Organisations can significantly improve quality, safety, productivity, and cost savings by strategically applying sensors, says Darshana Thakkar.

Industry 4.0 and the process of digital transformation are revolutionising manufacturing. Making decisions based on the meaningful use of real-time data collection from various machines can make the manufacturing process more efficient, suffer less downtime, and ultimately add more profits to the bottom line. Smart sensors are a critical element in making factories smart. The function of the sensor is to convert parameters of physical science, such as temperature, pressure, force, gravity, flow, etc., into electrical signals.

As MSMEs are India's growth engine and contribute significantly to its manufacturing output, it's a matter of concern. How smart is the factory of an MSME organisation?

Traditionally, machines on the shop floor require manual labour to do checkups and routine maintenance. When a machine breaks down, the maintenance crew will respond to the crisis, which can be disruptive and costly. With growing competition, the MSMEs must also transform their manufacturing practices. Unfortunately, many factors and limitations restrict the automation journey of an MSME organisation.

Today, I am sharing a few critical pieces of information about how a small organisation can start its automation journey most simply. Sensor technology is the key to this revolution to begin with.

MSMEs can do partial automation in a small business by applying sensor technology systematically. Here's a step-by-step guide to help small businesses begin their journey towards automation:

• Determine which processes would benefit the most from automation (e.g., production line, inventory management, quality control).

• Identify areas where manual intervention is prone to errors, inefficiency, or safety concerns.

• Define a goal about what you want to achieve with automation (e.g., reduced downtime, improved quality, enhanced safety).

• Set specific, measurable targets such as reducing production defects by 20% or cutting energy costs by 15%.

• Understand the different types of sensors available (temperature, pressure, proximity, motion, etc.) and their applications.

• Ensure sensors are compatible with existing systems for easy integration.

• Plan for a phased rollout, starting with the most critical areas and gradually expanding.

• Create a budget that includes the cost of sensors, installation, and any necessary training or maintenance.

• Select sensors from reputable manufacturers to ensure reliability and accuracy.

• Ensure the chosen sensors suit your business's specific applications and environment.

• If necessary, hire professionals to install sensors to ensure correct configuration.

• Integrate sensors with existing control systems (PLCs, SCADA, etc.), for seamless data collection and control.

• Set up systems to monitor sensor data in real-time.

• Configure systems to automatically respond to sensor data (e.g., shutting down machinery if a sensor detects a critical fault).

• Set up alerts to notify personnel of any issues detected by the sensors.

• Train employees on how to use and interpret data from the sensors.

• Provide ongoing training to keep staff updated on new technologies and processes.

• Continuously monitor the performance of automated systems.

• Regularly analyse the data and make adjustments to optimise processes.

The next question is how to select an appropriate sensor. A few factors to consider:

1. Power source: Based on the available power source, such as battery or solar.

2. Sensing Technology: Based on Required parameters such as temperature, pressure, humidity, motion, etc.

3. Wireless Technology, if available: Bluetooth, 4 G/5 G internet, etc.

4. Processing Technology: Based on available technology such as Edge computing, cloud computing, Hybrid computing, etc.

5. Form of the sensor: Based on requirements such as smart, modular, disposable, etc.

In an engineering manufacturing organisation, sensors enhance efficiency, quality, safety, and productivity. Here are some key areas where sensor technology is very effective:

1. Production and Assembly Lines

• Proximity Sensors: Detect the presence or absence of components to ensure proper assembly.

• Vision Sensors: Perform automated inspections for quality control and detect product defects or inconsistencies.

• Force/Torque Sensors: Monitor the force applied during assembly to ensure it is within specified limits.

2. Quality Control

• Optical Sensors: Measure dimensions, surface finishes, and other physical attributes to ensure they meet specifications.

• Temperature and Humidity Sensors: Maintain optimal environmental conditions for sensitive manufacturing processes.

• Ultrasonic Sensors: Detects flaws or irregularities in materials through non-destructive testing.

3. Inventory and Supply Chain Management

• RFID Sensors: Track the location and movement of materials and products throughout the supply chain.

• Weight Sensors: Monitor inventory levels based on weight, ensuring accurate stock counts.

• Barcode Scanners: Automate inventory tracking and management processes.

