Welcome to the future world - SICK 4.0 NOW Smart Factory
Cover image 4.0 NOW Factory
SICK's Freiburg plant has become a real-world example of a connected smart factory with fully automated, digitalized production and control processes. The "Industry 4.0" projects implemented here have given the company a decisive competitive advantage.
With the full unfolding of the Fourth Industrial Revolution, it seems everyone is now talking about Industry 4.0: the ability to network and control machines and processes using information and communication technologies is revolutionizing the production processes we take for granted.
Although the future production process is yet to be fully developed, it has already become a reality at the SICK Freiburg factory: it is not a rigid production line, but rather consists of 12 fully automated production modules, 9 manual workstations, and 1 hybrid workstation, scattered like islands throughout the hall. The spacious and bright hall of the SICK Freiburg Hochdorf factory is very quiet, with only occasional snippets of conversation audible.
Sensors are manufactured according to the "formula".
The production process can be adapted to change the order of module usage based on demand. Before a production order is placed, the required product model is first configured online in SICK's production control system according to customer requirements. To do this, the production system retrieves all customer order data from the ERP system to configure the required production model. In addition to product attributes or quantities, the information retrieved includes which modules and production steps need to be used. The combination of characteristic attributes and values, the so-called recipe, is provided by SICK's own system, and the production process is controlled accordingly. The production system sends information to the machines and continuously receives feedback. All components—sensors, machines, and personnel—are organized and networked remotely, maintaining communication with each other.
Flexible, scalable, and customized production processes
This is not just a testing phase, but a real sensor factory that has already given SICK a decisive competitive advantage in a rapidly evolving market. “We currently produce five product lines here, with another 12 in the planning stages. It is foreseeable that we will be producing over 500,000 product models here in the future,” notes Joachim Schultis, Head of Optoelectronic Sensors and Fiber Optics Business Unit. “This production method allows for virtually unlimited customization. This enables us to respond well to the increasingly diverse and personalized needs of our customers. We can even produce small batches on demand, and at reasonable prices.”
The system also offers significant advantages in developing new products: "We can develop new products and bring them to market quickly. We are further expanding based on our existing scale." In addition to its high flexibility, the system also optimizes resource utilization: with the help of the software, we can prioritize orders and deploy modules and staff in the most efficient way. This helps achieve "just-in-time" production.
Automated quality control and management
Each module has an automated quality control system based on process data and set limits. An integrated automated optical inspection (AOI) system verifies the camera system's operating steps and displays fault alerts, such as when parameters are outside the limits. After the entire process is complete, the module transmits information to the production control system and moves the parts to the next workstation via 4.0 NOW Factory.
Material handling is handled by Automated Guided Vehicle (AGC) systems. These systems receive handling commands via a network, thereby supporting flexible manufacturing by optimizing product production steps. Similar to calling a taxi, nearby available AGCs will respond to handling commands.
Stay informed and be prepared
The dashboard provides real-time updates on the status of technical modules, production, and various key metrics. Process and sensor data are uploaded to the cloud, enabling predictive maintenance and ensuring high machine availability.
All information generated during the production of SICK sensors is stored in a big data cloud, fully documented, and linked to the product's serial number. The location of a product or its material composition information can be accessed with the touch of a button. If a product is defective, the production history linked to the serial number helps determine if any discrepancies occurred during production. This data is generated by the SICK sensors installed in the factory.
Human-machine collaboration
Economist Warren Bennis once joked, "The factory of the future will have only two employees: a human and a dog. The human's job is to feed the dog, and the dog's job is to prevent the human from touching the machines." This is not the case at the SICK Freiburg factory. According to Joachim Schultis (Head of SICK's Optoelectronic Sensors and Fiber Optics business), this scenario remains a vision: "I think the factory of the future is a place where humans and machines complement each other in the same workspace, where learning organizations become more comprehensive and increasingly involve machines."
While the 4.0 NOW production process is already quite quiet from the current perspective, the scenario of an unmanned factory is still unimaginable. Process automation is an ideal goal, but highly complex work steps still require human intelligence and skill. “In our Freiburg plant, complex connection processes involving sensitive parts are still done manually. For example, placing a sensitive glass lens into a sensor housing requires human expertise. Given the high development costs, automating this installation step is pointless at this stage,” explains Joachim Schultis. However, we are already seeing changes in individual job roles; for example, the plant manager's role has changed. He or she is no longer responsible for planning machine usage. In the future, the plant manager's job will be to improve plant efficiency.
Investing in the Future
SICK recognized the immense potential of Industry 4.0 early on and intended to fully leverage this technology at its Freiburg plant. Through two years of planning and implementation, along with substantial investment, SICK once again played a pioneering role in the industry: “The courage to build interdisciplinary teams to tackle new challenges and the focus on innovation are what set SICK apart and give us a decisive competitive advantage,” said Joachim Schultis. SICK has laid the foundation for the plant's further development: “We have a long-term vision for the future, and our current production system is already capable of producing products we haven't yet developed,” added Joachim Schultis.
In Freiburg, SICK has created the perfect conditions for leveraging Industry 4.0 technologies and driving Industry 4.0 development: “Over time, we have accumulated invaluable knowledge in developing and improving these types of production processes,” explains Joachim Schultis. This knowledge encompasses not only processes in digitally connected factories but also the continuous optimization and marketing of SICK products, solutions, and services. After all, sensors are fundamental to any Industry 4.0 scenario, responsible for providing data to control systems. “We only install our own sensors and sensor systems in the factory. They must demonstrate their performance in a real-world environment. This allows us to gain a deeper understanding of how the sensors work, identify areas for improvement, and inspire us to develop new products.”
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