The Impact of Industry 4.0 on Heavy Fabrications
In recent years, the digitalization of manufacturing has gained traction and become increasingly prevalent in machine shops. This movement is known as Industry 4.0 as well as the Industrial Internet of Things (IIoT), and offers many advantages for heavy fabricators such as more data-driven processes and decision making.
Simply put, Industry 4.0 is the use of, and higher reliance on, connected technologies to optimize operations. IIoT machines are equipped with internet connectivity and other necessary hardware like sensors or processors that measure and report data via the internet. This form of smart manufacturing is changing shop floors by enabling the acquisition and accessibility of far greater amounts of data, at far greater speeds, and far more efficiently than before – allowing manufacturers to make decisions based on real-time data as well as machines make adjustments real-time based on performance feedback. Use of connected equipment and machines is becoming the norm and is the future of manufacturing. Below are some of the key impacts of Industry 4.0 on heavy fabrications.
- Enhanced Quality: smart manufacturing can be utilized with a variety of equipment including CNC machines and robotic welding. The type of real-time data collected by machine sensors includes temperature, vibration, power, torque, speed, current, and voltage. Various machine conditions are monitored such as gear and bearing health, wear on drills and cutting tools, and machine balance. Machine learning utilizes this data to take corrective actions real-time - improving the quality and consistency of heavy fabrications and reducing the potential for parts that do not meet tolerances.
- Predictive Maintenance: manufacturers are becoming increasingly aware of the downtimes and costs resulting from unexpected equipment failures, and are adopting preventative maintenance plans to secure a competitive edge. Smart machines collect and use data to monitor their own health, alerting of potential failure points or anticipated issues based on the data collected – a process known as predictive maintenance. The IIoT enables predictive maintenance, which is based on the real-time condition and performance of a specific piece of equipment, compared to traditional preventative maintenance which is generally based on averages and historical data of equipment that is collected manually. The best maintenance programs typically utilize a combination of preventative and predictive approaches.
- Improved Cost Visibility: it is crucial for machine shops to clearly understand the costs associated with manufacturing a given part, especially heavy fabrications. Digital manufacturing and the ability to collect more data real-time offers machine shops more traceability that leads to better cost visibility. Shops are able to more readily compare the forecasted versus actual cost and time for a given job – quickly detecting outliers and errors real-time as well as monitoring trends over time to identify improvement areas. In the end, higher cost visibility enables machine shops to make process improvements that save OEMs time and money.
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Contact the team at ABS to learn more about our advanced 5-axis machining solutions.
- Advanced Robotic Welding Technologies: smart machines, such as those utilized in robotic welding, are able to create a signature of a robot’s health. When the robot’s signature varies from the norm, artificial intelligence predicts an issue and allows manufacturers to proactively schedule downtime for maintenance and repairs before the equipment suffers damage or a failure that would unexpectedly stop production. When it comes to robotic welding, end-of-arm-tooling effectors are now often equipped with sensors that are IIoT connected for real-time data collection and optimization. These sensors can also give robots a perceived sense of touch and sight during welding operations, improving weld performance real-time. This level of detail is extremely valuable as it optimizes robotic welding performance and improves consistency – saving heavy fabricators and OEMs money and time.
- Increased Reliance on Cobots: robotic technologies continue to advance and the possible applications for Industry 4.0 robots continues to rapidly expand. One area that is gaining traction in machine shops is cobots – collaborative robots that work side-by-side humans. Cobots come with padded joints and other safety features that make them safer when working in a shared space with human operators. Today’s cobots are able to “see” parts and can pick and place them as directed. Additionally, cobots are easily programed, making this form of automation a good option for machine shops, like ABS, that specialize in heavy fabricationsand need to be nimble in their workflows.
Due to the rotational axes, A- and B-, 5-axis machines are able to bring the part closer to the cutting tools. This enables the use of shorter cutting tools, which is key to creating a better surface finish. Shorter cutting tools are less likely to vibrate while operating, which is especially important at higher cutting speeds. Shorter cutting tools with less vibration also results in less tool deflection and runout – all of which contribute to a smoother and better surface finish on the final part. For these reasons, 5-axis machines typically achieve a higher-quality finish compared to parts fabricated with traditional CNC machines.
ABS Heavy Fabrication Capabilities
Established in 1971, ABS Machining has grown to become the recognized global leader in large machining, fabrication, and assembly for OEMs, and is one of the largest and most advanced manufacturing companies in North America. Our fleet of CNC Boring Mills, Vertical Turning Lathes, and Table Type Boring Mills are supported across six state-of-the-art facilities located across North America. Our facilities house over 50 cranes ranging in lift capacity from 5,000 pounds to 160 tons and we are proud to have 80 of the largest machine tools ever manufactured.
ABS Heavy Fabrication is a full-service facility certified to CSA47.1 (AWSD1.1) and ASME Boiler Vessel B31.1 and 31.3 standards. Our welders are certified by CWB/AWS and ASME, and are fully trained on flux-core, gas metal, submerge arc, tig and stick electrode welding techniques. Individual customer requirements are followed and enforced in conjunction with our in-house certified weld inspectors. (CWI Level 2's). Below are some of our fabrication services:
- Robotic Welding
- Flux Core Welding
- Forming
- Metal Fabrication
- Mig Welding
- Full Penetration Welding
- Sub Arc Welding
- Metal Core Welding
- Laser Cutting
We offer a unique combination of medium to high volume production machining and welding services. Our team is committed to producing an un-paralleled level of quality and throughput, while also focusing on cost. We also offer secondary services such as mechanical assembly, making ABS a true single source solution for the most challenging programs of today and for the future.
Contact us today to see how we can help with your next heavy fabrication project, or give us a call at 1-844-227-6224.
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