They also started minor initiatives with little upfront costs. By connecting such initiatives to business indicators, they might utilize their early achievements to motivate them to spend more on incremental projects.
As a result, they won't need to use manual procedures anymore, which will free them up to discover a comprehensive digital system. This is the basic data from which you can build feedback loops using additional information from factory floor processes.
This additional input might be sensor data or data entered by workers at various stages of the operation. This marks the beginning of your journey toward enlightenment. You will be able to view the bottlenecks on the production floor.
When manufacturers' problems are detected by data, they may start considering ways to modify things in a variety of dimensions. Your digital backbone is now in place. You have algorithms that enable you to improve manufacturing floor activities as well as feedback and input loops that offer insights.
Here Are Ten Examples Of Smart-Manufacturing Technologies
Smart technology development is continuing. For instance, smart Manufacturing may be done without a 5G cellular network. Yet, a 5G connection can offer more capacity than 4G, simplify deployments, and lessen reliance on Wi-Fi and hardware.
High-tech smart Manufacturing is built on these advanced technologies. They are not very different, though. Devices, machines, and systems frequently contain several of them. Sensors that are wirelessly linked to the cloud and processors with inbuilt artificial Intelligence (AI) that may take actions or generate warnings may be found in an IoT device.
AI/Machine Learning
As machine learning and artificial intelligence (AI) can process data more quickly than people and spot patterns in data more quickly than humans, they go hand in hand with smart industrial data analytics. Cobots are frequently equipped with some form of AI in smart factories and other robotics systems.
AI is becoming more accessible and is being incorporated into edge computing, IoT, and smart manufacturing machinery. Video of a manufacturing floor may be used by AI-based computer vision to extract information. For instance, Drishti's AI-powered analysis of manual assembly lines may aid in employee training, lower product faults, and improve procedures.
Augmented Reality/Virtual Reality
Applications for augmented reality (AR) and virtual reality (VR) are widely used in smart Manufacturing. These programs are especially important for employees to address the widening skills gap. Since the pandemic's start, smart Manufacturing has enhanced AR/VR training and remote help. Employees on the production floor may receive instructions from distant specialists who are literally viewing through their eyes thanks to Microsoft's mixed reality HoloLens 2 eyewear.
Automation/Robotics
Cobots are becoming increasingly common as a result of social-distancing regulations, and smart Manufacturing is utilizing robots in more applications. Robots and automated machines are capable of a variety of levels of Intelligence, autonomous decision-making, sensing, and communication. Robots, however, have excellent connectivity to both the cloud and smart factories in general.
Hybrid Manufacturing/Additive Manufacturing
Rapid prototyping has been transformed by 3D printing, commonly referred to as additive Manufacturing. Nowadays, it supports conventional production with finished goods or even infrastructure like tiny buildings and bridges. It is anticipated that mass production will ultimately utilize it. To save waste and speed up production, hybrid Manufacturing, which combines metal additive and subtractive Manufacturing on one machine, is being developed.
Big Data Analysis
The use of big data is essential to smart Manufacturing. Data may occasionally be used to quantify the "smartness" of a device. Data-driven smart Manufacturing, which uses the cloud to store and process information, feeds machine learning. Outside the production floor, smart Manufacturing requires big data analysis. It influences business decisions about cost structures, growth plans, and risk assessment in logistics.
The use of augmented reality, virtual reality, or, in the case of Microsoft's HoloLens 2, mixed reality, enables new approaches to on-the-job training and skill upskilling that can be done remotely. Microsoft.
Cloud Computing
IoT sensor data may be stored on remote servers and evaluated using AI/machine learning algorithms thanks to cloud computing. One illustration of how the cloud may be utilized for smart Manufacturing is the VW Industrial Cloud. It compiles information from 122 VW Group locations and uses real-time processing to make improvements. VW wants to develop a market for smart manufacturing software by eventually connecting over 30,000 sites worldwide from 1,500 suppliers to the Industrial Cloud.
CNC Machining
Precision multi-axis cutting, lathing, drilling, and other operations are carried out using computer numerical control (CNC), a sophisticated computer-aided manufacturing program based on the models and designs of computer-aided production (CAM) software. Wireless sensors that can be utilized in smart Manufacturing are present on many CNC machines.
