Smart Factory Showcase presents Industry 4.0 in Brazilian AGCO factories

The fourth industrial revolution, or industry 4.0, is the movement in which technologies such as augmented reality and robotics in production lines are used to generate improvements, increase efficiency and, consequently, boost competitiveness. To showcase all the innovations that are already used in Brazilian units, AGCO, a global company that designs, manufactures and distributes agricultural machinery and solutions, hosts the Smart Factory Showcase, in Canoas (RS), on July 18th.

The event’s theme is “The Factory of the Future, Today” and presents the most modern in manufacturing, technologies that not only guarantee cost improvements, but, most importantly, improve production efficiency and quality. There is still a considerable opportunity to adopt these innovations in Brazil; According to a study by CNI (National Confederation of Industry) carried out in 2017, only 1,6% of the companies consulted operate with industry 4.0[1].

“Industry 4.0, in association with Lean Manufacturing, is the next evolution of factories, connecting machines, people, materials and processes in the most efficient way. Digitalization and automation are revolutionizing how factories operate, creating a favorable environment for JIT (Just-In-Time) production, with safety, quality and zero waste”, says Alexandros Aravanis, director of manufacturing engineering and continuous improvement at AGCO .

"The Smart Factory Showcase shows how we are implementing the latest technologies in our factories to continue to lead in the agricultural machinery sector and the Industry 4.0 movement”, says Daniel Cantarelli, manufacturing engineering manager at AGCO. “Before Brazil, the only unit to host this exhibition so far was in headquarter of AGCO in Duluth, Georgia, in the United States, which highlights the strategic importance of our country for the company”, he adds.

AGCO's smart factory concept aims to integrate the pillars of material, personnel, equipment and processes, increasing the productivity and quality of the machines produced. “With greater technology at home, we can always offer rural producers the most innovative products for the field, developing new products for even more connected farms”, says Cantarelli.

Check out some of the technologies that will be presented at the Smart Factory Showcase:

Exoskeletons - New in Brazilian factories, the equipment is attached to the operator's body, offering support and providing more comfortable and healthy positions during repetitive movements or those that require physical strength.

Google Glass – Augmented reality glasses that show the employee information, tasks and photos on the screen just above the field of vision, facilitating the execution of the operation. Currently, the devices are used by quality inspectors at the Canoas and Ibirubá (RS) plants.

3D printers – Already in operation at the Canoas (RS), Mogi das Cruzes (SP) and Santa Rosa (RS) units, the equipment is used to quickly and accurately manufacture everything from prototypes of new components to templates that help in the production of new parts or products. .

AGVs (Automatically Guided Vehicle, in English) - Robotic and self-driven platforms, which trace a programmed route to transport monoblocks through the factory. Before the use of this technology, assembly was done with easels fixed to the floor on “rails”. With AGV's, employees carry out installations and checks while the component is automatically guided through the plant. The technology is also used in the logistics of supplying materials to production lines. 

COBOTs (collaborative robots) – The Cobots, already being tested at the Mogi das Cruzes unit, can carry out their activities in the same environments as the operator, with due safety. The robots are easily programmable and can be guided manually, or taught to follow the path alone. In addition to having devices to limit force and power, the operating speed reduces when it senses the presence of a human around it, guaranteeing total safety for operators.

virtual model of factory and Virtual Simulation (Plant Simulation) - Through prior reading carried out with lasers, a 3D model of the factory is created on a computer, which guarantees accuracy of up to 6 millimeters. This way, those responsible can quickly scan and simulate future process designs, adapting the internal organization of production lines, whether to receive new products or optimize activities.