How unified namespace drives efficiency, quality in manufacturing

Unified namespace insights

• Unified namespace (UNS) provides benefits to facilitating digital transformation in the manufacturing sector.
• Benefits of implementing a UNS in manufacturing include improved efficiency, quality and profitability through seamless data integration and communication.
• Four implementation strategies will help those involved successfully adopt a UNS in a manufacturing organization.

In the complex world of modern manufacturing, many systems and personnel work together to generate goods and services, striving to maximize profits while ensuring long-term sustainability. These systems encompass everything from shop floor equipment that controls and monitors production processes, to top-floor enterprise applications managing business operations. To optimize efficiency, cost-effectiveness and quality, these systems must seamlessly exchange information as they perform specific roles, and the unified namespace (UNS) can help. This is the crux of digital transformation in the manufacturing sector, enabling a harmonious digital interaction that drives profitability.

Defining unified namespace, how it helps manufacturers

The effectiveness of this data integration hinges on the approach used across various systems within a manufacturing enterprise. UNS is a data integration concept and solution that enables manufacturers to organize all information sources and consumers to reflect the enterprise’s actual structure. This standardization of information structure across an enterprise ensures that any system that understands the structure can easily locate or provide the information another party needs (Figure 1).

Figure 1: Simplified Diagram of unified namespace (UNS) architecture shows how UNS links disparate systems, such as manufacturing control, manufacturing execution system (MES), production processes and enterprise resource planning (ERP) system using open communications. Courtesy: HiveMQ

Simplified view of UNS architecture

By centralizing information in a single hub, the UNS ensures that data is readily accessible, from a single source of truth, by all systems at any given time. Rather than keeping data isolated within different systems of manufacturing operations, data is organized and combined in a common language and data platform, making it seem like it’s all stored in one location. Providing a unified view promotes enhanced collaboration among departments, teams and stakeholders and encourages a unified approach to problem-solving and process optimization.

The UNS holds not only the structure of a business but also the current state of all its systems, making data-driven decision-making an integral aspect of operations. Ultimately, the UNS is the cornerstone of a successful digital transformation strategy in manufacturing, fostering efficiency, quality and profitability.

The need for a UNS in manufacturing

The need for UNS in manufacturing is becoming increasingly evident as the industry grapples with the challenges of data silos and disparate systems. Traditional manufacturing operations often involve multiple, isolated systems that don’t easily integrate and communicate with one another, which hinders the efficient sharing and analysis of data (Figure 2).

Figure 2: Simplified diagram of traditional architecture reveals inadequacies of manufacturing operations systems and other connecting systems across level in an organization.. Courtesy: HiveMQ

This lack of interoperability results in inefficiencies and makes it challenging for organizations to comprehensively view their operations. As the complexity of manufacturing processes continues to rise, with the introduction of advanced technologies such as internet of things (IoT) devices, automation and artificial intelligence (AI), the demand for a more streamlined, integrated data management approach such as unf becomes even more crucial.

The growing importance of real-time data analysis in manufacturing further underscores the necessity of a UNS. In an industry where rapid decision-making and responsiveness are essential, having instant access to real-time data is invaluable. A UNS allows companies to break down data silos, consolidating information from various sources into one, accessible data model.

This unified data model enables more efficient analysis and better-informed decision-making, empowering organizations to optimize their operations, minimize downtime and quickly respond to changes in market conditions. By replacing traditional industrial data architectures with a UNS, manufacturers can overcome the challenges posed by disconnected systems and harness the full potential of data to drive innovation, productivity and profitability.

How UNS improves efficiency

A UNS offers numerous benefits in driving efficiency within the manufacturing industry. By consolidating data from various sources and formats into a standardized structure, the UNS eliminates data silos and inconsistencies, facilitating seamless data exchange between business applications and production-floor systems. This enhances communication among these varied systems through a standardized and open protocol such as message queueing telemetry transport (MQTT), simplifying information exchange and fostering faster, more efficient decision-making processes.

Due to the abstraction of underlying systems provided by the UNS, the integration and incorporation of new equipment, systems and technologies into an existing manufacturing enterprise infrastructure is simplified. This scalability allows manufacturers to adopt new technologies and best practices to continuously drive process optimization and efficiency in a non-disruptive manner.

