Adding Value in Production Process

By OEM Update Editorial August 31, 2020 5:54 pm IST

Our industrial automation and networking solutions help manufacturers – both large and small – to connect, monitor and control operations.
Sameer Mudhalwadkar, Sales Director – SAARC & Middle East, Red Lion Controls

Red Lion offers a range of industrial automation and networking devices to enable a rapid and easy to install data transfer in the factory environment. In an interview with OEM Update, Sameer Mudhalwadkar, Sales Director – SAARC & Middle East, Red Lion Controls said that the use of advanced technologies such as IIoT, Big Data, Cloud Computing and Robotics influences the value added in the production process like never before.

How technology is transforming manufacturing?
Today, manufacturing technologies are developing rapidly. Where manual manufacturing used to dominate the production process, humans are now only active as operators of complex systems and equipment. Manual functions such as particularly recurring simple tasks in series production are almost completely taken over by machines. This prevents human error and failures due to lack of personnel. The use of new technologies also increases productivity and throughput. Furthermore, an ROI is easier to determine, since constant values are available by using automatised machines and equipment. In particular, the use of advanced technologies such as Industrial Internet of Things (IIoT), Big Data, Cloud Computing and Robotics influences the value added in the production process like never before. They bring speed, visibility and flexibility to the production of manufacturing companies, creating the factory of the future with increased precision and efficiency.

How is your company gearing up for ‘Future Factory’?
An important aspect is in the area of retrofitting. Connecting existing systems that have been in operation for years or decades and are not to be replaced or upgraded with new, state-of-the-art systems. Heterogeneous production plants with different machine languages must be able to communicate with each other in order to establish a smooth data flow on the factory floor. Only then can a company work productively and efficiently. In addition, they must be made fit for the future, so that new technologies can be integrated wherever possible without having to replace systems and equipment.

Our industrial automation and networking solutions help manufacturers – both large and small – to connect, monitor and control operations. Red Lion develops new technologies that provide automated and securely networked production processes. Where can production processes be controlled automatically, how can they be easily operated and at the same time, pass on valuable production data from OT to IT?

In addition to the establishment of an almost smooth data flow, the release of unused data potential is very important for efficient production. Unused or not released data in SCADA systems are made accessible.

What are the enabling technologies you offer for smart manufacturing?
Red Lion offers a comprehensive range of industrial automation and networking devices to enable a rapid and easy to install data transfer in the factory environment. The goal is to collect and compile data and make it available to the production process and beyond. As a leading supplier of digital displays, the portfolio has expanded to HMIs, visual data management systems and especially IIoT protocol converters and gateways. Since the acquisition of the companies N-Tron and Sixnet, networking solutions have been offered in addition to automation products. Gigabit switches managed and unmanaged switches, PoE+ 240 Watt, Layer 3 switches are in demand worldwide, especially due to their extreme robustness. I/O Modules extend the product range.

Our latest innovation is FlexEdge, an intelligent edge automation platform addresses the automation, field and process/control levels – PLC, SCADA – and connect them to Manufacturing Execution Systems (MES), operations (ERP) and executive business processes on even one platform.

The platform brings industrial data together as never before to transform edge computing. FlexEdge provides a scalable solution to integrate complex multi-vendor environments into digital transformation strategies, while providing a future-proof solution for changing application needs. Users can avoid costly and complex rip-and-replace scenarios by simply leveraging the FlexEdge sled architecture. The design enables organisations to leverage new communications technologies as they become available. Powered by the programming software Crimson 3.2 which is developed and owned by Red Lion, FlexEdge enables connectivity to virtually anything in your system with point-and-click simplicity. And the new equipment working with the existing infrastructure means capital budgets are kept in check.

Additionally, the FlexEdge form factor adapts as applications need change; effortlessly scale by adding up to ten hot-swappable I/O or PID modules. On-device wiring diagrams and removable wire clamp screw terminal blocks ease installation, while the at-a-glance module status indicator and individual channel LEDs improve troubleshooting and system testing. Engineers can select the right FlexEdge software functionality for the application. Select from Networking Gateway, Protocol Gateway, Advanced IIoT Gateway, or an Automation Controller with IEC 61131 capabilities. If the application changes, simply upgrade the gateway to meet the applications requirements, it’s that easy. Reduce or eliminate costly equipment changes as simply as pushing new software. A rugged construction, a wide operating temperature range, industrial certifications and Red Lion’s Crimson software provide a dependable solution for control, networking and data visualisation in even the harshest environments. Analysis features will help your organisation develop cyclical processes to ensure operational improvements and continuous cost reduction.

How automation can improve warehouse efficiency and productivity?
Automation in warehouse helps to gather real time data remotely that use for improving KPI, productivity. A key point is improved operational efficiency. Automation of warehouse setup and management not only helps companies to achieve higher warehouse productivity but will also lead to significant cost savings compared to the employment of labour. An important aspect of this is the visualisation of data. Which product is needed where to ensure a smooth production flow? When is the minimum stock level reached, when do you need to reorder?

Another aspect is Lean Management. Most of today’s modern facilities strive to implement lean production to improve operational efficiency and reduce production costs. Lean production and material handling techniques help manufacturers minimise waste of materials, resulting in better inventory.