Welcome to the smart factory of the future

What will the smart factory of the future look like? The correct answer to that question can give you a decisive competitive edge. It allows you to anticipate what you will need - to be successful tomorrow and how you can benefit from new technologies today. 

The best people to ask about the smart factory of the future are those who are shaping it. Like the experts at Atlas Copco, which has been at the forefront of compressed air technologies and innovation in productivity solutions for decades. 

That is why we talked to several of its product managers about what the future will hold. They explained which smart technologies are available and how you can use them to your advantage. 

If the answer to the initial question could be summed up in a single word, it would be “efficient.”  

Whether it comes to the use of time, energy, materials or processes, the smart factory of the future will be much more efficient. 

A large part of the efficiency will come from automation. All types of different machines from different manufacturers will be able to “communicate” with each other. And, using central control and artificial intelligence, they will know what to do based on that information.

To illustrate this point, Ilmir Gareev explains what the smart cookie factory of the future  could look like. And he should know. As global Atlas Copco product manager for IoT (Internet of Things), he is dealing with these issues on a daily basis. 

The company would just focus on the taste of the cookies. The rest of the production is taken care of by a smart factory. 

Eventually, the cookies would all be made-to-order. Every piece of equipment would know what to do once that order is received. The compressed air system would be aware of any increase or decrease in demand. And no human would be involved in the entire process until the consumer unwraps and eats the cookie.  

This example illustrates the importance of state-of-the-art control of the entire system rather than individual pieces of equipment. 

To be “smart”, a factory needs data. Lots of it. In the case of a compressor, that information includes the air demand, the ambient conditions, the required air quality, whether the compressed air system has leaks, etc. Which is where sensors offer a solution to gather this continuous stream of valuable information.

A smart system then uses this data to optimize the performance of all of the equipment. And that means increasing efficiency and reliability. 

“Knowledge is power … literally,” Gareev explains. He adds that these additional insights can help the compressor consume drastically less energy. Take leak detection, for example. The average compressed air system loses 20% of its pressure to leaks. If the system can detect them – and in the future even fix them autonomously – a lot of energy and money can be saved. 

This is especially important for compressors. About 10% of all energy consumed in the world is used in the process of compressing air. 

If every compressor operated at its maximum efficiency, the world's energy demand and carbon footprint could be reduced a lot.

Where does this data come from? If you are using an Atlas Copco compressor with SMARTLINK, the information is processed automatically. 

Each connected equipment sends more than a thousand data points back to Atlas Copco every hour. Seeing how there is a quarter million machines with this technology, that means millions of bits of information every day. Each of them helps the compressor room of the future perform better. 

SMARTLINK sends its users an alert if there is a problem with the compressor. It suggests ways to fix it to allow the operator to take action immediately. But if it is a more serious issue, Atlas Copco is ready to help. 

This is one of the benefits of a connected, smart factory. 

“We often know better what our customers need than they do,” Gareev points out. 

For example, in the smart factory of the future, the compressed air system would detect a failing filter. Instead of alerting the operator, it would order a replacement on its own. 

“One thing that can make a compressor room smart is the capability to get support even before a problem occurs or escalates,” says Severin. “Pre-intervention could become a key concept.” 

Many of these technologies already exist in Atlas Copco products – at least to a certain degree. However, just because they are available doesn’t mean that customers are taking advantage of them. 

For example, customers embrace the ability to monitor their compressors remotely. They also like getting alerts if there is an issue. And these are truly helpful technologies. But that isn't where the true benefit of a connected compressor is.

This requires the right equipment as well as the information and know-how required to make sure it works optimally.  

“The GA VSDS is a brilliant piece of machinery,” notes Jan Vansweevelt. He is the product manager involved in designing the new generation of GA VSDS compressors, which are the most efficient in the world. In fact, it uses more of these technologies than any other compressor on the market. 

“But if you don’t install it in the right way, you waste a lot of energy,” Vansweevelt adds.

All of the product managers said now is the time to “get smart.” With the twin challenges of climate change and growing energy supply problems, there has never been a better time to invest in greener, smarter products. 

“There is an awful lot of momentum for energy reduction technology,” Vansweevelt points out. “High energy prices provide an incentive for companies to do more – and connectivity adds value.”

His colleague Charles Legrand goes one step further. 

It is another incentive for Atlas Copco to keep innovating. This is something all of the product managers agreed on – and they are proud of their work. 

“Innovation is the key to progress. And that is something that drives all of us at Atlas Copco,” Legrand says.

Gareev notes that sustainability, one of the core values of Atlas Copco, is always on his mind. 

“When we build or design something, I project what will happen in 10-20 years,” he says. “You have to be aware of future limits. You have to think broader, like what will help our customers in 10-15 years?” 

As a market and innovation leader, it is up to Atlas Copco to find solutions that make compressing air more sustainable. 

“If we don’t innovate, nobody will do it,” says Van Gaal. “That’s a big responsibility.”

So, what will the smart factory of the look like? All of the product managers agree that it will be automated, connected, more intelligent and sustainable. 

In some ways, it will look a lot like factories that exist today. For example, the GA VSDS or SMARTLINK would have seemed miraculous a few years ago. 

However, although the GA VSDS can already “talk” to other machines or react to its environment, there is a long way to go. 

“The holy grail is total automation to the extent that this is possible, like fully adjusting the compressor to its environment,” Vansweevelt notes. “It sounds easy when you say it, but there are so many factors to consider that it will take a lot of time to get there.” 

However long it takes, Atlas Copco will be leading the way. More innovations are in the works that will help make factories smarter and their production more sustainable.