PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
2 OVERVIEW A new era of manufacturing automation is being ushered in by rapid technological advancements in creating the connected factory. Mobile technologies are widely recognized as one of the leading forces helping to drive Industry 4.0 and further streamline manufacturing operations. However, manufacturers face a number of hurdles that are impeding mobility deployments and delaying those companies who want to harness the power of new technologies that hold the promise of the smart factory. Manufacturers see the implementation of mobile technology as promising because they view many other sectors already benefitting from the tangible improvements. They recognize opportunities for improvement across all areas of the plant from the shop floor to the warehouse to management. The sentiment among IT leaders is that because mobile solutions have proven so successful in reducing production downtime and increasing productivity, the inclusion of mobility in their plant s technology plan to deliver competitive advantages, is something that cannot be ignored. Interestingly, while most organizations have already put technology upgrade roadmaps in place, they typically lack many of the mobile solution architecture details that will certainly be needed to actualize any mobilization plans. PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
3 WHAT S HOLDING MANUFACTURERS BACK? Today many manufacturers still utilize manual paper-based processes across all areas of operations. In most cases there are some mobile solutions utilized in the plant for communications or notifications, but companies are still far behind their stated intentions in moving to mobile operations. Some reasons for these delays include: Legacy equipment Cost to upgrade Challenging plant conditions Legacy equipment Much factory equipment and systems are rooted in legacy technologies that don t easily connect to modern networking systems or common mobile devices. While factory machinery continues to function as specified, the electronic interfaces that were built into them are technologically dated. They typically have serial ports (RS-232) by which they connect to data collection and control systems. Consumer grade systems are not equipped with serial ports and some don t even have USB ports. This lack of backwards compatibility may force workers to carry multiple devices in order to carry out their maintenance and data collection tasks. Evaluating true TCO When evaluating the costs to upgrade to mobile technologies, manufacturers may be tempted to first consider consumer devices and protective cases because of the perceived cost savings. However, analyst data shows that rugged laptops and tablets deliver a higher return on investment than consumer grade devices with a lower total cost of ownership¹. And while there exists a price gap between consumer grade mobile devices and enterprise grade rugged devices, the difference is shrinking. The size of the price differential is even smaller when decision makers consider the features and device performance that manufacturers need in order to operate for full shifts or round the clock operations. As manufacturers evaluate mobile technology, it is essential to consider the true cost of a device over its lifetime and how its features and capabilities can impact the production line should an off the shelf device in a protective case fails in the plant. Dealing with dust, dirt and grease Factory environments are notorious for their rough conditions that prove challenging to consumer-grade mobile equipment. As a result, rugged mobile devices - such as computers, tablets and handheld barcode scanners specifically built for these conditions - offer the easiest ways to digitize the factory. The possible combination of dust, and dirt, liquid, and grease in potentially hazardous areas, call for careful consideration when deciding exactly which devices to deploy. When weighing in the potential for device failure and production downtime, decision makers need to examine rugged mobile solutions that can not only withstand, but outperform consumer grade devices. Overall, industrial environments have specialized needs that call for mobile devices that can operate in adverse conditions and still deliver best in class performance even when faced with rough handling across all areas of the factory. PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
4 MOBILE DEVICES CHANGING THE GAME The benefits of data capture and automation for enterprises have already proven to bring benefits in the form of increased employee productivity, competitive advances, streamlined processes, improved operations, and customer service. Manufacturing environments have their own sets of issues that offer similar possibilities for improvement despite the impediments industrial conditions present. However, companies that successfully navigate the obstacles in updating their operations can gain competitive advantages that separate them from their competition. In industrial environments this improvement can change the game from the old standard of preventive maintenance to a proactive approach. In this scenario maintenance needs are performed based on predictions made possible through monitoring actual conditions at levels of detail and timeliness unachievable without the use of mobile devices. Innovative organizations can realize numerous benefits from implementing rugged and reliable mobile devices that connect their shop floors to their back office operations in real time: Improved operations Being digitally mobile within the manufacturing environment means being able to perform activities freely and at any location within (or away from) the facility. Much like mobile phones have allowed freedom to communicate without being tied to wired phones, mobile computing devices like tablets make it convenient and simple to collect data, update