efficient way will allow us to have greater machine availability, which translates into higher OEE.

Another goal that we are keeping in mind is where we want to go and what would be our perfect plant. That is why we want each step we take to be as aligned as possible with that objective. As I mentioned before, autonomous mobility will help us in future phases when we begin the expansion project of our plant by annexing the adjacent property. This is a project that will make us reconsider all material flows, machine locations, warehouse locations, remodeling of existing spaces, etc.

Our way of working

Projects can be generated by different needs and must respond to market demands, technological advances, business needs, client requests, etc. Every time we are presented with an opportunity, we register the possible project in our backlog. Subsequently, we carry out a review of this list to make sure that all these projects are aligned with the strategic objectives of the company. Based on this list, we decide to carry them out, taking into account the return on investment or if the need raised must be resolved as soon as possible.

Once this is clear, we implement them, but one point that characterizes all the workers at Rieusset is our desire to grow, and what better way than to do so by sharing with others. We want to form synergies between companies so that together we can comply with all these projects that we propose. In many cases, emerging companies that may have an opportunity with us and in other cases, companies with extensive experience will be the ones that will help us grow in those areas where we do not have the necessary knowledge. What is clear is that sharing all this information will be what makes us move forward in the most efficient way.

We will continue to keep you informed in future blog posts!