Unmanned system combines machining centers and high-rise AS/RS

Mazak continues to provide the most advanced and highly productive manufacturing technologies available through strategic collaborations with other key OEMs. As the result of such a collaborative effort with Murata Machinery, Ltd. (Muratec), Mazak developed its new MAZATEC SMS (Smart Manufacturing System) that provides unmanned, lights-out manufacturing and high output, as well as IIoT connectivity.

The MAZATEC SMS combines Mazak’s machining, automation and Smart technologies with Muratec’s automated high-density storage and retrieval system. The MAZATEC SMS pairs multiple Mazak Horizontal Machining Centers and/or Multi-Tasking Machines with a Muratec vertically orientated, space-saving stocker-type system that has pallets, a material bucket and high-speed stocker crane. To match each manufacturer’s specific production and floor space needs, the modular system can have up to 150 stockers (in different sizes) in a six-level configuration that increases space efficiency by as much as 67 percent.

As key components of the MAZATEC SMS, Mazak’s SmartBox IIoT technology and Smooth PMC production management software along with Muratec’s automated system control all interconnect/synchronize with a customer’s enterprise resource planning ERP/MRP host and MES execution systems. These highly advanced digital innovations and complete connectivity make the MAZATEC SMS a smart factory solution for process control, monitoring and optimization to produce a variety of workpieces – even in small lot sizes – with extremely high efficiency.

The MAZATEC SMS can incorporate various sizes and types of machine tools into the same automated manufacturing system. Such flexibility is possible because the stocker system sets up faster and easier as well as accommodates different size machine tool pallets, as does the system’s single stocker crane. This capability also allows manufacturers to apply the MAZATEC SMS across a more expansive spectrum of part numbers/types for cost effectiveness and increased ROI.

Peripheral equipment for the MAZATEC SMS includes individual stations for loading and centering, tilt loading, raise and lower loading, work set up and part washing. In addition to keeping the machine tools supplied with work, the system’s stocker crane handles the MAZATEC SMS overall input of raw parts and the output of finished ones.

“With the combined technologies of Mazak and Muratec, the MAZATEC SMS advanced manufacturing system will significantly increase the competitiveness of manufacturers in today’s IIoT environment,” said Brian Papke, chairman of Mazak. “We at Mazak believe that such collaborations with other innovators in the manufacturing industry effectively foster new ideas and ways to combine processes and apply new technologies to improve the manufacturing performance of customers.”

For its part of the collaboration, Muratec contributes AS/RS durability and reliability. The company and its systems are well entrenched in the automotive and other industrial manufacturing environments. Unlike other comparable systems that tend to be standard in nature, Muratec’s base units are much more customizable and configurable for a wider range of applications.

Mazak has a long history in the production of factory automation systems, such as its earliest one the MAZATROL FMS (Flexible Manufacturing System) developed in 1984 and its current systems that include PALLETECH and the single machine MPP (Multiple Pallet Pool). Similarly, Murata Machinery has extensive experience as a provider of material handling systems to manufacturing facilities worldwide.

According to several reports there will be 50 billion connected devices by 2020. The Internet of Things (IoT) is spreading its divisions across diligences, organization, utilities, homes, and almost everywhere. IoT is helping in the next Industrial Revolution and will enable new form of analytics to analyze a massive cloud of dynamic, ever changing information and offer information that can be used for operative and analytical purposes. However, its first and greatest impact is expected to be in the industrial sector, where organised change is more feasible than in sectors where the public are involved.

According to Hrishikesh Kamat, CEO, Shalaka Technologies, “The IoT is regarded as a disruptive technology and a game changer. IoT is a network of physical real world objects that can sense information using different sensors, send the information using internet connectivity and perform actions as required. This helps dumb objects capable of understanding various parameters and reacting to stimuli.”

What is industrial IoT?
Industrial IoT is termed as IIoT which refers to IoT technologies in manufacturing. IIoT incorporates machine-to-machine communication, machine learning, artificial intelligence, machine learning, and big data technology, harnessing the sensor data and using them for preventive and predictive maintenances. The driving philosophy behind the IIoT is that smart machines are better than humans at accuracy, consistently capturing and communicating data.

“IIoT is the next generation of digital technology centered on smartly optimizing the industrial processes so as to enable the manufacturers to make the most of the industrial internet revolution,” says Sameer Gandhi, MD, Omron Automation, India.

Process cycle of IIOT: Collecting data from sensors (things) – decoding this data strategically using big data analytics to turn them into actionable information – presenting this actionable information to the right person at the right time – delivering efficiency by taking corrective action.

IIoT is actually an extension of factory automation and connectivity that has been a part of the manufacturing environment for decades. It’s high level of automation backed by huge data. These data are then further analyzed to make machines intelligent that can take decisions on their own.

