Plug and play technology in modern manufacturing

In today's fast-paced production world, it's more important than ever to be flexible, efficient, and quick to adapt. Plug and Play technology (PnP technology) is transforming how manufacturers integrate and utilise technology on the shop floor. Let’s explore use cases of plug and play technology and its applications across industries. As well as, weighing up its benefits and considerations for manufacturers.

What is plug and play technology?

Now, manufacturers are looking for ways to make their businesses more efficient and keep them competitive. They are particularly interested in adopting new technologies and assessing their impact on production.

Embracing new technologies is not always practical. Smaller manufacturers might not be able to afford to make the big investments needed for new technologies. Even if the company can afford the technology, there is no guarantee that it has the skills in-house to efficiently use them.

Manufacturers should consider the cost and find ways to adopt new technology. This will help them stay competitive and avoid a lack of innovation that could harm their businesses in the future. All manufacturers should consider how they can introduce the right amount of automation for their facility, without completely overhauling the system.

Plug and play technology enables hardware and software systems to be easily connected and configured without complex setup procedures. This technology makes it easier to add new devices, systems, and equipment to manufacturing systems. This allows them to work with current infrastructure without any problems. 

This reduces setup times, minimises downtime and boosts operational efficiency.

How plug and play technology is used in manufacturing

Automation and robotics

For modern robotics and automation systems to work, plug and play technology is vital.

Collaborative robots, also known as cobots, have PnP interfaces. These interfaces make it simple to program and reconfigure the robots for different tasks. This enhances the collaboration between humans and robots on the shop floor. This boosts productivity and reduces the need for extensive programming and training.

Flexible assembly lines

Manufacturers are adopting modular assembly lines with PnP components. These lines can be quickly changed to work with different products or production methods.

For instance, automotive manufacturers such as Bosch utilize modular conveyors and robotic arms. These can be easily adjusted to accommodate different vehicle models. This results in a more efficient production process and shorter setup times.

Condition monitoring and predictive maintenance

Plug and play sensors and monitoring systems are transforming maintenance practices. These systems can be easily integrated into existing machinery, providing real-time data on equipment performance and condition. Companies like Dow Chemical rely on Plug and Play sensors for predictive maintenance. The use of these sensors helps find issues before they become failures, which reduces downtime.

Success stories of plug and play technology

Siemens uses plug and Play technology through its TIA Portal [1] (Totally Integrated Automation) system. This solution has greatly improved the integration of automation and control systems. Also, setup times have been greatly reduced, making it easier for manufacturers to adapt to new production demands. As a result, the risk of operational bottlenecks has been greatly minimized.

Bosch Rexroth’s Smart MechatroniX and its plug and produce approach [2] integrates modular components, advanced control systems and IoT connectivity. This makes it easy to connect and rearrange systems quickly, which cuts down on setup time and increases operational flexibility. 

Engineers can also use plug and play devices in warehousing applications. Wearables manufacturer ProGlove [3] released the MARK, a hands-free scanner.

This removes the need for handheld scanners in manufacturing facilities. The scanner connects to a tablet, allowing for quick data sharing via barcodes. It also moves with the operator, which helps boost accuracy and efficiency.

Companies are also introducing plug and play technology that can improve maintenance. Engineers can install the MICA Industrial Internet of Things (IIoT) kit from Bosch and Harting [4] to any machine to improve condition monitoring.

It can be retrofitted to legacy devices. Because of this, it can detect when anything is wrong and notify a maintenance engineer right away. Engineers can then contact their automation parts supplier and replace the equipment before downtime occurs.

Benefits of plug and play technology

With plug-and-play devices, companies can increase the efficiency of assembly lines without the cost to upgrade the system. These plug and play devices are incredibly easy to use. They can be taken out of the box and added to the production line seamlessly. There is no need to configure or test them; they will begin working instantly.

Using plug and play technology can simplify how companies adapt and maintain the production line. Unplanned downtime can be costly for manufacturers, particularly if the machine requires a specialist maintenance engineer to fix it. By investing in plug and play devices, manufacturers can simply unplug and replace the machine without the cost of bringing in an external engineer.

Considerations for implementing plug and play technology

All of the parts and systems must be standardised and suitable for integration to work. This involves selecting equipment and software that adhere to industry standards and can interface seamlessly with existing systems.

While plug and play technology simplifies many aspects of manufacturing, workforce training is essential. Investing in training programmes is crucial for upskilling employees in handling new technologies and systems. This is crucial for maximising the benefits of PnP solutions.

The need for strong cybersecurity measures is growing as the number of interconnected production systems increases. Protecting against cyber threats ensures the integrity and security of production processes, safeguarding valuable data and operational assets.

In conclusion

You don’t always have to buy the latest version of a product to have the smartest and most useful technology. Plug and play technology is transforming the manufacturing landscape, making companies more flexible, saves money, and boosting productivity. Companies across industries are reaping the rewards of this technology.

Manufacturers are increasingly embracing PnP solutions. Those who make the right investments in technologies and strategies will be at the forefront of shaping the future of manufacturing.

For more insights and support on integrating plug and play technology into your manufacturing processes, EU Automation is here to help you navigate this journey towards a more efficient and adaptable future. Please get in touch with us today.

Citations:

[1] https://assets.new.siemens.com/siemens/assets/api/uuid:14c5e638-cd23-41bd-a26a-1c9449288ead/article-toward-the-digital-factory-gated.pdf
[2] https://2022461.fs1.hubspotusercontent-na1.net/hubfs/2022461/DCEN-GB/Rexroth-Techpaper-Plug-and-Produce-in-factory-automation-uk.pdf
[3] https://proglove.com/ 

[4] https://www.harting.com/AT/en-gb/solutions/mica-ciss-industrial-iot-kit