Exploring the Process of Upscaling and Expediting Digital Transformation for Industrial Automation at TSN

Many businesses leverage economies of scale by boosting production to achieve commensurate cost savings. However, it’s not always the case that increased production leads to reduced unit costs. Nowadays, most companies have optimized their economies of scale, and the cost per additional unit is rising. With mass production no longer being the sole solution, the question arises: what comes next? The swift evolution of markets and the challenges in global supply chains have compelled companies to innovate and adapt to remain competitive. Implementing Industry 4.0 and Industrial Internet of Things (IIoT) applications and leveraging digital transformation to revolutionize smart factories have become vital for companies to thrive in the current volatile environment.

The Importance of Responsive Manufacturing for Ongoing Success

Embracing responsive manufacturing is crucial for agility in meeting market demands. The concept revolves around a company’s ability to swiftly adjust production processes to cater to customized demands—a pivotal capability for staying competitive and navigating supply chain disruptions triggered by the impacts of COVID-19. Responsive manufacturing, encompassing close collaboration within ecosystems and strategies for personalized mass production, forms the bedrock of Industry 4.0 and IIoT. It entails a production framework centered on data connectivity, communication, and rapid decision-making. The following table outlines the essence of responsive manufacturing.

• Essence of Responsive Manufacturing

Time-synchronized Networking Improves Transition to Responsive Manufacturing and Boosts Benefits

Selecting the appropriate approach for retrofitting existing facilities, especially during expansion, can be daunting. Time-synchronized networking emerges as a game-changer for digital transformation in the automation sector, serving as the cornerstone for a consolidated infrastructure. TSN offers time alignment, low-latency communications, high reliability, and efficient resource management. This facilitates the convergence of Information Technology (IT) and Operational Technology (OT) networks, connecting all end devices and centralizing data aggregation on a standard Ethernet network. Real-time data enabled by TSN facilitates digital transformation, empowering factories to fine-tune production strategies in response to dynamic markets and emerging challenges.

The potential impact of responsive manufacturing is significant. Firstly, in terms of asset management, cost savings kick in right from the initial phase of establishing a consolidated infrastructure. TSN allows the connection of multiple applications and diverse systems on a unified network, simplifying operations and maintenance by necessitating fewer devices and cables at the ground level. Furthermore, a unified network merges IT and OT networks, enabling the integration of modern IT technologies like artificial intelligence and machine learning for enhanced operational efficacy and increased asset control. Secondly, businesses can transition from selling products to offering services, providing further customization while reducing Minimum Order Quantities (MOQ) without compromising profitability, thereby expanding opportunities for owners. Thirdly, integrating control mechanisms significantly reduces production cycle times. Previously, shifting the entire production process to a new product may have taken weeks, but by integrating different control systems, this can be accomplished in days, rendering responsive production not just plausible but lucrative.

Exploring Three Real-life Instances Harnessing the Power of a Unified Network

Moxa has collaborated with global clients to leverage the perks of responsive manufacturing. Let’s delve into how TSN accelerates digital transformation in industrial automation.

• Unified Network Unleashing the Potential of Responsive Manufacturing

A product manufacturer aimed to unify their systems—production, assembly lines, and logistics—on a single network to shorten production cycles and lower ownership costs. TSN streamlines control integration, cuts cycle times, simplifies the network topology, eases asset management, and enables service delivery through a unified network.

• Aggregating Diverse Applications on a Unified TSN Network to Slash Production Cycles

A global industrial machinery giant leverages TSN to consolidate multiple applications in CNC machinery. The deterministic laser and motion control systems need to synergize seamlessly to achieve scalable, fast sensing, and advanced machine control. TSN facilitates the efficient integration of these devices, resulting in reduced production cycles.

• AI-Enhanced Operational Efficiency in a Hydroelectric Plant for Reduced TCO

The operators of a hydroelectric plant unified their disparate networks and adopted an AI system for network control using the TSN standard. This integration simplified operations on a unified network compared to separate networks. The hydroelectric plant bolstered efficiency, quickly adjusted power output to the grid, and transformed into a cost-effective facility with enhanced maintenance, efficiency, and flexibility.

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TSN epitomizes cutting-edge technology that empowers industry leaders to expedite their digital transformation in industrial automation. In this article, we provided a brief overview of responsive manufacturing and its enabler, TSN. Building on this foundation, the three real-world cases exemplify how organizations can overhaul their industrial operations while capitalizing on the advantages of TSN.

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