Miller Magazine Issue: 125 May 2020

87 ARTICLE MILLER / MAY 2020 Eventual obstacles In front of smart productIon and rIsks specIfIc to flour mIlls When it comes to obstacles, two different approaches have to be considered. With emphasis to a problem in technical and administrative terms, “absence of technical infrastructure, presence of cyber security risk, expected outcome not to be worth the cost of smart production in- vestment” can be given as an example to the first one. Concerning psychological worries relevant to fear and ex- pectations, “fear of being unable to carry through transiti- on process, obligation of new workforce to be highly qua- lified after labour having been reduced, and apprehension of not being able to control production due its flexibility” can be given as example to the second. We have to mention cyber security issue particularly as it includes a tangible worry. The smart factory can be exposed to threats or dangers due to connections and IIoT, but this should be thought as urgency to include security element into the system, and not be considered as a barrier. If we have a look at milling sector distinctively, we will see that automation levels in most factories are not ready for Industry 4.0. Additionally, another problem is that dust isolation could yet not be provided in full. Although both problems have been decreased in recent- ly built factories, there are some question marks. Problems such as not having reached expected decrease in unit ener- gy costs per production despite automation, and power cuts in different regions have not been solved yet 8 . Furthermore, sector workforce has currently not the qualification required for the workforce of smart factories. No matter what the situation is, there is no obstacle to build new flour mills as smart factories. Dust problem can be solved with electro-mechanical machinery, and auxiliary units of high quality, and electricity problem can be solved both in cooperating with electrical-electronics supplier and in using electrical-electronics precaution te- chnology. Transition to smart factory will be also possible in current mills through technical development and digital transformation. ROAD MAP FOR SMART PRODUCTION IN FLOUR MILLS Realization of smart production in flour mills is actually to put Industry 4.0 in practice with all its elements. First step is to decide. When you took decision, it means that you decided whether you want to be able to respond to market demands faster, to increase Overall Equipment Efficiency (OEE), and to reduce losses in parameters like energy, raw material and time 12 . In order to evaluate whether you need a transition as you have serial production, you can use the formula below pro- posed by respected manager Mr. Yavuz Çopur from auto- mation industry: A = U x P x R where A is golden value per hour, U is production amount per hour, P is product unit price, and R is market demand percentage 5 . The higher A is, the more you need a transi- tion to Industry 4.0. After taking decision, you have to start with digital transformation, but you should not forget that a smart fa- ctory does not mean necessarily a “dark factory”. Human has still a role. Transformation will be successfully executed if care is ta- ken to these below 14 : • To see transformation as an opportunity • Guide and prepare the employees • Agility • To be user-centred • To show change ability Success will be possible in preparing the infrastructure with starting a road map and determining needs and short- comings, in reaching a level to carry out data analysis, and in starting with a partial exercise instead of starting comp- letely at once. References 1 Bartevyan, L; Industry 4.0-Summary report, DLG-Expert report 5/2015: DLG e.V., Frankfurt am Main, 2015 2 Scherf, B; Flexible Schichtplanung in der wandlungsfähigen Fabrik, IT & Production, Juli/August 2015 3 Mittal, S; Ahmad K, M; Romero, D; Wuest, T; Smart manufacturing: Characteristics, Technologies and enabling factors, Proc.IMechE Part B, Journal of Engineering Manufacture, Vol.233(5), 2019 4 Kesayak, Burak: Endüstri Tarihine Kısa bir Yolculuk, www.endustri40.com , Erişim: 24.04.2020 5 ST Otomasyon, “Veri işleme ve veri analitiğine konumlandık” Yavuz Çopur ile söyleşi, Nisan 2020. 6 Kottig, U; Der lange Weg zur Smart Factory, IT & Production, Juli/August 2015 7 Gültay, M.S; Un Fabrikalarında Endüstri 4.0 Kullanımı, Değirmenci Dergisi, Sayı 88, Nisan 2017 8 Treacy, F; Making the Move to Industry 4.0, 8.4.2020, www.machinedesign.com , Erişim: 17.04.2020 9 Rüssman, M; Lorenz, M; Gerbert, P; Waldner, M; Jusus, J; Engel, P; Harnisch, M; Industry 4.0, Boston Consulting Group, April 2015 10 Sosa, G; New technologies come to the milling industry, Miller Magazine, No.123, March 2020 11 Gezer, M; IoT ve IIoT nedir ve IIoT altyapısı nasıl oluşturulmalıdır?, www.trovarit.com , Erişim: 17.04.2020 12 Hoske, M.T; Industrial Internet of Things, Industry 4.0, Control Engineering, June 2015 13 Alfin, F; Artificial intelligent milling system, Miller Magazine, No.123, March 2020 14 Neugebauer, T; Wie gelingt die Transformation, IT & Production, Juli/August 2015