Smart Manufacturing

Industrial 4.0 is the Driving Force behind the Digital Transformation of Manufacturing. Smart manufacturing is the application of technology to digitally transform how manufacturing companies operate. It is driven by a need to boost efficiency, become more agile to respond to market unpredictability, improve quality, safety and compliance

Industry Trend

Smart manufacturing is the most current, highly beneficial result of technological advancements in recent years, and is becoming the focus of manufacturing globally. Smart manufacturing can accurately predict requirements, identify errors, as well as make innovation and the manufacturing process more manageable. It is the process of combining and implementing various technologies and solutions into the traditional manufacturing process, and it is also the process to reshape all manufacturing industries with digitization.
Xingtera’s Digital Manufacturing Solution Suite puts together state-of-art solutions powered by 5G, advanced industrial IOT, machine vision, automation and robots, AR technology and data analytics platforms—designed to help manufacturing companies to innovate its product and production process, and realize intelligent manufacturing. Our Smart Manufacturing systems will deliver high efficiency, improve quality, boost productivity, increase profit and enable new business models. The cloud based, End-to-End turnkey solution will simplify our customers’ digital transformation for sure.

What are Challenges in Today's Manufacturing

Manufacturing is an exciting industry, but like any other market sector, it faces its fair share of challenges. Manufacturing companies must overcome these hurdles and challenges to continue succeeding in 2021 and beyond.
Skilled Labor Gap

Without using digital applications, there is no way to trace vehicle routes, to access data on service history down to the component and part level, to maintain compliance records, and to send notifications when preventive maintenance is due. This kind of headaches make the fleet management very complicated and difficult.

Demand for Cost Reduction

Properly maintaining vehicles on regular basis is very important. Fleet managers need to ensure that preventative maintenance schedules are maintained. To ensure the fleet vehicles are in good working order, it is critical to develop solid maintenance strategies. As such, the fleet can run efficiently without unexpected breakdowns that can cause lost work and reduce fleet efficiencies.

Inventory Management Challenge

Companies have budget for fuel costs, depending on the type of fleet vehicles deployed. Even modest fluctuations in diesel cost can have a major impact on the company’s financial bottom line. It is essential to implement a tool to report fluctuating fuel usage, alert for issues which can be resolved or downtime.

Demand for Higher Productivity

Controlling costs is challenging in fleet business. Fleet managers always struggles to figure out how to increase efficiencies and costs by analyzing the relevant data about their fleet. This includes inspecting and reducing fuel consumption, analyzing driver behavior, identifying the optimal vehicle to dispatch for an urgent call and calculate the best route, and maximizing the return on effort.

Disruptive Technologies

Xingtera’s Smart Manufacturing solution has adopted the most advanced technologies in order to catch up with the trend of industrial 4.0 and help our customers to implement a revolutionary solution for their manufactories.
  • 5G Private Cellular Network

    • 5G Private Cellular Network

    If AI is the Brain  behind Industrial 4.0, 5G  is literally the Heart of Smart  Manufacturing. Here is why:

    Industry 4.0 makes use of highly automated, intelligent and collaborative cyber-physical systems which require highly stable, low-latency wireless connections, legacy fixed Ethernet won’t fit the changes and the limits of commercially-supplied Wi-Fi and LTE cellular networks can not perform due to its limits. 5G stands out because its high bandwidth, massive connections and ultra low latency. Transitioning to a private 5G wireless network offers flexibility to reconfigure, upgrade and evolve the setup as needed enabling factory operations to run smoothly and cost-effectively.

  • Machine Vision

    • Machine Vision

    Machine vision system automatically acquires and analyzes an image to deliver desired information and control machines or processes. It is the automatic extraction of information from digital images for process or quality control. In factories, there are lots of repetitive inspection tasks that requires human inspectors to fulfill. Machine Vision perfectly fits this kind of work. It is faster, more objective, and works continuously. Machine vision can inspect hundreds or even thousands of parts per minute and provides more consistent and reliable inspection results. As result, these systems replace incapability of human inspector to maintain a high level of error recognition for a long period.

  • Automation and Robots

    • Automation and Robots

    With skilled labor harder to find and retain, many warehouses and manufacturing facilities are implementing automated robotic solutions into their operations. And with recent technological advances, it’s now possible to automate small batch runs and sensitive, difficult components once thought impossible or too costly to automate. Automated robots and robotic systems are designed to be integrated into your operations with a specific task in mind, and are tailored to meet the unique needs of your business. Here are six common applications for integrating automated robotic systems: 1) Robotic Welding;  2) Robotic Packaging; 3) Robotic Pick & Place; 4) Robotic Dispensing; 5) Robotic Cutting; 6) Robotic Non-Destructive Inspection

  • Augmentation Reality

    • AR and VR Technologies

    Virtual Reality (VR) technology creates a simulated three-dimensional environment that a user can perceive as real and provides an immersive experience in the artificial environment, whereas Augmented Reality (AR) increases the user experience in the real world by layering additional digital content and information onto the physical world as if it’s in your own space. In the era of Industry 4.0, the manufacturing industry is focusing on automation, Interconnectivity (IIoT), Machine Learning, and Artificial Intelligence to create new ways of operating. The use of AR/VR applications in manufacturing is is huge, especially in areas like product R&D, workplace design and layout, inventory management, remote maintenance and servicing of equipment, workers safety and real-time employee training and much more.

