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Description
Interconsult Bulgaria Ltd., based in Sofia, is a key player in Bulgaria''s thriving ICT sector, with a focus on Information Technology and computer service activities. Notably, the company is leading the Green Monitor 4.0 project, a progression from its predecessor, the Green Monitor system. This innovative initiative adopts a comprehensive approach aligned with Industry 4.0 principles.
Green Monitor 4.0 goes beyond machine maintenance, extending its reach to digitize overall business and manufacturing processes. This encompasses workflow automation, integration of management systems with the shop floor, creation of digital twins for crucial manufacturing equipment, implementation of smart data models and AI, and the integration of augmented reality in production maintenance activities.
The project''s primary objective is to drive the digital transformation of production, resulting in paperless business processes, minimized waste materials, and a reduced carbon footprint. Tested and implemented in two production enterprises—Bulgarian OPTIX JSC and Norwegian HTS Maskinteknikk AS—the project aims to establish modern, economically efficient, and environmentally friendly production processes. A tangible outcome is the development of a new Industry 4.0 holistic concept rooted in industry best practices, expert knowledge, and practical examples. Furthermore, the project will deliver fully operational components and software tools aligned with the Industry 4.0 framework, along with the creation of six new jobs.
Summary of project results
In the framework of the previous project period of the EEA and Norway Grants in Bulgaria 2013-2016 InterConsult Bulgaria together with Kongsberg Terotech and NTNU developed an innovative software system called the Green Monitor. The system was focused on helping enterprises to be more environmental friendly by implementing condition-based and predictive maintenance on the manufacturing machines. A number of green effects have been measured and achieved including: 50% reduction on lubrication liquids, 10% reduction on cutting fluid consumption, 5% reduction on energy consumption, 2.5% increased machine availability, 2.5% reduction of wasted material, 12% reduced number of maintenance hours. Since then, the idea of Industry 4.0 has tremendously evolved together with the overall manufacturers demand on innovation and smart manufacturing solutions. The value of implementing technologies like 3D visualization, Virtual reality, Mixed reality, Machine learning and digital solutions is becoming more visible and is placed on top of the agenda of the manufacturers today. SMART manufacturing combined with environmental friendly production processes is placed in the priority list of the modern and effective enterprise today.
The European market today lacks technologies, competence and approach oriented to the SMEs. SMEs are facing a number of challenges on starting their digitalization strategies which are related mainly to the: - Lack of the necessary financial resources and human capacity for implementing expensive and time-consuming digital strategies; - Lack of management power and competence to drive big process and technology changes in the enterprise; - Inability to identify the suitable IT solutions and technology available because the majority are still targeted to the large enterprises.
Currently the majority of the big IT vendors are aiming at getting the market share of the large enterprise sector. On the other side SMEs are also struggling to reduce the cost and stay competitive on the global market. New disruptive technologies shall be implemented in order to help efficient and cost-effective production processes at their side as well.
The following activities took place during the project implementation:
- Development of new Industry 4.0 holistic concept for the enterprises based on industry best-practices research, expert knowledge and practical examples;
- Development of core components and software tools of the Industry 4.0 concept covering: 1. Automated paperless business and manufacturing processes; 2. Digital twin of critical manufacturing equipment; 3. Augmented reality-based application supporting machine maintenance processes; 4. Smart models on sensor data gathered from machines empowered by Machine learning and Artificial Intelligence.
- Installation and testing of the platform s in two production enterprises.
The project outcomes will help small and medium-sized production enterprises in their path to digitalization and Industry 4.0 while making them also more environmental friendly. The Green Monitor 4.0 project has addressed all aspects of the digitalization strategy of a production enterprise from the process analyses to the implementation of digital supportive tools and technologies.
The technological process developed has a direct impact on the environment, because it uses a new method of operations with significantly less resources – both natural and human resources.
The internal environmental benefits of implementing the project are the following:
- Introduction of a new technology with a minimal impact on the environment;
- Reduce the consumption of energy;
- Significantly reducing the waste output, especially oil and coolant. The actual oil consumption difference will in fact be significantly higher than before due to improved efficiency and the fact that oil has a limited lifetime before it has to be changed. Coolant consumption will drastically reduce due to the optimized operations of the machines.
- Reduction In the use of water in the production. The cooling liquid has to be dissolved in water before it is put in use the between coolant and water is 1:10. By reducing the amount of the needed coolant, water consumption will drastically drop.
- The use of paper will be reduced significantly with the introduction of paperless processes. The main aim of the solution is to aim the long term goal of becoming paper independent.
The external environmental benefits of implementing this project are the following:
- Increasing market opportunities by improving environmental performance;
- Improving the image to customers, partners, investors, environmental authorities, local community.
Summary of bilateral results
HTS Maskinteknikk (HTS), Norway, is a leading machine manufacturing production enterprise in Norway. The main role of HTS in the project was to bring know-how and knowledge to design the overall Industry 4.0 concept and to make the specifications of the digital IT tools and solutions. HTS has also provided a test bed for implementing the project end results.