Shopfloor Operations And Digitisation

Over the years ZF has implemented several processes and time-tested best digital use cases for operational excellence. These are claimed to have been fully deployed throughout the plant for maximum safety, efficiency and quality production. M2M communications, autonomous process controls, real-time data and production management, automation, supply chain optimisation, remote diagnostics, predictive maintenance, and cyber-physical systems are among the key contributors to digitalisation at the new facility. The company aspires to leapfrog from industry 3.0 to industry 5.0, reflecting a commitment towards leveraging the latest developments in digitalisation. ZF aims to create a factory with sense, where human intelligence, advanced automation and digital technologies unite to drive innovation, improve decision making and achieve greater operational excellence.

Core Elements Of The Oragadam plant

1. End-to-end data-driven processes and decisions

At the factory, ZF has the Digital Manufacturing Platform, a cloud-based Industrial Internet of Things (IIoT) platform for meeting digital requirements. The platform works as a centralised hub for the factory providing automated data collection, real-time insights and seamless communication. The platform contributes to improved efficiency, productivity and agility in the manufacturing process.

2. Efficient and sustainable intelligent resource management Through intelligent resource management, ZF has shifted from plant-level tracking of resources to per-part/person-level tracking. This also helps in tracking real-time efficiency and Key Performance Indicators (KPIs).

3. Intelligent machines and fully connected production lines

All machines on the shopfloor are equipped with condition monitoring, this helps in optimising the downtime and in minimising the maintenance cost. All machines are interconnected through Machine-to-Machine (M2M) communication to prevent defects and accidents on the shopfloor.

4. Paperless shopfloor

At this plant, the company has replaced all paper-based products with digital platforms. So that any person can access the document or e-check sheet using the digital gadget provided by the operator.

5. Real-time data visibility and transparency

The company encourages employees to develop their applications and dashboards through which they can access production details remotely and increase transparency as well.

6. Digital-enabled workforce

The shopfloor personnel have operator kiosks and digital gadgets such as tablets or smart phones to access all the digital platforms and resources.