Evaluating proven processes against the promise of advanced modern technology is a delicate balance many OEMs constantly have to consider. At the heart of that decision is ensuring that both older and newer technologies are able to communicate effectively with one another and the operator. Bosch Rexroth’s Dave Cameron explains how modern control systems, when integrated properly, serve as a valuable bridge that can streamline processes with both legacy and cutting edge technology.
Q: What are the biggest challenges manufacturers in food and beverage, chemical and pharmaceutical industries face as they continue to operate in a hybrid environment of older and newer technology? Do any of them have hesitancy in adopting newer technology out of concern it won’t be able to communicate with newer technology, or vice versa? If so, what’s been your message to them?
A: Technology advancements in manufacturing are happening at a faster rate and there are clear solutions to manage older production lines if investing in new equipment is not desired. The ability to update existing equipment with more capable controllers, sensors and devices to advance production of older equipment is a valid option. The solutions often involve gateway devices, added sensors and edge devices which allow data collection off the machines, toward a digital twin approach for improved OEE and predictive maintenance. Solutions are available that do not interrupt the existing system and process, rather they are added to them to modernize the legacy equipment.
Once the modernization and realized benefits are understood, most companies are willing to invest in their existing production equipment.
This is part of Bosch Rexroth’s ctrlX AUTOMATION solution portfolio of products. We have been offering customers solution sets for their production for several years. The updates can involve many other vendors’ products which is why system integrator companies are a good fit to bring this all together.
Q: What role does data monitoring play in system integration and how should OEMs implement it within their processes if they’re not already doing so?
A: Data is always key to understand the quality of production, prevention of downtime and the trends of the system. What to do with the data is often discussed, but each customer decides that value based on the ultimate desire of the production system. It’s clear that data is everywhere in our daily lives and drives artificial intelligence (AI) and analytics for decision making. This is no different in process and production. Data is used to make decisions and improve all aspects of the process.
To implement more data monitoring, OEMs can begin with simple equipment upgrades to capture data. Working with the right system integrator makes this process much easier and caters to their individual needs.
Q: How important is it for automation solutions and control solutions to be flexible and quick to on-board, given the shifting consumer landscape, particularly within food and beverage?
A: Automation solutions must be flexible and easier to implement. The need to connect everything easily, the ability to scale for flexibility of production, and to speed up the time to market are requirements.
Bosch Rexroth has designed the ctrlX AUTOMATION system for exactly this concept. The app-based system is like a smartphone approach to industrial automation to achieve these demands. The system is designed for required security, easy programming and modularity by choosing the desired apps to connect devices and implement solutions much faster.
Q: How has smart technology and AI played a role in control system development and increased level of automation within process manufacturing?
A: The improved computer power has launched great use cases of AI in recent years. Machine learning based on data from the system is clearly going to drive manufacturing to a new level over the next several years. Systems will learn from the data on how to adjust and adapt to an ideal quality and productivity level.
Q: Do you anticipate a greater influence of cobots/robots/autonomous solutions in the future?
A: Yes, a greater install of autonomous solutions will be used in manufacturing based on the hardship of dependable labor, the need for health and safety protection in certain jobs and the efficiency and throughput required.
Q: Has training and onboarding for employees working on the line changed, given that operations are becoming highly digital and connected?
A: People have shifted much more to online self-serving information needs, training and troubleshooting. Bosch Rexroth offers a great toolbox for users in the area for the ctrlX AUTOMATION products including easy how-to videos, forums, the GitHub community and the apps store with key data and trial usage. Tools for selection of products and configurators, and simulation tools are available for the digital experience expected today.