reports, document conditions, access documentation, and many other tasks that otherwise require employees to be physically present at specific locations. The resulting freedom simplifies tasks and allows more to be done in less time. Increased efficiencies Data collection is but one way that mobile devices increase efficiencies. Mitch Black, President of MOBI says, We ve already seen instances where mobility solutions have made a difference within the manufacturing space. In one case, we were able to uncover more than $15 million in hard cost savings utilizing Managed Mobility Services (MMS) to refine a company s mobility program. Increased worker productivity Mobile systems connected wirelessly to backend management systems like PanaCIM, deliver information to workers so that they are prepared for the next task before they arrive. The mobile device with such a software can display lists of tools needed, the location of the work to be done, access to documentation, and interactive instructions when needed. In a warehouse environment, real-time inventory checks are an invaluable tool, ensuring managers can keep track of all items upon delivery for improved loss prevention and productivity. In addition, managers can fulfill orders more quickly and efficiently with the ability to locate items on their mobile solutions and communicate with employees on picking and packing for streamlined fulfillment. Improved regulatory compliance Regulatory compliance, particularly track and traceability, is an important issue for an increasing segment of the manufacturing industry. The integration of rugged mobile devices with data capture systems, such as barcode or RFID, provides much greater insight into all stages of production versus paper-based systems. Mobile solutions offer time stamping updates, increased product recall functionality and automated data alerts eliminating delays and transposition errors when information is transferred from paper documents to digital systems. Improve employee retention As companies look to attract younger talent, those employees look for advanced systems that reflect their values and technology choices. While younger workers appreciate immediate and constant access to information, their devices do not always feature the most up-to-date security programs or secure information access, says Black. Tech savvy employees are enthusiastic to make use of the best and most advanced systems, but devices need to be inherently secure to protect the enterprise and its data at the same time they delight employees. PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
5 MANUFACTURING TECHNOLOGY CHECKLIST As manufacturers look to modernize and create their smart factories, they have several decisions to make with regard to mobile technology selection, implementation and deployment. Requirements differ based on each facility s needs but there are more commonalities to requirements than there are differences. This checklist details the key technologies and capabilities manufacturers should consider when creating a mobility strategy in preparation for Industry 4.0. Productivity & Security Reliability Workers need to complete their tasks even if they happen to drop their device. Dropping a tablet device should not make the unit unusable. Broken screens and cracked housings can stop a job in the middle of a critical operation and send the employee back to find a replacement. Mobile devices must be able to withstand hard handling, not contribute to production downtime. Select the mobile device with the lowest failure rates. Screen Visibility Factories present different lighting conditions across a variety of locations. Workers moving between indoor and outdoor locations need to be able to view and interact with their mobile devices regardless of dark interior lighting or bright sunlit conditions. Opt for enterprise-class devices that are clearly visible even when used outdoors under bright sunlight. Be sure to test the device under all lighting conditions during the pilot phase. Multi-shift operation Shops that work multiple shifts often pass mobile equipment from one shift operator to the next and do not have time to dock and recharge their equipment. Choose computers, tablets or handhelds that have long battery operation lives, hotswappable batteries, or quick charge options that support multi-shift operations. Security Critical to maintaining control over industrial equipment as well as securing intellectual property, device security should be designed into the system starting with the chip set and integrated with the overall design, software and networking components. Be diligent in choosing enterprise grade mobile devices as consumer grade mobile devices rely on software add-ons to secure the applications and network only. PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
6 Features Compatibility with legacy equipment Manufacturers continue to use equipment that was designed decades ago and incorporate connection technologies like serial ports (RS-232) to communicate with control and data collection functions. Modern consumer grade mobile devices generally rely on USB ports which don t allow them to connect to legacy devices. Consider what kind of connections are in use on the shop floor and deploy mobile equipment that can connect to all your equipment. Wireless capabilities Wi-Fi may be ubiquitous in the business world but even when it is available within manufacturing plants, connections can be weak or not easily available. Look for devices that have robust radio connection capabilities and specially designed antennae and are able to maintain connections where consumer grade devices cannot. Scanning capabilities Scanning in factory situations means more than simply using a camera to read a barcode. Today s manufacturing environments increasingly turn to RFID tags that are scanned electronically. Efficient scanning requires the capability to scan multiple