Smart Factories & Manufacturing

The Next Evolution in Industry

The landscape for a more connected, digital, smarter factory has become apparent. There is a demand for enhanced productivity, flexibility and sustainability in modern factories by utilising advanced automation that is data driven. 

Securely connecting the workshop floor to the business system keeps employees better informed about changes, enhances business analytics, and enables the organisation to adapt quickly and effectively to demands – whether in production or administration. 

Securely connecting the workshop floor to the business system enhances production flexibility, enabling smaller, more customizable batches, quicker adaptation to changing demands, and faster development cycles to bring products to market. This integration ensures the organization can respond dynamically to both production and administrative needs. 

Smart factories are not just an upgrade but a strategic transformation that ensures businesses stay resilient, agile, and future-ready. 

The Role of Automation, Industrial ICT, IIoT, Functional Safety, and Cybersecurity in Smart Factories 

Smart factories represent the forefront of modern industrial innovation, where efficiency, adaptability, and connectivity converge. At the core of these systems is advanced automation, the backbone of streamlined operations. Automation eliminates repetitive tasks, reduces human error, and accelerates production processes, ensuring a positive flow from concept to delivery. 

A key enabler of smart factories is industrial ICT, which facilitates the integration of operational technology (OT) with enterprise-level business systems. This integration allows for a holistic approach, connecting technologies and machinery to deliver adaptable solutions with enhanced diagnostics and analytics. By unifying systems, smart factories gain real-time decision-making capabilities, predictive maintenance tools, and improved operational visibility, all while fostering a more secure and resilient environment. 

An IIoT platform enables factories to gather vast amounts of data from connected devices, giving managers and operators insights into production processes. This data can be analysed to optimise workflows, reduce downtime, and predict equipment failures before they occur. 

Functional Safety is crucial in smart factories, ensuring that all safety-critical systems, such as emergency stop mechanisms and safety interlocks, are properly integrated, regularly tested, and maintained. Compliance with standards like ISO 13849 ensures that safety-related control systems are designed to meet rigorous performance levels (PL) and risk reduction requirements, minimising the risk to personnel and equipment. 

Cybersecurity is a critical component of a smart factory’s infrastructure. As more devices are connected and data is transmitted across networks, the factory becomes more vulnerable to cyber threats. Securing this digital ecosystem is paramount to protect sensitive data, intellectual property, and critical manufacturing processes. 

 

Our Solutions 

At Fairfield Control Systems, we understand that every challenge requires a collaborative and tailored approach. We work closely with our clients to deliver secure, integrated digital operational technology that drives innovation, enhances productivity, and ensures safety and reliability. 

What We Offer 

Collaborative Engagement 
  • Early Involvement: We engage early in the process to assist with planning, budgeting, and specifying system interfaces. This ensures smooth integration between technologies, systems, and machines. 
  • R&D and Technology Evaluation: Supporting clients during research and development phases, we help evaluate and select the right technologies with the necessary connectivity for optimal performance. 
System Integration 
  • Smart Tool Integration: Precision and efficiency are achieved by embedding intelligent tools into your operations, enabling real-time feedback and connectivity with digital systems. 
  • Custom Connectivity: Our expertise includes developing proprietary drivers and data brokers to connect disparate technologies and ensure full system integration. 
  • IT and OT Interface: Acting as the bridge between IT and OT, we create secure, managed networks that deliver operational resilience and robust cybersecurity. 
Enhanced Productivity 
  • Dynamic Work Instructions: Delivering adaptive, step-by-step guidance that adjusts to real-time conditions, reducing errors and boosting consistency. 
  • Light-Assisted Kitting: Optimizing assembly processes with illuminated guidance systems to improve accuracy and speed when selecting components. 
  • Bench/Gantry Systems: Industry 4.0-enabled ergonomic solutions with features like adjustable height and lighting settings saved via RFID, integrated 3D projection, and visual verification for precision. These systems are scalable and compatible with enterprise platforms. 
Cutting-Edge Technology 
  • Augmented Reality: As a value-added reseller and integrator of DELMIA Augmented Experience, we deliver hands-free guidance, training, and support to reduce downtime and enhance workforce capabilities. 
  • Data Dashboards: Providing real-time data visualization for actionable insights, enabling informed decision-making and performance monitoring. 
Safety and Compliance 
  • Safety and Cybersecurity Assessments: Evaluating and ensuring your plant’s safety, reliability, and resilience, with a focus on functional safety and cybersecurity. 
  • UKCA and Functional Safety Support: Assisting with compliance when integrating tools and machines into larger systems, ensuring adherence to regulations and standards. 
Ongoing Support 
  • 24/7 Assistance: Delivering around-the-clock support and planned preventative maintenance to keep your systems running smoothly. 

By integrating modern technologies, ensuring compliance, and providing support, we empower our clients to achieve operational excellence and stay ahead in a competitive landscape. 

Collaboration in Action: Delivering Innovation with BAE Systems 

Fairfields played a pivotal role in developing a smart gantry system for BAE Systems, enhancing the production of Typhoon aircraft components. These systems, integrating augmented reality and real-time data visualisation, simplify complex assembly tasks while meeting military-grade security requirements.  

Discover how Fairfield’s expertise has driven innovation in aerospace manufacturing by visiting the BAE Systems website: 

Fairfield Control Systems | BAE Systems 

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