Design for Manufacturing
Using a range of design concepts and alternatives, Design for Manufacturing (DFM) or Design for Manufacturing and Assembly (DfMA) is a design strategy that maximizes prefabrication. Products and components are created expressly for production. This increases the effectiveness and efficiency of Manufacturing. This entails utilizing sophisticated CAD/CAM software to design and produce products and component parts.
IoT/Edge Computing
Smart manufacturing equipment, machinery, and robots are examples of IoT devices. They consist of wireless sensors that access the internet and transmit data for analysis. Due to their low price, inexpensive CPUs have taken on a greater role in Internet of Things (IoT) devices.
They may thus carry out computational activities locally before transferring them to the cloud, in other words. Edge computing is the term for this. The term "Industrial IOT Internet of Things" (IIoT) describes IoT equipment used in Manufacturing that may make predictive decisions utilizing waste- and cost-efficient input data.
Simulation/Digital Twin
Simulation software is used in smart Manufacturing to produce digital replicas of real-world components and products. Prior to fabrication, these digital twins may then be digitally verified and improved. The value of simulation increases as the digital twin gets closer to the real digital representation.
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Benefits of Adopting Smart Manufacturing
Smart Manufacturing can be used by businesses to improve productivity, reduce costs, remain competitive, and plan for the future.
A survey being conducted by the nonprofit Manufacturing Enterprise Solutions Association (MESA) asks businesses to name the greatest obstacle preventing them from moving toward smart Manufacturing. According to 58% of respondents, the primary barriers to smart Manufacturing are a lack of expertise or financial worries. Smart Manufacturing may be dangerous and requires considerable financial and human resource expenditures.
Manufacturers may benefit from implementing smart-factory projects, whether or not they have already begun doing so. Nonetheless, the advantages often outweigh the operational and financial concerns.
Groups A (49%) and B (51%) of respondents to the research have no active smart industrial projects. There were some continuing smart industrial activities in Group B (51%). The analysis found that between 2015 and 2018, Group A's productivity index was likely to have decreased by 2.3% annually, whereas Group B's productivity increased by 3.3% on average over that time. The average rise in Group B's production output was 10%, while the average increase in firms' capacity utilization was 11%.
Many businesses see the value of smart Manufacturing but have not yet adopted it. According to Wellener, 86% of the manufacturers he studied thought that within five years, smart Manufacturing solutions would be the main factor influencing competitiveness. This emphasizes how critical smart manufacturing skills are for keeping manufacturers competitive in the future.
Regardless of the economic slump or supply chain interruptions brought on by the COVID-19 epidemic, businesses now need to think about smart manufacturing techniques to stay competitive.
According to Wellener, executives discussed their experiences with putting in wearable devices to let line workers signal when they cross into a coworker's 6-foot personal space, computer vision systems for virtual plant tours for customers, and even quickly putting in cobots to increase the workforce since workers can no longer work shoulder to shoulder on the line.
What Is The Impact Of Smart Manufacturing
Smart Manufacturing may increase a company's productivity, safety, and ease of employee training. A corporation may become more adaptable through smart Manufacturing, according to Khris Kammer, chair of the MESA Knowledge Committee.
Look at how many businesses during COVID-19 switched to producing other goods, such as PPE or associated medical equipment, says Kammer. They could swiftly bring new goods into their production settings and then retool, train, and act.
According to Kammer, smart manufacturers may be flexible with their products and engage in mass customization, enabling producers to supply low volumes of highly variable goods. New business models built on subscriptions and "lot size one" items may result from this. According to Kammer, this results in companies pushing some new advances in supply chains rather than being squeezed by them.
Individual firms, as well as the broader manufacturing industry, may benefit from smart Manufacturing. A different innovative business model that smart connected product production has made possible is manufacturing as a service (MaaS). MaaS, or "on-demand manufacturing," as Xometry refers to it, links production demands with suppliers who have the extra capacity to meet them, claims Jonnalagadda.
This is referred to as "the Uberization of manufacturing" by Jonnalagadda. MaaS requires machine learning to effectively connect consumers with manufacturers, just like ride-sharing businesses that employ it to swiftly match passengers with drivers.
