To grasp the current manufacturing trends and seize the Zeitgeist of Industry 4.0, a new smart IoT industrial park in Hangzhou has been put to use by Dahua Technology, a video surveillance solution provider.

Dahua Smart (IoT) Industrial Park occupies in total 512 acres in Fuyang district of Hangzhou, about 20 minutes’ drive from Dahua headquarters, designed to host 6000 staff (by 2017, 4500 people have been working/living in the 262 acres of phase one area). With topnotch technologies, personnel, materials and other benefits, Dahua’s smart industrial park will bring productivity and quality to a brand new level.

Efficient information integration

The automatic production solution based on integrated information system not only grants a higher productivity that significantly shortens the delivery cycle time for Dahua customers, but also a greater flexibility to specialised requests and ever-changing reality.The employment of software such as ERP, PLM, PDM, MES, APS and WMS helps to achieve information integration

The employment of software such as ERP, PLM, PDM, MES, APS and WMS helps to achieve information integration, which, combined with industrial cameras, RFID sensory technologies and automation technologies, can integrate personnel, logistics, works, engineering projects and finance from respective sections of production(preparation, assembly, testing, packaging, inspection, shipment), rendering the whole process visible, traceable and digital.

The mounter serves as a good synecdoche to illustrate the incredible efficiency of the whole production system. The concerning high-end devices (including mounter, printer, automated optical inspection equipment, Ersa reflow soldering tools, etc.) provided by ASM (originally Siemens) achieve a speed among the fastest in the world.

Fast processing

According to IPC standard, X4iS, the latest high-speed mounter can process 125,000 components per hour, or 35 per second. X35 multifunctional mounter can do 54000 components per hour, or 15 per second. A production line in X series can enhance the productivity by 2.7 times while reducing the consumption of energy by 52%, comparing to the original production line in D series under the same conditions.

Dahua Smart Industrial Park provides the great benefit of internal synergy

The faster speed also applies to the development of new molding, since Dahua Smart Industrial Park provides the great benefit of internal synergy, allowing the end-to-end vertical supply chain with marketing, R&D and manufacturing efficiently integrated.

The advanced organising system is supported by topnotch equipment, such as MAKINO high-speed graphite processing machine, GF CNC, GF WEDM-LS machine, Hexagon 3D Nikon projectors and electronic displays. With a processing accuracy of +/-0.002 to +/-0.005MM, while also supporting CAD / CAM / CAE collaborative development and simultaneous manufacturing, these machines enable Dahua to develop new mechanical molding in as short as 7 days.Higher quality results in less likelihood for products to malfunction especially when they are used in critical situations

Time- and cost-saving solution

By far, this developing system has already produced high precision molding for Lechange Robots, monitoring cameras in TP1-TC6 series, G20 intelligent head-gears, smoke alarm for fire detectors, etc., all of which proving the effectiveness of the system in shortening the development cycle and keeping the competitive edge with new products in the business.

Higher quality saves lots of time and economic costs for clients. Even more importantly, higher quality results in less likelihood for products to malfunction especially when they are used in critical, not-allowed-to-go-wrong situations.

Dahua’s products are guaranteed with a higher quality for two reasons: first, Dahua has set a high standard of accuracy in production; second, with a reliability lab at the production end, Dahua has put together an effectively closed loop for quality control in the manufacturing process.

Accuracy has always been one vital index defining the manufacturing ability because it directly sets the limit to quality and range of products to be produced. Again, take the mounter mentioned above for example: it can process components, in metric size, as small as 03015(0.3x0.15mm), with a +-0.025mm SMD precision (within the 3-stigma range), boasting world leading performance and capable of covering basically all types of components used in the industry.Dahua industrial camera plays an important role in IoT, providing a closed loop for quality control in the manufacturing process

Enhanced vision and intelligent analytics

Dahua industrial camera plays an important role in IoT, providing a closed loop for quality control in the manufacturing process, in which all materials, personnel and devices are connected and products are traceable to the specific production line and precise time it got made.

Boasting a variety of functions, Dahua industrial cameras are used in different sections of production, enabling automatic assembly, high-precision graphic inspection and product flaw inspection.

Through high-definition machine vision, Dahua industrial cameras automatically and precisely locate the components, limiting the assembly error to micron level. Equipped with enhanced vision and intelligent analytics algorithm, the industrial camera can spontaneously detect and recognise flaws in the performance and outlook of products, thus promising not only the volume of cameras production but also the steady quality of each and every one of them.In the future phase, this industrial park is expected to be more intelligent to enable a safer society and smarter living

Safe society and smart living

Reliability must be put to test, in R&D as well as in manufacturing process. The reliability lab at the production end serves to assure quality by randomly taking products from production lines and put them into reliability tests simulating falling, high/low temperature, worn-out conditions, which are conducted by industry leading testing equipment in the lab. Thus what’s conceived in R&D is confirmed from the production line, the synergy of both ends promising better products (for common use or specialised needs).

This lab is also responsible for testing all the raw materials. Thanks to the aforementioned information integration, all tests are automatically conducted, recorded and traceable.

