Modular production is a flexible production system that allows the manufacture of highly personalized products without having production costs as high as in the case of custom manufacturing. It is about manufacturing a product through different parts or modules that will become known as standard.
This way, all these modules are combined, giving rise to many products or services. Each module will be made up of parts that are no longer considered independent items.
Product and innovation cycles are getting shorter thanks to the increasing demand for small batches and individualized solutions. Reduced production and innovation times can be a problem for manufacturers, especially those in the manufacturing and pharmaceutical industries.
The process plants used in these industries and by cosmetic companies and food producers are often not flexible enough to adapt and change in the short term.
Enter modular production, which simplifies changing production quantities or adapting equipment to produce new products or formulations. Modular production breaks large tasks into several smaller parts. Production is divided into individual standardized services.
Since each module is interconnected, there are multiple configuration possibilities. Manufacturers can “plug and produce,” changing configurations required for the manufactured product.
Modular Production and Module Type Package (MTP) offers a high-performance solution that has revolutionized production in multiple industries. Before we examine the benefits of MTP, let’s take a closer look at what challenges manufacturers face concerning agile manufacturing.
EKM Insight Data Collection Features
- Accurate, Normalised, and Reliable Meter Billing
- Asset management
- Consumable supply chain management
- Planned service and maintenance management – effective service chain management
- Usage tracking and planning
- Designed for Lifecycle Service Management
- The critical element – Customer Value
EKM Insight Data Collection in Just Four Steps
Step 1: mechanical and functional modularization
First, the technical process is divided into sub-processes, and a module is defined for each. This contains all the mechanical and automation components that allow it to function autonomously.
Step 2: Modularize automation
Each module has its decentralized control, remote I/O components, and pneumatic controls, and all of its functional capabilities are programmed. Naturally, it also includes all sensor and actuator technology for the processes.
Step 3: Coordination of the entire system
Once the modules are interconnected to a process system, each module offers specific functionality encapsulated through a standardized MTP-compliant interface. This way, the operating mode, status, measured process values, etc., can be read and written. The module’s functionalities in the overall system are coordinated via a tight Process Orchestration Layer (POL). The MTP allows the integration of the modules without problems.
Step 4: Flexible adaptation of modular systems
You can build the systems you want through the described modules and precisely meet current requirements and needs simply by adding flexible modules: numbering up instead of scaling up modules.).
Using a modular manufacturing program has several advantages as well as drawbacks.
EKM Insight Advantages, we can highlight:
- — In the event of a failure, a specific part of the module is not restored or fixed, but the module will be repaired or replaced.
- — Repairs are faster and less complex, reducing maintenance costs and the personnel dedicated to it since specific training in a given part is not required.
- — Tasks are simplified when planning, scheduling, and managing production and materials.
As drawbacks can be mentioned:
- — In the event of a failure, the independent parts that cannot be left to be able to reuse are those that are not damaged. This entails a cost for both the company and the user.
A clear example of modular production would be the case of the manufacture of automobiles or computers, in which there are some standard components, and depending on how they are combined,
We will have products with customized characteristics.
Each module will be made up of parts that are no longer considered independent items.
In the event of a failure, a specific part of the module is not restored or fixed, but the module as a whole will be repaired or replaced.
Repairs are faster and less complex, reducing maintenance costs and the personnel dedicated to them.
Tasks are simplified regarding planning, scheduling, and managing production and materials.
In the event of a failure, the independent parts cannot be left to be able to reuse those that are not damaged.
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