March 2018 ST Machine Magazine interview

Smaris information technologies, which are used in the production site, can provide a real-time management system with the data to be taken from machines, including the brand-model independent all kinds of machine in the "digital production" process General Manager Mehmet Demirbas, especially the machines used in the production sector "Industry 4.0 and IoT" focused on the applications, he said. Emphasizing that many companies in the production sector do not even know what the losses are, Mehmet Demirbas and "industry, a cultural know-how," said Smaris information technologies sales and Business development manager Hakan Erol with a full knowledge We interviewed.

Mehmet Demirbas: Smaris has been providing software and consultancy services on SAP and Microsoft Technologies for 14 years, with the partnership of stepper technology companies providing products and R & D services on electronic systems with Vectorora information technologies We.

Our goal is to establish projects under the main concept of "Industry 4.0 and IoT", to produce solutions and provide continuity with support services our priority. As we entered this job, we have taken into consideration the industry 4.0 orientations, which began to take place in the room of enterprises gradually in the world since 2011. The industry has become an important trend not only in the world, but also in Turkey as the 4.0 concept, and it continues to be inspired by the talks and productivity-enhancing efforts in companies every passing day. The concepts of Industry 4.0 and IoT have begun to be known, mixed and quickly consumed in Turkey, especially with many issues, we all see it.

For example, 3d, which uses VR glasses can say that I have passed to industry 4.0, using a 3d printer… We see an effort to identify an industry 4.0 on each side, independent, unrelated efforts, but most of them are far from real life. But you have to admit that the industry has just begun to work in 4.0, a lot of bosses, professional executives and employees, from the engineer to the company's owners, and we're very important.  This is the most important part of the job for me. The managers at the decision-making point of the companies now realize that they should work in this area. As you know now that the information is over the age of communication, the age of digitalization has begun.  

In the past, the definition of a real-time phrase was different. In the 1980s, if a business could report what they were doing in the periodic 1 month, it was real time. This corresponds to the daily pursuit in the 1990s. Daily reporting was called real-time. With the increase of mobile technologies, especially in the 2000s, this definition now coincides with hours and minutes, with brand new measuring systems, much more precise digital machines and more real-time in the post-2015 period, indeed " "To be a judge of the moment." Real-time communication requires instant ownership of the ability to see, manage and control all the details of any entity that is owned by that business all over the world. 2 months ago, I participated in an important automotive forum Tüsiad Deputy Secretary General Sec. Nurşen Numanoglu's messages on this subject is not much, "the industry companies in Turkey should be able to take the road in the field of digitalisation in the industry, if not, until the year 2030 many of them can not survive Very clearly expressed.  Again, I would like to convey an anecdote from this conversation, "those who were wealthy 40-50 years ago, could build a factory and say a few generations later. There wasn't a big problem with the way the firms couldn't keep up with the age. Today, there are huge differences in the list of today's companies with the biggest companies of the 2000s. " Important business organizations such as Tüsiad do not say, "If you do not work hard," he says, "You won't survive," which I really care about.

 First, the locomotive companies in Turkey, and then all small and large-scale businesses have to do something on the way to digitization. The industry 4.0 was first expressed at the Hannover Messe fair in 2011. Keyword cyber-physical systems. In this business, there are electronic, software, automation systems, communication technologies, and they need to be addressed as a whole.  That is why we have partnered and develop our own field equipment and electronic system, we can produce our electronic cards, our electronic designs and embedded software ourselves. The biggest drawback of software systems and software companies in this regard is that software systems are far from physical systems, electronics, and the software does not matter where it works. In the electronics section we can make or integrate the electronic components we need. Today, in a few of the largest 500 companies in Turkey, we are using our own equipment in many medium-sized production firms, and we are trying to experience a 15-year vector. We are making software systems from the lowest level to the highest level in Vectora. In our portfolio, there are all systems available to each of the workers, operators, managers, CFO and COO. From the lowest MES systems to the top analytical systems and predictive forecasting systems, we appeal to all of them. We take them from different places and do not act like collecting PCs, we are producing all our own solutions.

Can we say that in all processes of digital transformation, Smaris serves companies as a single business partner?

Mehmet Demirbas: Absolutely. Industry 4.0, as a matter of scope, concerns every industry. Our primary interest is; Production, especially discrete production. The most important foot numerically controlled machines in discrete production. We can offer a single system with data to be taken from those machines, including all kinds of large and small scale, brand model independently used in all kinds of production sites. Especially with our knowledge and skills, our projects and our experiences.  

A machine manufacturer or end user who is aware of the necessity of digital transformation comes to you, then how is the process progressing?