Moreover, integrating data and streamlined communication paves the way for real-time analytics and monitoring, empowering manufacturers to promptly identify bottlenecks and inefficiencies. This will lead to more informed decision-making and swift optimization. Additionally, the UNS is a fertile ground for advanced analytics, such as predictive maintenance, which enables manufacturers to foresee when equipment will require maintenance, reducing downtime and further optimizing processes.

Product quality gains from implementing a UNS

The lowest-hanging fruit for quality adherence in manufacturing is eliminating manual data handling and entry errors from paper-based records. The UNS facilitates automated and digitalized data integration from different systems used for quality management, such as laboratory information management systems (LIMS), corrective and preventive actions systems (CAPA) and manufacturing executions systems (MES).

Figure 3: MQTT broker diagram: HiveMQ provides an enterprise-grade MQTT platform that is central to Unified Namespace implementation by providing a scalable, reliable and secure UNS data infrastructure. Courtesy: HiveMQ

Further, the real-time, comprehensive data view provided by a UNS (Figure 3) allows manufacturers to use advanced data exploration tools to swiftly detect patterns, correlations, trends or deviations that might indicate quality problems or inefficiencies in the production process. By leveraging these insights, companies can initiate a systematic root cause analysis to determine the underlying factors contributing to the quality issue. Because of the openness and lightweight nature of message queuing telemetry transport (MQTT) and a UNS protocol, quality-related metrics can be tracked, even during use by consumers (Figure 4).

Moreover, a UNS can facilitate better collaboration and information sharing between the plant and its suppliers. With a standardized data structure, the plant can more easily exchange quality-related information with suppliers, such as product specifications, inspection reports and performance metrics. This improved communication can lead to better alignment on quality expectations and faster resolution of issues.

The impact of UNS on profitability

One of the primary ways in which the UNS reduces costs is by lowering system setup and maintenance expenses. This can be achieved because a standardized and unified data exchange and communication approach simplifies system integration, configuration and maintenance, reducing complexity and lowering labor costs associated with system setup, maintenance, expansion or upgrades.

Taking advantage of UNS’ simplicity of integrating new devices, technologies and systems in manufacturing businesses leads to a faster time-to-market for new products or production lines. The streamlined nature of the UNS system accelerates deployment, allowing companies to launch new initiatives more rapidly than ever before. This provides a competitive advantage through rapid adaptation, enabling businesses to stay ahead of rivals and respond more effectively to changing market conditions.

Another significant benefit of a UNS is its ability to improve decision-making within the manufacturing company. By providing a comprehensive and accessible data view, the system enables executives and managers to easily access and analyze critical information. This enhanced visibility into operations allows for better-informed decisions, ultimately improving efficiency and productivity. Furthermore, a UNS supports advanced analytics and forecasting capabilities, empowering businesses to accurately predict market trends and optimize strategies, ultimately resulting in increased profitability.

Four Implementation strategies for adopting UNS

Four steps summarize UNS implementation.

1. The successful adoption of a UNS in a manufacturing organization begins with a thorough assessment of the current state of data integration. Companies should evaluate their existing systems, data sources and communication protocols to identify areas for improvement. This analysis will enable organizations to pinpoint gaps and inefficiencies, providing a clear starting point for implementing a more unified and streamlined approach to data management.

2. It is crucial for businesses to choose the right technology and partners for implementation. Companies should research and select a platform that is compatible with their existing systems, scalable and capable of handling the unique requirements of their industry.

3. Additionally, finding experienced partners, such as system integrators or consultants, with a proven track record in implementing UNS solutions can be invaluable. These partners can help guide the process, provide insights and ensure the implementation is tailored to the organization’s needs.

4. Finally, developing a phased implementation plan with clear objectives and milestones is essential for a smooth transition to a UNS system. A well-structured plan will help to minimize disruptions, allocate resources effectively and maintain a focus on the goal of improving efficiency, quality and profitability.

Kudzai Manditereza is developer advocate for HiveMQ. Edited by Tyler Wall, associate editor, Control Engineering, CFE Media and Technology, twall@cfemedia.com.

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