Xometry might make Manufacturing as a Service (MaaS) reliable enough to match production needs with capacity. Any upcoming supply chain bottlenecks would be lessened as a result. Xometry.
The "network effect" advantages of smart manufacturing ecosystems are the main topic of the paper "Accelerating Smart Manufacturing," which focuses on another industry-wide trend. Here, several organizations and businesses collaborate using cutting-edge, interconnected technology to accomplish shared objectives.
Examples include America Makes additive manufacturing community effort and COVID-19 response manufacturing programs. Together, designers, manufacturers, and the healthcare industry were able to collaborate on more than 280,000 PPE pieces in just two months, thanks to the platform.
Smart Manufacturing communities have the potential to be mutually beneficial in all situations since they have access to common knowledge, innovation, and benefit for everybody. Compared to those with fewer ties, Fortune 500 businesses with over 15 strategic alliances had a double-digit gain in revenue year over year in 2022.
Also, smart manufacturing firms had a speedier pace for launching new goods and services, greater capacity for innovation, quicker digital technology maturity, and higher operational efficiency, all of which translated to lower operating costs.
Smart Manufacturing's Impact on Sustainability
The use of resources efficiently may be naturally encouraged by smart manufacturing technologies. Physical waste may be drastically reduced by simulating a variety of physical tests, such as car crash testing, in virtual settings.
The simulation may be used to anticipate and test the durability and life expectancy of various materials and assist in the selection of the best materials for the most environmentally friendly products. DFM can improve a product's sustainability. AI is used, for instance, by generative design software to generate a range of design possibilities that lessen the product's weight and material needs while keeping its strength and cost.
If done with the appropriate objectives, smart Manufacturing may be a potent instrument for accomplishing sustainability goals. Among them are 3D printers, 3D laser scanners, robotics apparatus, AR/VR equipment, and simulation and visualization tools.
Industry 4.0 experts are upbeat about the possibilities of these technologies, including Bernard Marr & Co. By restoring the world's ecology and undoing the environmental harm caused by previous industrial process revolutions, their improved asset management can assist.
Read More: What are the Biggest Benefits from Smart Manufacturing Software
Smart Manufacturing: Making the Transition
In its 2016 white paper "Smart Manufacturing-The Landscape Described," MESA urged the development of data and communication standards to promote interoperability across smart manufacturing machines and applications. Industry 4.0 requires that you do this. In the business, many concur.
There are several standards, and numerous businesses use various forms. All of these standards cannot be connected to the program. Every vendor connects CNC machines in a different method. "It needs to change," he adds. A system that links to all machine kinds is required.
Cybersecurity and data protection are also of utmost importance; according to the "Accelerating Smart Manufacturing" research, 58% of firms are worried about data and intellectual property theft as a result of taking part in an ecosystem for smart Manufacturing.
Once smart Manufacturing reaches a critical mass at a time of economic uncertainty, these problems are likely to be overcome. Nonetheless, according to the "Accelerating Smart Manufacturing" report, 62% of businesses maintain or boost their technology initiatives.
"Out of difficulty often arise inventiveness or advancement," says Kammer. According to Kammer, many great visionaries are attempting to use these enabling technologies to do feats they have never been able to. This involves completing the product production process more quickly after the ideation phase. If you mix the finest of technology with necessity, amazing things will happen.
Smart Manufacturing: Some Considerations
Manufacturers may increase productivity, quality, risk management, sustainability, and profitability with the help of smart Manufacturing, which gives them the tools and knowledge to do so. Several elements of smart Manufacturing can have an impact on a variety of business outcomes, including downtime reduction.
How do you grow smarter? What exactly is "smart"?
While thinking about adopting smart Manufacturing, bear the following in mind.
Your Workforce Is One Of Your Key Stakeholders
Your most crucial stakeholders, your staff, need to be informed and educated as the first step in your smart business journey. You may be able to see the advantages smart Manufacturing has for operations, but it's important to make sure that everyone who will be impacted by the change, from top management to the plant floor's technicians, engineers, and operators, is aware of these advantages. Smart Manufacturing's practical advantages will be simpler to comprehend and embrace. This will result in sustained success.
