Digital factories, guided by the national "Made in China 2025" strategy and the international 5G development strategy, represent a key direction for the transformation and upgrading of the entire manufacturing industry in recent years. Their main content involves applying digitalization and intelligent manufacturing as key technologies to digital factories. They embody the integration of modern industrialization and informatization, and are an essential path to achieving intelligent manufacturing.
In China, the most widely accepted definition of a digital factory is: a new production organization method that simulates, evaluates, and optimizes the entire production process in a computer virtual environment, and further extends this to the entire product lifecycle. It is a product of the combination of modern digital manufacturing technology and computer simulation technology, primarily serving as a bridge between product design and product manufacturing. From this definition, we can conclude that the essence of a digital factory is the integration of information.
Many companies are enthusiastic about unmanned factories or "black light factories": without people, the workshop doesn't need lights, and operations can continue at night. Unfortunately, this dreamlike world of interconnected robots is currently largely a demonstration project and generally impractical. In unmanned power plants, mechanical operation tasks may have some value. However, in manufacturing scenarios with diverse orders, "black light factories" are often fraught with challenges. Unmanned factories are like a custom-made play: performed for a specific group of people at a specific time.
In reality, the focus of factories is not on having no people, but on serving people, as the aging trend of society is decisive. The retirement of older factory workers and the struggle to fill vacancies with younger employees are inevitable. How to best utilize the existing workforce will be the most important challenge for every workshop.
The development of intelligent manufacturing in recent years has brought forth many digital technologies. However, the role of humans in this process seems to be like an intermittent circuit, rarely able to operate continuously. In reality, new types of "armor" brought about by digital transformation are gradually arriving. Human potential is being amplified at each level.
Ford's robotic arms have been on duty for some time now. Several years ago, Ford partnered with rehabilitation robotics company Ekso Bionics to develop the EksoVest assistive exoskeleton, which can enhance workers' arm strength. This wearable robotic arm can easily increase arm strength by six kilograms. The latest EksoVes can be worn on the upper body to support the arms when performing repetitive high-altitude tasks. These robotic arms use air springs instead of any electrical components. Designed to "eliminate work-related neck, shoulder, and back injuries," these wearable devices are flexible and breathable.
The factories of the future will not only have robots, but also "mechs." A head-to-head clash—the workshops will be quite a spectacle.
In the past two years, Robotic Process Automation (RPA) has become incredibly popular. This type of robotic software simulates human operations on a computer, automatically executing process tasks according to rules. In production management, it reduces a significant amount of repetitive labor. Just like someone determined to lose weight targeting their excess fat, layers of repetitive processes will be replaced. For example, fragmented tasks such as copying from one system and pasting into another will be automatically "stitched" together.
In building a digital factory, software and hardware support and promote each other. Software digitization mainly involves workshop networking, equipment networking, and management software platforms. Hardware digitization includes PLC control equipment and network interface development. The Internet of Things (IoT) can collect equipment operating parameters and status signals. Smart terminals are installed on-site, allowing personnel to receive and provide feedback information, achieving paperless operations.
Regardless of the advancements in automation, digitalization, and intelligent technologies, the manufacturing environment remains a stage where humanity plays a dominant role. There is a spirit on the job, and everyone is a spirit. Focusing on people, not machines, is always the best mindfulness. A revolution in on-site skills is underway. Strengthen human resource development to welcome the new superhumans of the digital workforce. The dream of the mech warrior is back.