Mehmet Demirbas: Some firms know that it should start somewhere, but it can not know where to start and what to do. We're directing them with certain questions. The experience we acquired from the field shows us; Businesses have more than one brand-model machine and we can see machines belonging to different brands, even in machine groups that do the same. We first ask, "Can you get all the information about your production and analyze and report it and turn it into an action?" The two different machines engaged in the same job, how long have been produced, what is the average cycle times, what is the product group, which is the machine, which is the fault for the operator, what is the information such as fire statistics to be analyzed in fact Only 2-3 of the countless information needed. How are the actual production time fluctuations? What error codes were created on these machines? How many times have the machines stopped? Such information is often learned by the operators of companies. The operators are being asked, when the machines have problems, the posture, the error information, the report. Unfortunately, this expectation does not usually overlap. The operator does not have any information. You're addicted to the person. It's hard to even come up to 50 percent. Machines; If they can be directly incorporated into the instantaneous monitoring systems, the machine may have a hundred different types of error codes, two of the postures are perhaps continuous and depending on a certain part, we want to remove the following results: "In your machine, this type of Depending on the following types of error codes while producing the products, the posture is rising, the average cycle times increase in the following conditions, the frequency of the X-piece changes in the machine while producing these types of products increases slightly. In the future, this could lead to a major maintenance problem or malfunction for you. "

When we talk about these things, we see that hardly any of them have been analyzed. In fact, they don't really know what their losses are yet, or they're just guessing. There are even approaches to active production time for their machines to stay open. In fact, he doesn't believe in seeing the report in this approach, but he's pretending to believe it. We, our own equipment, electronic boxes and application systems to come and build, inspect, report, give you advice on action, "we say.

Reports received, according to these reports, how are the recommendations and improvement processes progressing in the factory?

Mehmet Demirbas: This point is fully related to the competence of the company. They'll get the action from here. If a company "one person" is dedicated to these processes, production manager, Maintenance Manager, Planning Manager or an authorised engineer, it makes no difference, it is very easy to post. Our target group consists of these people, and communicating with them is our primary goal.

Unfortunately; There are also approaches to "choosing to buy a new machine in the machine park instead of allocating budgets to such systems". But to look at the big picture rather than save the day, you have to think about 5 years or even 10 years later. We're moving to a new era in the world, and those who can see the way are doing their warning. Those who know what this job is and who will appreciate the value added, are the ones who will invest and value.

Hakan Erol: In Turkey last month, efficiency rates were announced as 76 per cent. According to this data, there are no businesses under 75 percent of the OEE value in Turkey. Go ahead and ask the employees in the business process; It is estimated that 50 percent or above 60 is not above the maximum. Increase the efficiency rate from 50 to 70 percent; The same machine means increasing the efficiency by using the same staff and equipment by 40 percent. There is more than a machine in Turkey, without buying a new machine in enterprises, 5-10 percent yield increase, we will receive 20 to 40 billion extra revenue from the production site. But when you say 75-80 percent, you say I can't get a new job. To get a new project, we need to build a new machine park, new building.

There is a high rate of production methodology in Turkey, we see 25 per cent of the fires compared to the sector, but we don't really know why we're actually giving fire to a data mining approach. When you digitize the system, the machine; You follow the operator, the work order and the raw material. Ultimately, the connection between them reveals the reason affecting the quality. When you find the problem, you have an opportunity to take action to improve it.

Sometimes operators may also be lacking in machine-related training, or you can see that the machine might be suitable for other work, not suitable for that job order. Six months or 12 months after the customer, we can give these machines an X-ray in case you could do this kind of thing with that operator.

Our producers make profit-loss accounts by the end of the year.  If we have made 20 kinds of production throughout the year, which segments in which the productions are more profitable, concentrate on that segment and expand our market, can give an R & D idea, can be an action-giving objective data.

With the industry 4.0, people are now starting to ask, "How will you reduce my company?" They're asking if you can put in a half or a full autonomous system. These are very good questions for the answers.

Even once in the previous period, I witnessed a digital conversion offer before going to the factory. The industry is a cultural know-how. In the important part of the companies, unfortunately, the knowledge of how they do a job is not documented in the document.

In these solutions, can you describe your application for the machine industry and a project that has been transformed into a success story if possible? What kind of requirements did your customer come up with? What kind of solution did you produce? What kind of benefits were achieved?

Hakan Erol: We have left the general trends on the road. What time was the machine opened, when it closed, the operator's stance information, the fire entered the information, the Energy analyzer, the data pool, like how many kw of electricity has expended. We've done a wide range of pilot studies in different places. I want to share a nice example of these. In the production processes of one of the first 100 automotive manufacturers of turkey, different NC systems were used in different companies such as laser cuts, abkant, presses, bending machines and welding machines. We wanted to do something that has not been done in Turkey until this day. We focus on the main reason that disrupts quality. Because that's the area where the firm has the biggest problem. First you start with OEE, but then it comes out of the agenda. We are trying to remove the point in which the job order is cut, how much energy is spent in a laser cut, and the quality problem in the segment from the process data there. It took about 4-5 months to collect process data from the production site. Now we are beginning to integrate the complete integration of SAP's ERP software and MES system on the back side. We have revealed the online scada of each machine. When the project is finished after 2 months, perhaps for the first time in Turkey, all points of a process in the metal industry will be monitored in real time and reported in real time. We haven't seen a company that can make such a project any other than Smaris. We are participating in an international fair in April, aiming to demonstrate our solutions in the Champions League.

