Connected Enterprise Maturity Model for Excellence in Manufacturing

The well-used ‘Connected Enterprise Maturity Model’ for implementing a more intelligent OT/IT network, that incorporates measures and best practices necessary to ensure effective change in both, technologies and organizational cultures.

The accelerated connection of operations technology (OT) to information technology (IT) enables unprecedented collaboration across the enterprise, linking processes and facilities to suppliers and customers in new ways. It enables continuous-improvement (CI) teams to implement real-time decision-support tools that boost productivity and profits - often without direct intervention or additional staff. 


Are You Ready?

Use the 5-stage ‘Connected Enterprise Maturity Model’ outlined here to find out…

The ‘Connected Enterprise Maturity Model’ for implementing a more intelligent OT/IT network, has proven to provide significant reductions in costs and improved capabilities. Rockwell Automation developed this five-stage maturity model that incorporates measures and best practices necessary to ensure effective change in both, technologies and organisational cultures.

Traditionally, manufacturing has been considered as a process that convert raw materials into physical products in the factories by managing resources with best automation practices available.

Today, drivers such as technology, sustainability, optimization and the need to meet customer demands have once again encouraged the transformation of the manufacturing industry to become adaptive, fully connected, and aware of its own power quality. One of the most significant trends in manufacturing is of improved information technology solutions involving the union of conventional automation with the information technology.

The digital factory concept offers an integrated approach to enhance the product and production engineering processes and simulation is a key technology within this concept. 
Simulation helps to create digital models of products, production systems, logistic systems so that one can explore a system’s characteristics and optimize its performance. These digital models have the ability to run experiments and what-if scenarios without disturbing existing production systems or – when used in the planning process – long before the real production systems are installed. Extensive analysis tools, such as bottleneck analysis, statistics and charts give us an opportunity to evaluate different manufacturing scenarios.

Wireless products have fundamentally changed our lives – and they are also playing an increasingly important role in the industrial environment. Here too, the enormous potential of wireless technology opens up totally new perspectives. 

In the new connected world of smart manufacturing, industrial wireless instrumentation is rapidly becoming the technology of choice for a growing class of applications. It is quickly gaining relevance in automation applications. In some applications, it is not the amount of data that poses challenges, but the distances to be bridged. Whenever the plant architecture does not allow conventional wiring, values are only accessible through frequent visits to the field. Wireless instrumentation can be a solution to one such problem.

A key component in making Industry 4.0 a reality are machines that can produce the desired components faster, more flexibly and more precisely than ever before. Also Consumers want products that reflect their individuality. 

Moving away from traditional brand loyalty, they prefer loose relationships with multiple suppliers who can provide increasing levels of product personalization, from fashion and apparel to home ware and furniture, from automobiles to fast-moving consumer goods. To drive this interaction, consumers are accessing ever more intuitive websites to move back along the supply chain, becoming part of the product design function of a business and providing design intent for products that have yet to be manufactured.

Until now, industrial robots always worked separately from humans in specially safeguarded protected spaces. Smart manufacturing has broken down this barrier with a new generation of collaborative industrial robots. 

Collaborative robots sometimes also known as “cobots" for short, are the robots that are capable of human-robot collaboration (HRC) and work hand in hand with their human colleagues. Human-robot collaboration is thus combining the best of two worlds: humans with their superior creativity and cognitive abilities and the robot with its greater repeatability, strength and precision.

Networked production and control processes in complex machine environments determine the industrial future and make Industry 4.0 possible in the first place. Smart Sensors already today support dynamic, real-time-optimized, and self-organized industry processes. 

They record real operational statuses, turn these into digital data, and share them automatically with the process controller. The added value of sensor communication depends significantly on the quality and reliability of the delivered data.

Augmented reality is the integration of digital information with the user's environment in real time. Unlike virtual reality, which creates a totally artificial environment, augmented reality uses the existing environment and overlays new information on top of it. 
AR is taking information that is found in a variety of applications, such as maintenance records, inspection and repair manuals, and engineering specifications, compiling it, and displaying it on the physical features of the thing or machine. Moving the smartphone or tablet around the object to show different views reveals new information related to the object’s features.
The core idea of Industry 4.0 is being connected with intelligent products that communicate with users or other products, enabling new digital business models that shall harness collected data to offer additional services which will lead to the formation of a fully digital value chain.
The digital universe is expected to grow to around 44 zeta bytes (40 trillion gigabytes) by 2020. Embedded systems data in the Internet of Things is expected to grow from just two percent of the digital universe in 2013 to 10 percent in 2020. The sheer volume of data created within the Internet of Things is so enormous in scale that it cannot be comprehensibly processed in conventional databases. Detailed and complex nature of data captured by intelligent devices demand advance analysis to derive value out of it.

The ongoing development of the automation landscape with Industry 4.0 means that companies are faced with new security challenges. Smart Manufacturing involves tremendous amounts of data, demanding a significant IT commitment to securely manage it all. 

In fact, with so many lean businesses currently outsourcing their IT resources, this new internal IT architecture alone may be a significant roadblock to Industry 4.0. Moving to an in-house smart network as the backbone of an entire business operation raises alarm bells about security — the network must be impenetrable at all times and at all costs. In fact, network security is considered today’s leading point of discussion about wholesale adaptation of Industry 4.0.

The world of automation is merging with the IT world. Safety & security is an important prerequisite for the function of Industry 4.0 systems, which in contrast to traditional production plants have interfaces to their environment. 

In future Industry 4.0 systems will be reconfigured and optimized autonomously – i.e. by the system itself during operation – so this requires a reassessment of safety & security during runtime. It must also be ensured that no unacceptably high safety risks will arise as a result of residual security vulnerabilities. Ultimately, confidence building on this issue should be supported among small and medium sized enterprises, as the crucial basis for production in ad-hoc networks. Transparency, participation and open communication are important prerequisites in this regard.