A new wave of technology aims to turn your data into valuable knowledge. Derek Parker reports.
THE pressures of global competition and the impact of the international financial squeeze are forcing companies in the manufacturing sector to become more adept at the use of technology in every aspect of their operations.
In turn, providers of technology must become more attuned to the needs of manufacturers according to experts in the field.
“You need to look for every possible cost advantage to beat cheap imports,” said Scott Frayne, MD of Intercad, a provider of 3D CAD/CAM systems.
“It means that a company can make custom-designed products with very fast turnaround times – and by that I mean not weeks but days or even hours.
“But for it to work you have to be willing to invest some time in really getting to know your customer and understanding what they need.”
Frayne noted that Intercad has, in the past year, released a set of specialised products that sit on top of its existing SolidWorks 3D CAD package.
“For example, one of our clients is a manufacturer of trucks, but their customers often want a truck for a special purpose,” he explained.
“The DriveWorks product allows for that level of design, and there is a ‘wizard’ that provides a step-by-step interface, allowing customers to choose their own configuration.”
Frayne believes that another way forward is to further integrate the stages of design, and Intercad has created a new package to help mechanical and electronic designers work together seamlessly.
The SolidWorks Enterprise PDM (Product Data Management for the Enterprise) package allows designers in different locations to securely share information using either a broadband Internet system or a specialised intranet.
“A lot of our research and development effort is spent on improving efficiency, simplicity, and speed. Companies can’t afford the time to go through extensive training to learn complex procedures. They need technology that gives them clear value.”
SCADA systems
Another area of technology looking at significant change is Supervisory Control and Data Acquisition (SCADA) systems.
“Manufacturers are looking beyond SCADA as a tool only for operators” said Stephen Flannigan, global director of SCADA for Citect, which provides the technology to a wide range of clients.
“SCADA systems used to be insulated, stand-alone systems, but increasingly they are being integrated into IT-based systems available remotely through the web.
“That can certainly enhance competitiveness of a business as they will have access to real-time information to help them make the right decisions.”
However, this integration raises a host of security threats, not only from hackers and disgruntled employees, but also from terrorists, especially where critical infrastructure is concerned.
“We see SCADA-related security measures as an area that will change significantly in the next two years.”
Flannigan believes that end users need to implement layered security, from system firewalls and encryption of communications to updating their SCADA systems with enhanced security.
“In fact we recommend that any company that monitors and controls critical infrastructure have a security audit of their SCADA system to ensure it is safe.
“At the same time, system users are looking for improved productivity from their supervisory and control technology. If economic conditions tighten next year – something which now looks certain – we anticipate that companies will want to expand their existing systems instead of purchasing new ones,” said Flannigan.
“On another front, we are seeing a demand for data collection systems to evaluate energy efficiency, and for energy reporting. This is partly a reflection of public and political concerns about the environment and carbon emissions, and partly a need for effective control of costs.”
Citect recognise that as the amount of data SCADA systems collect multiplies, there is a real problem of operators becoming overloaded with information and alarms. In response, company is developing reporting tools that allow operators to be more effective, reducing complexity for better performance.
RFID technology
The theme of information moving up to the strategic business level is also being felt in the area of warehouse management, storage, and freight movement, pushed along by maturing RFID technology.
“The intersection of RFIDs with mobile reading equipment, either hand-held or vehicle-mounted, has led to a huge boost in flexibility, turning a static system into a dynamic one,” said Steve Dolan, director, channels & alliances, Sybase Australia & NZ, a global firm specialising in mobile and RFID-related technology.
“If you think about warehouse management being related directly to the effectiveness of handling being done by forklifts, for example, there can be clear reductions in the amount of handling and the number of errors, and therefore an increase in operator and equipment productivity,” said Dolan.
But the big shift, he believes, is the way in which new ‘middleware’ technology has turned the raw data generated by RFID systems into information which is meaningful to those people further up the oversight ladder.
The visibility of the data means that the supply chain can be understood very well, and any problems can be identified and addressed quickly.
“RFID technology is now robust and reliable, to the point that the amount and quality of data it provides is a given. The issue that will give companies a competitive edge is how they can turn data into knowledge that improves overall productivity.”