These benefits can be a benefit to the workforce by reducing or eliminating repetitive and paper-based tasks and allowing workers to perform more complex and high-value tasks that require creativity and human discernment.
For instance, Hindalco Industries Ltd uses smart manufacturing techniques to get real-time operational insight and KPIs. They are able to enhance product quality, supply chain effectiveness, and asset dependability as a result.
The role that individuals played in Hindalco's digital transformation was acknowledged. The business aimed to equip its team with digital literacy and wow its staff with cutting-edge equipment. More than 75 digital ambassadors (early career workers) from various divisions were employed by the organization to foster innovation. Using digital immersion exercises, this team has helped to make smart manufacturing a success.
Create A Data Strategy That Is Purposeful
Smart Manufacturing offers the advantage of being able to retrieve data from machines in real-time. However, this data can be of little value if it is not used in conjunction with your business goals or the current set of challenges that affect your Manufacturing balanced scorecard.
The business of smart Manufacturing is not a one-time thing. It's a process of ongoing progress. Start off modestly by implementing one machine or one line. You may discover what information you can gather, examine, and offer, as well as the anticipated outcomes. You can move on to a different use case if the impact is not considerable.
Given the fluidity of business cycles, quick-repeatable positive results are essential. The ideal way to lay the groundwork for smart Manufacturing is with a short project cycle of three to six months.
Being purposeful in your data approach will enable you to make a clear call to action. After the selection of your approach, you must develop a workable plan that specifies the data to be retrieved, the analysis to be performed on it, and the subsequent application of the results to the pertinent stakeholders.
Make sure the data you gather is consistent with the main objectives of your company. Since they are too complex to gather all the data and then try to discover business use cases, smart manufacturing projects frequently fail. Clear data needs and use cases are a prerequisite for successful initiatives. They then give data management that meets these demands priority.
Smart Systems And Devices Are Enablers For Smart Manufacturing
Smart Manufacturing depends heavily on smart technologies. You have a lot of gadgets in your factory that can produce and deliver data. This information needs to be transformed into something helpful. This collection of useful insights leads to smart production.
Information may help manufacturers identify issues more accurately and make more informed decisions. How soon does a sensor need to be replaced or cleaned? More data may be provided by higher-tier systems, which may provide you access to a wider choice of KPIs for assessing your production performance.
Information gateway solutions that work across operational and information technologies are connected to smart systems, from components to PLCs (IT). The appropriate individuals inside your business should get the data in the appropriate format. Most websites have the information they require. Also, it can be kept in several systems. Start with security infrastructure and gateways to access the current data rather than concentrating on new devices.
This may be used in conjunction with analytics to spot trends and foresee future issues before they materialize. This is only possible with the appropriate knowledge. One such example is Shandong Mining. It made an investment in smart Manufacturing solutions after seeing the potential for bettering its equipment monitoring. As a result, maintenance expenditures were reduced by up to 30%.
Safety And Sustainability Are Top Priorities
Each development program must include both safety and sustainability, which are also the fundamental principles of any intelligent application. Initiatives for smart Manufacturing have the potential to address sustainability and productivity. If you don't include this attitude in your project planning cycle, you run the danger of losing stakeholder participation and missing crucial ROI arguments for project financing.
Smart Manufacturing Is A Journey And Not A Destination
Technology is constantly changing, and so are opportunities. Smart Manufacturing provides many benefits and solutions.
- More adaptable digital production and supply chain management infrastructure will enable businesses to respond swiftly to changing product needs.
- Operational data enables users to be proactive rather than reactive based on the insights gathered.
- increased plant uptime and dependability
- To simplify system integration, operation, maintenance, design, and operation tools are organized.
- Your balanced scorecard is powered by your digital infrastructure. It emphasizes sustainability and safety in addition to productivity.
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Conclusion
You may begin your adventure in smart Manufacturing in a variety of ways. Start your path toward smart Manufacturing where it makes sense. Scale up next. You become more productive overall and have superior decision-making abilities as you gather more facts. Manufacturing done smartly is clever. Smart Manufacturing will have a significant positive impact on your business.