In conclusion, Dahua Smart (IoT) Industrial Park is endowed with the latest and world leading manufacturing equipment/system boasting high level automation and intelligence, which is essential to satisfy the ever higher demands from clients in terms of delivery time, specialised use and quality.

There is still great potential to this new smart industrial park. It is literally only in its phase one. And in the future phase, it is expected to be more intelligent, to realise client-centred flexible production and to enable a safer society and smarter living.

Download PDF version

In case you missed it

How Internet of Things (IoT) aids facility management and physical security
How Internet of Things (IoT) aids facility management and physical security

As buildings become more complex and smarter, the age-old traditional maintenance methods that are based mostly on hands-on human monitoring are becoming more and more inadequate. Instead, the world is fast adopting building automation as a key component of smarter and more proactive maintenance strategies. The aim is to free up maintenance staff and give them time to focus on other tasks while machines monitor the different systems that work together to make the facility functional. Specifically, Internet of Things - or, IoT - enablement appears set to transform the way facility managers deliver service to building occupants. The trends are many and the possibilities are almost mind-boggling, from inventory management, to work scheduling and energy efficiency, the list goes on and on. Below, we look at a few ways in which IoT is being used for Facility Management and Security. Revolutionise maintenance through condition-based maintenance For years now, the norm among maintenance professionals has been a time-based approach, or in simpler terms, performing maintenance operations after a set period of time. But a major flaw of this system is that components were being replaced periodically whether the parts were actually worn out or not. Of course, that meant some of these maintenance activities simply weren’t cost-effective. To avoid this waste from continuing, a subset of IoT known as IIoT can now be used to optimise the maintenance process. IIoT works as a centralised network of connected systems and devices that can talk to one another and generate and relay data Rather than changing parts on a time-based schedule, IIoT works as a centralised network of connected systems and devices that can talk to one another and generate and relay data. Selected equipment are fitted with sensors that monitor specific operational parameters and let maintenance professionals know how the machines under supervision are working, understand their current condition, and then pinpoint the optimum time they need to be maintained. The information generated this way is vital as it allows maintenance staff to intervene just in time to avoid costly downtime and other associated inconveniences. This is, in a nutshell, the basics of predictive maintenance and condition-based maintenance. These days, by implementing condition-based maintenance, IIoT is being used to effectively monitor a wide range of systems such as lighting, HVAC, fire suppression, security, etc. The applications are numerous and so are the benefits. On page 52 of this guide by the US Department of Energy, they state that a functional predictive maintenance program could yield up to 10 times ROI, reduce maintenance costs by 25% to 30%, and reduce downtime by 35% to 45% Along with fire suppression, IIoT is effectively monitoring a wide range of systems such as lighting, HVAC and security Remote monitoring of facilities Physical inspections have been a critical condition for the success of conventional maintenance programs, even in hazardous environments. But, with the increasing emphasis on personnel safety, organisations want alternative solutions that allow staff to examine assets without being physically present. Facility managers and their team working in industries like manufacturing, oil and gas, and mining can relate with these constraints. And these industries can benefit greatly from deploying predictive maintenance solutions. For example, in the oil and gas industry, IIoT sensors can be used to monitor remote and highly critical assets. These sensors can be used on pipelines to detect anomalies (especially corrosion) and pass that information to supervisors for necessary action. By doing this, potential failures are quickly predicted to avoid often disastrous incidents. Managing energy consumption Sensors are also being embedded in building components and devices like HVAC systems, lights, doors, windows to understand energy consumption and proactively manage it. Facilities that use this technology could achieve substantial energy savings. In a press release by IT research and advisory company, Gartner, they stated that IoT can help reduce the cost of energy - as well as spatial management and building maintenance - by up to 30%. Looking at HVAC systems very closely, we see that they are a major source of energy usage in any building These sensors work by monitoring different conditions in the building and causing a power-saving action based on the data received. For instance, occupancy sensors can order lights to turn on when it senses motion in a room and then turn off the same lights when there is no presence there. That way, there is no need to wait for someone to remember to switch off the lights when they are not needed.   Another very common use is in HVAC monitoring. Looking at HVAC systems very closely, we see that they are a major source of energy usage in any building. So, the issue is how can one use IIoT to manage HVAC and possibly reduce their energy usage? Well, in its most common form, IoT-enabled HVAC works as a connection of sensors and thermostats that monitor factors like indoor air quality, temperature, and environmental changes then communicate with the rest of the HVAC equipment and make needed adjustments for occupants’ comfort. Not only that. IoT-enabled HVAC works as a connection of sensors and thermostats that monitor factors like indoor air quality, temperature, and environmental changes The technology can be configured to: Track energy consumption at different distribution points throughout the building. Track usage from the power source right down to the consumption point. Detect sudden voltage drops or spikes (usually an indication of some fault). These are essential benefits because HVAC units are notorious for consuming large amounts of energy when they are working inefficiently. Security and access control Smart surveillance is another important area of application for IoT in facilities management. It takes several forms such as the monitoring of life-saving systems like intruder or fire alarms, invisible barriers, and other safety installations. Facility managers are using IoT across different industries to obtain live information about potential emergency situations with a view to responding before the issue escalates. In such cases, quick detection of any strange activity is key because many of these installations have tangible negative effects when they fail or when they are intentionally sabotaged.Smart surveillance is another important area of application for IoT in facilities management Fortunately, the surveillance equipment can also be setup to send alerts to mobile phones to aid emergency response or evacuation as the case may be. Smart surveillance is also priceless for monitoring the situation in partially or fully automated remote facilities (especially oil and gas installations and mines), and in hostile environments with critical equipment where humans cannot work for extended periods of time. If you are not yet using IoT in your facility, you may be wondering where to start from. To avoid getting overwhelmed, a good place to start would be to try a small-scale deployment of this technology then review its ROI and impact on your operations before adopting a more widespread IoT implementation. This way you can gradually scale up as you and your staff come to understand and adapt and to this new way of doing things.