  • IoT Solutions

    • IoT Solutions

    Smart manufacturing is the concept of leveraging data collected from many sensors and machine-to-machine communication to make informed decisions that help in optimizing production. IoT, using wired and non-wired connectivity, allows this data to flow freely. The data is collected and analyzed and then combined with contextual information, shared with the manufacturers. IoT gives them the capability to remotely monitor and manage processes and make the needed changes in real-time, and help them improve productivity, costs, quality and resource management. Therefore, the IoT has emerged as one of the core components of manufacturing transformation, ushering the world into the era of ‘smart manufacturing’.

  • Data Analytics

    • Data Analytics

    Data analytics is the science of analyzing raw data in order to make conclusions about that information. In factories, embedded sensors and connected production equipment, such as conveyors, fastening tools and robots, can provide manufacturing engineers and plant managers with reams of data. That information enables better and faster decision making within factories, and makes continuous improvements more quantified and disciplined. With advanced data analytics, manufacturers can capture and analyze data to gain meaningful insights into manufacturing challenges, take a deep dive into historical process data, identify patterns and relationships among discrete process steps and inputs, and then optimize the factors that prove to have the greatest effect on yield.

    Key Features

    Xingtera Smart Manufacturing solution suite is designed to develop a fully connected and flexible factory that can self-optimize its performance, learn and adapt to new demands, and become more and more intelligent.

    What makes it different?

    If the smart factory offers ways that can successfully address some of today's big challenges in manufacturing industry. What are the key features that make it so different?

    • Pervasive Connectivities – Assets are fitted with smart sensors so systems can continuously pull data sets from both new and traditional sources, ensuring data are constantly updated and reflect current conditions.
    • Optimized System – It allows operations to be executed with minimal manual intervention and high reliability.
    • Transparency –  Real-time data visualizations can transform various data captured in the field or in production and convert them into transparent and  actionable insights, either for humans or autonomous decision making
    • Proactive system – Employees and systems can anticipate and act before issues or challenges arise, rather than simply reacting to them after they occur.
    • Agile flexibility – This feature and capability allows the smart factory to adapt to schedule and product changes with minimal intervention.

    Application Scenarios

    Xingtera is offering customized Smart Manufacturing solutions for different businesses scenarios.

    Machine Vision Inspection

    PCB flux defects may come in the form of corrosion and can cause harm to the assembly. Using real time machine vision can replace the human visual manual inspection and improve PCB production quality. 75%+ labor work can be removed.

    Autonomous Mobile Robots

    Autonomous Mobile Robots offer many benefits, such as liberating workers from loading and unload, low valuer and repetitive tasks, reducing error, re-work, and risk rates, and improving safety for employees in high-risk work environments.

    Augmented Reality

    Industrial AR helps to create and deliver easily consumable work instructions through a highly visual, interactive method of presenting relevant digital information in the context of the physical environment - connecting employees & improving business outcomes.

    Pervasive IoTs

    The pervasive adoptions of IoT in manufacturing enables the transition of tradition manufacturing systems into modern digitalized ones. It assists manage analytics and predictive maintenance.

    Welding Robot

    Robotic welding is highly productive for completing high-volume, repetitive tasks in your operations. Welding robots are both easy to program and able to help address the growing skills gap in the welding industry.

    Application of Data Analytics

    By combining airframe manufacturing data with artificial intelligence and machine learning, product managers can capture human variability and work content that reduces rework, disruption and downtime.

    Main Benefits

    Smart manufacturing is highly beneficial and crucial across industries and sectors currently. Xingtera's Smart Manufacturing solution suite offers four significant benefits of smart manufacturing as below.
    Automated Data

    In a truly digitalized factory, assets are suited with smart sensors so systems can continuously and automatically pull data sets from both new and traditional sources, ensuring data are constantly updated and reflect current conditions. Integration of data from operations and business systems, as well as from suppliers and customers, enables a holistic view of upstream and downstream supply chain processes, driving greater overall supply network efficiency, at the same time, provides managers with precise data and the ability to measure key performance indicators more efficiently.

    Significant Cost Reductions

    Smart Manufacturing introduces lots of cost reductions: replacing manual workers with an automated system benefits the company by reducing wasted time and money while increasing productivity; an advance in the augmented reality sector, combined with virtual reality, makes it effortless for manufacturers to train on the job and cut on the costs; a fully connected factory increases forecast accuracy and reduces waste, helping reduce costs with proper demand management. While the cost decreases, the speed and throughput of robots has increased significantly, resulting in lower cost per assembly and cost per placement.

    Reduced Workforce

    With the applications of advanced technologies in factories, lots of tasks around manufacturing have been automated. Manufacturing firms find themselves in less need of employees. The desire for an unskilled and trainable workforce that was embraced some time back is slowly shrinking as innovation has become more prevalent. Machine sensors have become common in the industry. They are utilized to collect significant amounts of information. With this kind of innovation, the job make-up in the industry is shifting. Manufacturers now require workers with top-tech skills.

    Enhanced Productivity

    In a smart factory, sensors, machines, workpieces, and IT systems will be connected along the value chain. These connected systems can interact with one another, gather and analyze data across machines to predict failure, configure themselves, and adapt to changes, enabling faster, more flexible, and more efficient processes to produce higher-quality goods at reduced costs. This in turn will increase manufacturing productivity, shift economics, increase industrial growth, and modify the profile of the workforce—ultimately changing the competitiveness of companies and making the business stand out.

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