Smart Manufacturing Expert Insights

 Key takeaways

Data from the factory floor, combined with a sophisticated set of technologies, may yield a wealth of information.

Automation, AI, the Internet of Things, edge computing, cloud, 5G, additive manufacturing, and digital twins are all examples of strong technologies that may be woven into Industry 4.0 processes to build smart plants. These tools assist manufacturers in extracting information from structured and unstructured data and sharing it throughout the ecosystem.

The human-machine collaboration has the potential to boost factory productivity to unprecedented heights.

AI can assist in the creation of automated, value-based workflows that allow humans to focus on higher-level activities, such as developing their digital expertise. Intelligent automation can aid in reskilling and the redeployment of human resources. Employees will have the opportunity to try out whole new careers.

A larger ecology revolves around the intelligent maker.

The smart factory links to insightful data both on and off the manufacturing floor. Integrating external contextual logistics with shop floor data allows for real-time directional adjustments. Improved quality, operational efficiency, preventative maintenance, proactive choices, and increased worker productivity are all possible outcomes.

             Manufacturing's muscle: connected, predictive, and self-optimized.

• According to nine out of 10 businesses polled, each hour of shop-floor downtime may cost up to $300,000. 
• One out of every four people believes that a single hour may cost anywhere from USD 1 million to USD 5 million.
•  The mismatch of processes and workflows is the largest issue for manufacturers. 
• Product fault detection may be improved by up to 50%, and yields can be increased by up to 20%, thanks to intelligent manufacturing. 
• The technology is complicated, requiring both IT and OT expertise to design and implement. Intelligent automation has improved revenue by about 8%, according to manufacturing businesses.

           Manufacturing sophistication is divided into three stages:

• Standard
• automated
• intelligent

            Edge computing, 5G, and hybrid multi-cloud are three linked technologies.

• Edge computing is a distributed computing architecture in which computation is done in part or entirely on intelligent devices and nodes scattered across the network.
•  Almost 40% of Fortune 500 organizations claim to be sophisticated edge computing users, citing the potential to create quicker reaction times as the primary benefit.
•  Edge computing may also aid in the automation of compliance and regulatory data gathering and administration.

            AI + data + automati interaction

• To gather, analyze, monitor, and learn from that data, AI is required throughout the IT infrastructure.
•  Intelligent automation is one of the most significant business objectives for four out of five top businesses in the next years. Machine learning is being piloted or adopted by 55% of firms. 
• AI is required to extract meaningful subsets from massive data collections. 
• Low latency is fostered at the edge, and the quantity of data managed locally and in the cloud is limited. AI can also help with data labeling, ensuring the correctness of models and classifiers.

            A significant victory for digital twins

• Digital twins are already used by 75% of companies using linked devices. 
• Data scientists and design experts utilize digital twins, which are virtual duplicates of physical devices, to mimic scenarios from real-world gadgets. 
• Robotics, sophisticated analytics, and AI learning systems are among the technologies they're developing. 
• The information from data-gathering sensors in the real-world equivalent is used to create a digital twin. The digital twin should behave similarly to its physical counterpart, employing external pressures to demonstrate various responses to event-driven scenarios such as component failures.
•  As a product is improved, digital twins can give important input.

  The following are three common problems that manufacturing facilities confront as they move toward intelligent, linked operations:

• Pilot scalability's Achilles' Heel
• The linked shop floor and security
• People's point of view: Retrain, reskill, and redeploy

            The advantages of forging a route for the clever manufacturer

• Benchmarking research conducted by IBV Intelligent IoT is used by 43% of major manufacturers.
• According to the IBV survey, just 29% of their colleagues are delaying the use of these technologies.
• Leading manufacturers are 32 percent more likely than their counterparts to report exceeding their industry in terms of revenue growth.
• In terms of lead time, quality, and pricing, these pioneer firms outperform their competitors. They're on the verge of revolutionizing their industries and dominating future value chains.

  Artificial intelligence (AI) and intelligent insights are at the heart of smart manufacturing.

• Transform data into informed decisions.
• Create "thinking" manufacturing processes.
• Develop your digital abilities.