“IIoT is a system that incorporates complex machines with high-end software programs and sensors for collecting the real time data and analyzing it to increase productivity and reduce operational time and costs,” avers Hrishikesh.

Building blocks of Industrial IoT
The building blocks of Industrial IoT constitute of Sensing Node (Sensor), Processing Node (MCU), Connectivity Node (Wired/Wireless), Remote Embedded Processing Node and Cloud Computing and Digital Signal Processors. This building block will also have correspondent at each controller unit, software for each block, security in terms of integrity, confidentiality & reliability of the data being communicated between the blocks. Built-in hardware security at each node will be an essential requirement.

Says Sameer Gandhi, “This technology is an intricate and fascinating network of products, systems, platforms and applications communicating and sharing intelligence with each other & the manufacturing environment including the people. So it is basically not only making the machines intelligent but also making them communicate with each other and with their operators. This, over a period of time, leads to superior levels of optimization further leading to real time waste management, economies of scale by bringing down the operating cost and, thus, production of better output which benefits not only the manufacturers but the end users too.”

Applications of Industrial IoT
IIoT has application in every industry in all departments like maintenance, production, design, inventory management, operation and logistics, among others. IIoT enabled device can be used for many industrial applications like monitoring electricity consumption, viscosity of material, vehicle tracking, machine health monitoring, detection of harmful gases, raising alert, detection of sulphur to prevent corrosion, temperature, pressure & humidity monitoring, and many others. These are just tiny little hand-picked applications but IIoT has acceptability in almost all the industrial setup.

“The technology provides the possibility of achieving extraordinary levels of productivity while constantly assessing risks and relationships. At the core of the technology, currently, are varied smart sensors and PLCs that can connect to the MES/ERP layer facilitating access to real-time information exchange,” adds Sameer Gandhi.

Agrees Hrishikesh, “IoT helps to bring in traceability in the Manufacturing platform. Traceability is the ability to document the history, location or application of the item. Like for example, operator of the CNC, part machined, duration, time and other machine related information during time of action.”

Benefits of IIoT
Thought leaders around the world say the most valued companies will be those that blend digital capabilities and industrial assets.

“Introducing IoT flavour in CNC helps increase operational efficiency and increase throughput. This would eventually result in lesser manufacturing cost and better financial margins. IoT helps bring in intangible advantages like predicting machine breakdown and preventing/reducing downtime by taking proper measures. This helps to ensure that machines run at best efficiency and provide best throughput,” says Hrishikesh.

IIoT can help in:

• Predictive maintenance efficiencies: Machine break down is the biggest nightmare for any plant manager, this directly impacts the overall production cycle of the company and output. Placing sensors in equipment or machines and pairing them with software allows companies to predict when equipment will fail, and it gives them the opportunity to fix problems well before the breakdown.

• Innovative ways to track and analyze equipment: While predictive maintenance is a great way to use sensors for the IIoT, other companies are using them for real-time data tracking. Michelin sells some of its tires with embedded sensors to track fuel consumption, tire pressure, temperature, speed, and location in fleet trucks. That data is then sent to a cloud service, where company analysts look at the data and recommend to truck fleet managers how they can save fuel.  

• Increased revenues: Even though it’s very early to come up with some numbers about the increase in revenue or decrease in expenditure on factory maintenance or machine breakdown, the benefits are clearly visible as IIoT helps in increasing efficiency, saving money in maintenance, realizing full potential of the machine and enhance productivity.  This clearly reflects on the overall revenue of the company. According to Accenture, the value from IIoT technologies and services could bring in up to $15 trillion in global GDP by 2030.

Just to give an example Sameer adds, “Imagine an automotive assembly line, which would typically have a few thousand sensors. Now if any of these sensors fail, the entire line could stop working, which will require manual identification and repair/ replacement, leading to non-productive time. With IIoT, Omron is enabling to connect the sensor in a way, wherein we’re not only getting information from the sensor but also about the sensor. So we can now look into ambient conditions affecting the sensors and other deeper aspects, allowing us to predict the failure of a sensor, before it actually happens.”

India’s take on IIoT
The Indian Government’s plan to develop 100 smart cities in the country, for which Rs. 7,060 crores have been allocated in the current budget could lead to a massive and quick expansion of IoT in the country. Also, the launch of the Digital India Program of the Government, which aims at ‘transforming India into digital empowered society and knowledge economy’ will provide the required impetus for development of the IoT industry in the country. The various initiatives proposed to be taken under the Smart City concept and the Digital India Program to setup Digital Infrastructure in the country would provide a needed boost to the IoT industry. IoT will be critical in making these cities smarter.

Apart from this, programs like Make in India have boosted the investment sentiment in the country. Many global giants are setting up manufacturing facilities in India and Indian conglomerates along with SMEs are looking for more and more automation. This trend will certainly drive the future of the Indian IIoT market.