I'd like to give you a different example. In the project of a major copper wire manufacturer in Turkey, the manufacturer has many quality measuring instruments. There are many tests, such as the resistance of copper wires and twisting directions. In the pre-project we made for the different machines that found about 30, the operator took the wire, the barcode was a value, the values were then entered into the ERP system by someone else. As Smaris, we have made the process completely independent of the operator. The operator comes in and makes the barcode read. From the moment it is read, the specification of that product is shown on the screen of our IoT card. It takes the machine to measure resistance and automatically take it to the balance level, it writes to the database of quality control. The entire process operator only oktobar the barcode. The company measures about 3000 measurements per day and results are evaluated in ERP systems.

Again, one of the biggest companies in the world has requested a M2M (inter-machine communication) project in the "digital production" concept for a machine that has so far closed cycles. We've offered to pilot work, we're going to start working next week when we leave globally. We will also publish news from our websites and social media shortly after official approvals are received.

In summary, if you have a numerical control, PLC and industrial PC, so if you have a system that works with the machine, we know how to make all kinds of M2M projects in this structure.

Mehmet Demirbas: The ability to collect data, without any physical intervention to the machines, violate the warranty terms, using the current transfer methods, Ethernet protocols, RS232, Profibus, Modbus, profinet .

Cyber threats are always a question mark in the heads of producers in the process of transition to industry 4.0. How is the machine industry approach?

Mehmet Demirbas: Security needs to be examined in two separate sections. First; The part of the collection of data to be retrieved from the machines. We use our own hardware and embedded systems on this side. Because we are not using one of the standard operating systems, we are implementing our own security protocols against the attack. We are recently aiming to complete our own RTOs (Real time operating System) project, which is our R & D study.

The latter is MES, ERP systems, analytical systems, data warehouses, reporting systems. On the corporate side, we make suggestions by acting with that business. Some institutions want to operate these systems within their own structure. What we can do to them is to make suggestions and lead. We have our own local data centres for companies that are not within their own system. Finally, in the world; There are Amazon, Google, Salesforce or SAP cloud systems. If the customer we are working with is global or open to global firms, we can use it from our existing accounts in these cloud systems. These large enterprises have very strict security procedures, but customers can offer a different method if they say overseas, a different method of domestic derlée by administrative decisions. In short, we have all the security measures from the beginning to the last point of data from a machine.

What are the components of a successful industry 4.0 or digital conversion project?

Mehmet Demirbas: First the firm itself. While we consider ourselves a product developer, we are actually a service company. We provide a support for adding value to the firms. If we can steer them right, we'll do our job right. If the firm has shown an increase in the level of intellectual maturity, we can give all the steps of the digital transformation. Only local accounting programs are used in SMEs or in the middle-bottom segment companies that do not have any software systems. Everything else is executed in Excel, mail environment. We can even offer a roadmap to a company like this. Just let the firm be open to them.

What should turkey do to get way faster in these conversion processes?

Mehmet Demirbas: I will answer again under two separate titles. On February 14th, I attended a meeting announcing the 2017 report of Tubisad. Science industry and technology Minister Sn. Dr. Faruk made a concise speech. Mr. Secretary's speeches are very promising, and they are at a high level of awareness. The action at this point needs to be taken faster. We have many incentives in our country as we know it or not. There is no other country that has this much incentive category and number abroad. However, the industry 4.0 needs to be evaluated privately and differently. I also think that a separate roadmap for the digital transformation of the companies should be revealed by the state, and that the State should also supervise not only the incentive point. The State must also determine certain standards at this point. In order to benefit from incentives, companies should question whether they use the ERP system in all processes, for example. The ERP issue is important because companies starting at that point are surely going through the next stages for conversion.

For example, from one bearing manufacturer to the automotive manufacturer to the end-user, all processes must be monitored from start to finish, the entire company needs to move together from the top to bottom firm. The largest companies at the top need to take initiative for the installation of such systems, and the sub-suppliers must provide support for the installation of these systems. I should be able to see how all of the suppliers ' orders came from your system in an instant, or I should be able to see the quality of any order on your production line and the extent of the permits, so I can take immediate precautions "It is very important that you can meet your demands. In summary, the main producers need to expose a system with sub-suppliers.

Hakan Erol: Engineers must have a front foot in industry 4.0. From the period in which financiers are dominated by the system, the transition from industrial engineers, mechanical Engineers, electronic engineers, material engineers to the period of know-how should be done.  Turkey is required to create industry know-how. This is a long journey, we have to eliminate the agenda items that have damaged us as soon as possible. We have to create the squads first, there's no other way.