A new era of manufacturing is here: Smart Factories that are self-monitoring and adaptable to change in real-time. This ensures quality and reduces waste, cost, and downtime.
This includes 3D printing, which combines traditional subtractive methods with additive processes to create products layer-by-layer. This speeds up design iteration and increases productivity on the production line.
1. Automation
One of the most popular and widely adopted innovations in manufacturing is automation. Automated systems maintain consistent precision and eliminate human errors, allowing for high-quality products to be produced consistently. This is especially important for industries that require a high level of precision, such as automotive and transportation companies.
Automation also allows for quicker and more efficient production processes. This reduces the amount of time between when a customer places an order and when the product is delivered, which can help improve customer satisfaction and boost company image.
In addition, automation is more cost-effective than manual labor and uses less energy. Automation can also be used to perform dangerous tasks that are not safe for humans to do, which helps protect workplace safety.
There are a variety of different ways to implement automation in the manufacturing process, and it is often best to start small and gradually expand. This allows businesses to test the effectiveness of automation and determine whether it can meet their needs before making a significant investment. For example, a company can begin by implementing a collaborative robot that works alongside human workers to ensure their safety. Alternatively, they can use a bar feeder or automated picking system to control their material handling.
2. Robotics
Some people assume that robots will eventually replace human workers in the manufacturing plant. However, the reality is that robotic systems are used alongside humans. In fact, a company once increased productivity by 50 percent when they began using robots and didn’t lose any employees. Instead, the company gave its employees new tasks to work on that were more exciting and challenging.
Manufacturing robots are able to perform repetitive tasks at faster speeds than human workers, which increases production rates and allows companies to meet demand with shorter lead times. They can also handle dangerous or hazardous tasks that would otherwise require workers to wear protective gear. This reduces costs associated with accidents and safety incidents and ensures that quality standards are met consistently.
Industrial robots can be programmed to weld, paint, and assemble products with incredible precision and speed. They can also be reprogrammed quickly and easily to adapt to different product requirements, making them an excellent choice for rapid shifts in production. Additionally, they can be used to conduct quality control activities that require consistent inspection and measurement. This enables manufacturers to identify defects and inconsistencies sooner, ensuring that only high-quality products reach consumers.
3. 3D Printing
3D printing has evolved from a tool for rapid prototyping into a production process that can help streamline the entire manufacturing system. From product design to inventory management, technology is enabling lean manufacturing practices in every area of a business.
One of the most significant benefits of 3D printing is that it eliminates costly tooling, enabling companies to lower their minimum order quantities and more quickly respond to changes in demand. It also allows products to be fabricated closer to the point of sale, reducing inventory costs and warehousing requirements.
The flexibility of the 3D printing process also makes it easier for manufacturers to create custom, person-specific parts that are more ergonomic and tailored to specific customers’ needs. This is especially true in the medical industry, where it’s possible to create prosthetic limbs and other devices that can be fabricated to the exact specifications of each patient.
The technology is also making it easier to reduce production waste. Traditional manufacturing processes like CNC machining require the use of tools to cut the product into pieces, which leads to a lot of wasted material. With 3D printing, the same piece can be produced with multiple layers of materials, optimizing the use of each material and minimizing waste.
4. Smart Factory MOM
With the help of smart manufacturing technologies, manufacturers are able to collect and analyze data from all aspects of production. This helps them make better decisions and improve operational efficiency. Smart Factory MOM, a comprehensive industry 4.0 platform, makes this possible by providing real-time monitoring and analysis of manufacturing processes. Overall Equipment Effectiveness or OEE will definitely be a huge asset to a company majoring in manufacturing and factory-related jobs.
This allows companies to reduce their manufacturing costs and production times while increasing product quality. It also enables them to create customized products and meet the specific needs of their customers. Smart Factory MOM is an important component of a digital transformation project, and it provides a powerful platform for businesses to stay competitive in the ever-changing market.
The key advantage of smart manufacturing is that it automates and standardizes the work process, allowing for repeatable, consistent results. Additionally, it can monitor and track all aspects of production with real-time data, enabling companies to make changes at the touch of a button.
The smart factory platform has the ability to store and collect all operational data in a centralized database, which provides a clear view of production activities. The system then performs complex analyses to identify issues, predict problems and make corrections before they occur. This eliminates unplanned downtime and reduces follow-up costs.
5. Wearables
Wearables are sensory electronic devices worn close to the body and that provide data to aid workers with their tasks. From fitness trackers like Fitbit and Apple Watch, to virtual reality headsets, to hands-free smart glasses for data capture, these devices are revolutionizing the front-line workforce.
In manufacturing, wearables are allowing workers to monitor equipment performance, detect defects, identify bottlenecks, and improve product quality. They are also enabling workers to perform their duties without having to leave the production area, increasing productivity and reducing downtime.
These smart devices can also improve worker safety. By monitoring vital signs, detecting fatigue, and identifying toxic chemicals in the air, they can alert the worker or even trigger safety protocols in case of an emergency.
While the technology is still maturing, it’s on the verge of becoming mainstream in manufacturing. The ability to reduce physical strain and enhance working conditions can help companies retain skilled workers, boost worker morale, and cultivate a positive company culture. Exoskeletons and other wearable technologies can also help reduce injuries, which can decrease the costs of medical treatment and increase workplace efficiency. Additionally, by digitally recreating the factory floor and products, manufacturers can test out corrections and modifications before executing them physically.
6. Artificial Intelligence (AI)
Powered by data and a “hive mind” of information, AI is helping to revolutionize manufacturing by accelerating production lines and boosting quality. This is accomplished through a host of technologies, including:
Process Optimization: AI algorithms can use data from MES and IoT systems to identify bottlenecks and inefficiencies. This allows engineers to change production methods and processes to improve efficiency and cut costs.
Human-Robot Collaboration: Collaborative robots, or cobots, can be outfitted with AI to work alongside humans and perform repetitive or physically demanding tasks, improving safety on the factory floor and freeing up workers to focus on more complex and strategic activities. AI can also be used to automate software coding and other IT processes.
Product Design and Engineering: During the product design phase, AI can help manufacturers to generate design alternatives using generative design. This helps companies to stay competitive, agile and innovative.
Predictive Maintenance: AI can help to predict when equipment is likely to fail, allowing maintenance professionals to plan ahead and schedule maintenance accordingly. This can reduce downtime and maintenance costs.
Smart Supply Chain Management: AI can analyze data from MES and IoT systems and other sources to better manage inventory, supply chains and supplier relationships. This can help manufacturers to optimize inventory levels, minimize risks and ensure product delivery when needed.
7. Machine Learning
Machine learning is a subset of artificial intelligence (AI) that helps computers recognize patterns and make predictions. It has a broad range of uses across industries, including fraud detection, recommendations and more. In manufacturing, machine learning can help reduce costs, improve quality and increase productivity.
For example, machine learning can help identify product defects on a production line. This helps reduce downtime and allows technicians to take corrective actions immediately, which minimizes waste and increases productivity. Additionally, it can automate signal pruning, which reduces the number of signals that require manual investigation and enables faster root cause analysis from weeks to hours.
Another use of machine learning in manufacturing is to improve supplier management. This information can be fed into the planning stages and ensure that new products meet consumer demands with greater accuracy, clarity and speed.
In addition, ML can be used to break down the system barriers that keep shop floor and business systems separate. This enables greater speed, simplicity and scale to global manufacturing. This is accomplished through predictive insights, analytics and manufacturing intelligence.