4. Equipment and Machinery Monitoring

• Vibration Sensors: Monitor the health of machinery by detecting unusual vibrations that indicate potential failures.

• Temperature Sensors: Ensure machinery operates within safe temperatures to prevent overheating and damage.

• Pressure Sensors: Monitor fluid and gas pressures in hydraulic and pneumatic systems to maintain optimal performance.

5. Energy Management

• Smart Meters: Measure and analyse energy consumption to identify inefficiencies and opportunities for savings.

• Motion Sensors: Control lighting, heating, and cooling systems based on occupancy to reduce energy waste.

• Environmental Sensors: Monitor air quality and environmental conditions to ensure safety and health standards compliance.

6. Safety and Security

• Gas and Smoke Sensors: Detects hazardous gases and smoke, triggering alarms and ventilation systems to ensure worker safety.

• Proximity Sensors: Prevent accidents by detecting human presence near dangerous machinery and shutting down equipment if necessary.

• Access Control Sensors: Monitor and control access to restricted areas, enhancing security.

7. Predictive Maintenance

• Vibration and Acoustic Sensors: Detect early signs of equipment failure, allowing for timely maintenance before breakdowns occur.

• Thermographic Sensors: Monitor the thermal profile of machinery to identify overheating components.

• Oil Quality Sensors: Analyse the condition of lubricants to predict and prevent mechanical failures.

8. Environmental Monitoring

• Air Quality Sensors: Monitor levels of pollutants, dust, and other airborne particles to maintain a safe working environment.

• Water Quality Sensors: Ensure the quality of water used in manufacturing processes meets the required standards.

• Noise Sensors: Measure noise levels to ensure compliance with occupational safety regulations.

9. Logistics and Material Handling

• Load Sensors: Monitor the weight and balance of loads transported within the facility.

• Proximity Sensors: Ensure the safe operation of automated guided vehicles (AGVs) and robotic arms.

• Position Sensors: Track the location and movement of materials and products throughout the facility.

10. Process Control

• Flow Sensors: Measure the flow rate of liquids and gases in manufacturing processes.

• Level Sensors: Monitor the levels of materials in tanks and hoppers to prevent overflows or shortages.

• pH Sensors: Ensure the chemical balance of substances used in manufacturing processes is maintained.

Conclusion

Small businesses can implement partial automation using sensor technology by starting with crucial areas and gradually expanding.

Sensors play a pivotal role in modern engineering manufacturing organisations by providing real-time data that enhances decision-making, optimises processes, and improves overall efficiency. Organisations can significantly improve quality, safety, productivity, and cost savings by strategically applying sensors across various areas. Implementing sensor technology is critical to achieving advanced manufacturing capabilities and maintaining a competitive edge in the industry.With careful planning, investment, and training, small businesses can harness the power of sensor technology to stay competitive and grow sustainably.

Darshana Thakkar is an MSME Transformation specialist and Founder of Transformation – The Strategy HUB. With an Electrical engineering and MBA in business operations background, she has 28 years of hardcore industrial experience in transforming Small businesses. She helps MSMEs define growth paths, derive marketing strategies, improve business operations, adopt digital Transformation, and increase profitability.Darshana Thakkar is an author, speaker, and TV panelist. Her achievements, journey, and interviews have been featured in several newspapers, Premium business magazines, and TV.

She has won several regional, national, and international awards and is famous as an MSME activist and women's business leader. Her consulting venture, Transformation, was listed among the most trusted consulting companies in 2022 and among the top 50 consulting companies for MSME in 2023. She holds a few honorary positions in industry associations.

Major achievements:

·         Winner of Global Women Leader -2023 by Global Women Leadership Award

·         MSME Honor award-2022 -Champion of Cause by Tally Solutions

·         Winner of Gujarat Women's Leader Award – 2021

She is associated with a few other premier institutes as

·         Certified Women Director & Independent Director by IICA, MCA, GoI.

·         Member of the Board of Management at Makarpura GIDC Industrial Estate Cooperative Bank Ltd.

·         National President: WICCI-Entrepreneurship Development Council

·         Trainer, Startup mentor, & Jury member at CED, Government of Gujarat.

https://www.linkedin.com/in/darshanamthakkar/

[email protected] 

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