Is the physical security industry doing enough to prevent school shootings?
Is the physical security industry doing enough to prevent school shootings?

School shootings continue, as does a search for answers. What solutions are there to prevent school shootings and/or to improve the response (and thus minimise the death toll)?  In the physical security industry, we like to think we have solutions that can help, if not “solve”, the problem, but realistically speaking, how effective are they at the end of the day? We like to think we have solutions that can help, if not “solve”, the problem: but how effective are they at the end of the day? The sad answer – even after dozens of school shootings and even in the wrenching aftermath of the latest one – is that we don’t know. There is a gaping lack of knowledge and research when it comes to measuring the effectiveness of preventative measures as they relate to school shootings. Scarce resources on preventative measures The dearth of knowledge on the subject leaves schools at risk of spending scarce resources on measures that don’t have any real impact, or worse, that have a negative effect on education environments. The natural impulse following a school shooting is to do something – anything – to prevent the tragedy from happening again at any school, but especially at my school. But how is money best spent?Successful businesses are a good thing, but not at the expense of misspending education resources on solutions that don’t solve anything Congress has passed the Stop School Violence Act of 2018 to provide $50 million per year to develop programs to train students, teachers and law enforcement to prevent violence, and to create anonymous reporting systems, such as hot lines, for school violence threats. The bill authorises another $25 million for improvements to school’s physical security infrastructures. Congress also provides $1.1 billion in Title IV block grants, which districts can use to pay for diverse needs such as security systems. Several states are providing additional funding for physical safety measures and campus police, and local districts are also stretching their budgets to address security concerns. But is that money being targeted to measures that will help the situation? What is the role of technology in preventing school violence, and are we as an industry at risk of over-selling our preventative capabilities and diverting money from other measures that might have more impact? Successful businesses are a good thing, but not at the expense of misspending education resources on solutions that don’t solve anything. More metal detectors, armed guards and police officers could cause anxiety in some students and even interfere with the learning process Studies on school safety and protection Researchers, advocates and educators gathered this fall at American University to consider the need for better research to inform decision-making on safety, reported Education Week.The field is in desperate need of more evidence on what works, and schools want this information presented to them" A 2016 study by the Rand Corp. points to the problem: Lack of data and research on what works and what doesn’t. “Despite growth in the school safety-technology sector, rigorous research about the effectiveness of these technologies is virtually non-existent,” according to Rand. “The field is in desperate need of more evidence on what works, and schools want this information presented to them in vetted, digestible ways to help them with procurement.” Jeremy Finn, a professor of education at the University of Buffalo, has pointed out the difficulty of assessing the effectiveness of measures designed to deter events that likely won’t occur anyway. “How do you know when you have deterred a school shooting?” he asks. “It didn’t happen.” The effects on our students  Might technologies aimed at making schools more secure have an adverse effect on the learning environment? More metal detectors, armed guards and police officers could cause anxiety in some students and even interfere with the learning process. The physical security industry should freely acknowledge that the technologies we offer are only part of the solution to school violence Do security measures aimed at preventing active shooting incidents absorb resources that might better be used to address a more general and/or likely security threat such as vandalism or student discipline? Theoretically, security measures in general should help to prevent the probability of an active shooter at the same time they are addressing a wider range of concerns and threats. But do they? At the very least, we in the physical security market should be aware, and should freely acknowledge, that the technologies we offer are only part of the solution to school violence. Schools should take the broadest possible approach to the range of security challenges, and technology should be one tool among many. Furthermore, better data to measure what works is sorely needed to illuminate the best path forward.

How can the physical security market promote better employee retention?
How can the physical security market promote better employee retention?

Employee turnover is a problem for many companies, especially among younger employees who have not developed the philosophy of employer loyalty that was common in previous generations. Nowadays, changing jobs is the norm. The idea of spending decades working for a single employer seems almost quaint in today’s economy. However, excessive employee turnover can be expensive for employers, who are looking for ways to keep their brightest and best employees happily toiling away as long as possible. We asked this week’s Expert Panel Roundtable: How can the physical security market promote better employee retention in a competitive employment environment?