The age of edge computing in World Class Manufacturing 4.0

Figure: Relationship between edge computing and WCM 4.0

In the manufacturing industry, time is a valuable commodity and if a task needs to be done quickly, it should be done through edge computing. Edge computing refers to the utilization of processing power and data analysis at the edge of a network, as opposed to relying solely on centralized data centers. This approach brings about data processing capabilities at the edge of the network and decentralizes the traditional control room. It enables edge-networked actuators, sensors, controllers and devices to capture edge intelligence, process information, and disseminate reports close to the source of data generation. This is commonly referred to as "edge analytics".

In edge computing sensors, actuators and devices come equipped with microprocessors and microcontrollers to compute and wireless modules to communicate. This enables edge computing to bring about deep integration of the three elements of WCM 4.0 i.e. employee solutions, process lock-in and equipment optimization through efficient edge interaction of human, machines, materials and the environment. This is made possible through its distributed computing framework.

Several factors are driving the implementation of edge computing in WCM 4.0, increase in compute performance, introduction of hardware as a service, edge virtualization, containerization of software, cloud offerings for IIOT on edge, introduction of edge AI chips (Neural Processing Units), hardware based security, adoption of open/open-source tools, real time operation and cloud integration and low latency wireless.

In WCM 4.0, edge computing is an effective offloading strategy for constrained sensors, actuators, and devices as it enables them to leverage nearby microcontrollers and microprocessors for support with computationally demanding tasks. As manufacturing operations become more agile, Kanbanized, and decentralized, the autonomous duties of quality assurance are delegated to one or more smart contracts. These smart contracts enable the transition of products and processes from one stage to the next through equipment-guided quality appraisals.

A smart contract in WCM 4.0 can be defined as an operations protocol based on distributed ledger technology (blockchain) that autonomously executes, controls, and documents processes and operations according to the product manufacturing management system. Smart contracts are used to execute product and process acceptance tests and to verify the fulfillment of parameters and conditions to avoid defects, alterations, or misconstruction. Smart contracts verify compliance with the initial acceptance condition set by the customer, and edge computing allows for the application of smart contracts at the point of execution.

Edge computing, through advanced analytics, statistical algorithms, and machine learning, has brought about predictive analytics in WCM 4.0 maintenance practices. Edge computing-equipped sensors such as vibration sensors, thermal imagers, pressure sensors, current and voltage transformers, flow meters, temperature sensors, tachometers, etc., expose asset behavior to edge computing. This has enabled reliable and predictable performance of critical assets. Edge computing maintenance has enabled manufacturers to recover revenue, carry out smart replacement, reduce planned maintenance, increase asset availability, improve workforce, lower risks and decrease service losses.

Bandwidth can take time to make round trips to the cloud or nearby data centers. In manufacturing processes, a delay in milliseconds in critical chemical, physical, electrical or mechanical actions may result in a defective process, product or even safety implications. Edge computing brings about equipment optimization as it saves time, heightening equipment operations and availability while simultaneously improving product and process quality, resulting in excellent overall equipment effectiveness.

Edge computing brings in new opportunities, such as planning prediction, energy and supply chain optimization, for legacy industrial systems and ICT systems resulting in new data handling methods and techniques necessary to bring new age competitive advantages.