Department of Electronics and Information Technology, (DeiTY) has come out with a draft IOT Policy document which focuses on following objectives:

• To create an IoT industry in India of USD 15billion by 2020. It has been assumed that India would have a share of 5-6% of global IoT industry.
• To undertake capacity development (Human & Technology) for IoT specific skill-sets for domestic and international markets.
• To undertake research & development for all the assisting technologies.
• To develop IoT products specific to Indian needs in all possible domains.

The Policy framework of the IoT Policy has been proposed to be implemented via a multi-pillar approach. The approach comprises of five vertical pillars (Demonstration Centres, Capacity Building & Incubation, R&D and Innovation, Incentives and Engagements, Human Resource Development) and 2 horizontal supports (Standards & Governance structure).

Talking about the current state of Indian IoT industry, Hrishikesh says, “India has huge opportunities for IoT solution providers like us and we are very excited to be part of this growing IoT ecosystem in the country. Even though this technology is in very nascent stage in India where many companies are yet to adopt basic level of automation, we believe in the next 5 years there would be huge demand for embedded system, connected devices, cloud platform, data analytics services, high-end sensors, among others. We welcome the move of Indian government to further boost the adoption and development of IoT system in India.”

Future Ahead
Experts believe that the Industrial IoT market is going to be bigger than consumer IoT. According to General Electric, by 2020, revenues generated from the IIoT market will be about $225 billion. In comparison, GE forecasts the consumer IoT will only generate about $170 billion by that time. This clearly shows the opportunities in IIoT segment.

With companies investing a lot of money in IIoT and more and more devices are to be connected with internet in the coming future, India is not going to be left behind. Indian companies, be it small, medium or large OEMs, have realized the potential of IoT and ready to be part of growth story.

“Indian companies are looking forward with great enthusiasm and are ready to incorporate Research and Development activities into their organization. Many Indian OEM’s are looking towards Smarter Factories that are inclined towards higher efficiency and lesser downtimes. Many Indian Companies are looking forward towards incorporating concepts like IIoT, M2M communication and centralised data analysis and control,” concludes Hrishikesh

By Nishant Kashyap

Company to unveil groundbreaking innovations designed to drive the industry’s future

The stage is set for Mazak Corporation to raise the manufacturing technology bar at IMTS. In booth S-8300, the company will demonstrate a host of new high-level developments in full digital factory integration, smart technology and Industrial Internet of Things (IIoT) connectivity – in addition to new machining and automation systems – all of which will prepare manufacturers for the next industrial revolution.

Mazak’s SMOOTH Technology platform incorporates advanced manufacturing cells and systems that are revolutionizing part manufacturing processes through smart machines, big data, sophisticated analytics and the IIoT. At IMTS, Mazak will feature new enhancements that boost the computing power and intelligence of its SmartBox digital integration launch platform. The company will also demonstrate the user-friendly programming capabilities and processing speed of its MAZATROL SmoothX and MAZATROL SmoothG CNC controls. These controls are part of the SMOOTH Technology platform, which has transformed the way Mazak equipment performs, especially in terms of 5-axis and complex contouring operations.

Mazak will also show over 20 highly advanced manufacturing cells and systems. Among these will be the company’s latest developments in multi-tasking and 5-axis machine tools with enhanced single-setup, DONE IN ONE® part-processing capabilities crucial for tomorrow’s smart factories. Additionally, the company will unveil the next generation of its HYBRID Multi-Tasking technology, along with new software and accessories that give such multi-tasking machines even more functionality and multiple-process power.

“This year will mark the largest amount of advanced technologies we’ve ever brought to IMTS,” said Brian Papke, president of Mazak. “Our booth will be the premiere destination for show attendees who are committed to achieving the highest possible productivity through digital integration and smart manufacturing.”

Mazak will demonstrate various types and levels of smart factory automation at IMTS. These include gantry systems, robotics and other loading devices that provide the flexibility to adapt to different types of machine tools as well as changing part processing requirements.

Mazak’s new TOOLTECH compact tool magazine for automated tool changing will be making its debut in the booth. TOOLTECH stores big, heavy and large-diameter tools within a very small amount of required floor space. And as a shop’s tooling needs increase, TOOLTECH’s storage capacity can easily expand to as many as five levels and the capacity to hold 250 tools.

All the new and advanced machining and automation systems in the Mazak IMTS booth will be under power and running real-world part demonstrations. Applications experts from Mazak and the company’s Value Inspired Partners (VIP) program will also be on hand during the demonstrations to discuss total manufacturing solutions and part-processing improvements.

Later this spring, Mazak will launch a special IMTS microsite with more extensive booth news and information. Keep an eye on MazakUSA.com for additional updates.