types of tags without having to use multiple devices. Look for handhelds that include an angled scanner so employees can scan and use the touchscreen at the same time to increase efficiency. Safety & Durability Extreme operations From scorching heat and freezing temperatures to dust, dirt, grime and grease, employees can routinely encounter extreme environmental conditions. Ensure the mobile devices you select are functional in all temperature ranges and environmental conditions without requiring special housings or treatment. Hazardous location safe Shop floors can house hazardous conditions that can pose a risk when using electronic devices. Devices that are certified to meet ANSI 12.12.01-2000 Hazardous Locations may be needed for industrial settings with hazardous atmospheric conditions, keeping workers and their surroundings safe while still providing access to needed digital facilities. Select rugged mobile devices that conform to isafe/ansi standards to provide a level of protection from sparking or electromagnetic discharge that could cause an explosive event. Washability/Sanitization Factory workers are exposed to dirt, grease, and other elements that can be transferred to their mobile devices and particularly to the screens where those elements inhibit visibility, make them slippery, and can even be dangerous. Some production lines require sanitization where the screens and/or the entire unit must be able to be washed without causing damage or compromising the operation of the unit. Look for devices certified to be washable or sanitized without damage. IP (ingress point) ratings IP code ratings identify devices with regard to their ability to keep water, dust, and dirt from entering their housings and causing damage to components. Consumer grade mobile devices typically have lower IP ratings and consequently are more susceptible to damage from adverse conditions in a manufacturing setting. Look for enterprise ready devices with IP ratings that meet and exceed the conditions in a given facilities. PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
7 Form Factors & Accessories Employee Use Case - Mobile devices range in size from five to 20 inches, feature Windows and Android systems and a variety of rugged features. Mobile means different things for different workers in terms of accessibility. For some environments and tasks the mobile device needs to fit in a pocket or attach to a belt, while others may need to be mounted on a forklift. Increasingly, mobile devices eschew keyboards in favor of touchscreens or even voice input. If keyboards are necessary, the unit needs to be easily carried or mounted. Evaluate the physical environment and shadow employees on the job to determine the needs of your workforce. Many manufacturing environments find they need a combination of computers, tablets and handhelds to meet various tasks and conditions. Mounting and carrying options Industrial workers move between a variety of functions and need to have secure and reliable ways to carry and use their portable devices, for example on and off forklifts. The mounting options and carrying accessories should be as robust and reliable as the equipment being mounted. This precaution ensures workers can move between job functions and keep their devices where they are most accessible without the chance of breaking third-party mounts that may not fit properly. Service & Support Customer support options Mobile devices become part of the manufacturing process meaning that if a unit malfunctions or is broken, the manufacturing process can be at risk of being interrupted. Keeping operations on track requires the availability of spares and fast turnaround on repairs when needed. Look for device providers that understand the needs of manufacturing environments and have support plans designed to support them with quick response rates. Deployment Services Getting your mobile device operation up and running can be a tedious task which results in downtime and productivity loss. Manufacturers should look for mobile solution providers that can streamline deployment with a support staff able to come on-site and provide IT services, such as bundled kits, pilot installation and an active line to provide 24-7 troubleshooting service. PREPARING FOR INDUSTRY 4.0: CONSIDERATIONS & TECHNOLOGY CHECKLIST FOR MANUFACTURERS
8 PANASONIC FOR MANUFACTURING Modern manufacturing environments are increasingly taking advantage of mobile technologies to improve operations and minimize downtime. Panasonic manufacturers a range of rugged mobility devices purpose-built for the manufacturing industry. Available in a variety of form factors, including handheld barcode scanners, tablets, convertible 2-in-1 laptops and laptops in screen sizes ranging from 4.7 to 20 inches, Panasonic Toughbook and Toughpad devices are specifically suited to withstand the rigors of tough conditions that demand the best performance from both workers and their equipment. As a core manufacturer, Panasonic sets the industry standard for reliability with a less than 2% failure rate. Panasonic s history with mobility solutions in manufacturing is extensive as we are a manufacturing company, giving us a deep understanding of the complexities involved in the optimal coordination of capital, people, process and product. For example, we understand many manufacturers need to communicate with legacy and Ethernet, as well as newer equipment, enabling the technology to evolve as customers modernize. Companies taking part in the new industrial manufacturing revolution and making the shift to mobility should contact Panasonic today. EnterpriseSolutions@us.panasonic.com (888) 245-6344 panasonic.com/toughbook Source 1. VDC Research (2010). Total Cost of Ownership Models For Mobile Computing and Communications Platforms, Third Edition, Track I, Volume I: Mobile Devices. 2016 Panasonic Corporation of North America. All rights reserved. PSC-M16488WP