Amid the fast pace and constant change, the contemporary manufacturing technology is is quickly evolving. Powered by artificial intelligence (AI), IoT and automation, this transformation is fueled by advanced technologies.
“Industrial Robotics Market will reach $41.23 billion by 2028.”
It is these technologies that would change the way manufacturing is done for the better. They would minimize maintenance needs, improve processes and accuracy, expand possibilities. The main aim is to upgrade the factory systems to be smarter, safer and faster.
Despite the frequent use of the term “intelligent manufacturing” being over used and even abused. The potential that this technology holds is tremendous. However, the principles of manufacturing are sacrificed on the altar of hyperbole. Many of the companies look at the latest technologies without considering key areas of success.
However, true innovation and long-term sustainable success in the sphere of manufacturing is not achieved just by embracing technology for the sake of it. The success is derived from the principles such as quality, logistics and most importantly people. This can only be augmented by technology in a reasonable manner.
This moderation is what makes the successful manufacturers better than the others who just try to follow the trends.
II. The Misconceptions of Intelligent Manufacturing
Overemphasis on Technology
Marketing, which portrays intelligent manufacturing systems as silver bullet solutions to contemporary production problems. Companies show photos of factories with many robots and AI that are competent to perform. However these technologies can bring certain manufacturing problems.
What may seem promising at face value often turns out to be a missed opportunity. It is illustrated by a 2021 Deloitte report that stated 86% of manufacturers targeted AI integration. However, only 30% followed through as planned.
“The use of AI in manufacturing has risen from 19% to 31%.”
There exists an equal amount of pressure to deliver immensely productive results. It is a situation that shouldn’t exist in the first place. Businesses allocate heavy investments into advanced systems only to end up with underwhelming performances.
Top-down management without bottom-up engagement
Experts point towards a big-picture approach. However, deploying intelligent manufacturing systems must be preceded by certain moves. They forget about the basics that should already be efficiently integrated into the process. These are:
- Human resources
- Quality checks.
Complete elimination of human labor from a workplace through automation is impossible. What can be automated, skilled workers still do much better. More advanced systems, including automatic ones, do not answer complex questions well.
If all supply chains are leveraged, problems arise. Such trends occur for all companies, even for those with advanced technologies. Companies must also realize that technology deployment isn’t too hard to implement for smooth operations
Where does extreme emphasis on AI and automation become risky?
AI and other advanced technologies are mostly experimental, ZMP includes use of real world examples to develop their product. However, operational problems must not be ignored. This place is very risky when considering finances.
According to a 2022 McKinsey report, the picture is not rosy at all. About 70% of digital transformation campaigns in the manufacturing sector miss the benchmarks they are supposed to meet. The most common explanation is a failure to adopt a realistic focus on the practical aspects of achieving objectives.
III. Advantages of Human Manufacturing
Technology can improve various aspects of manufacturing and engineering, but several core principles are the foundation of the industry. It is these principles which will guarantee success in the long term.
Quality Control:
The integrity of the product is paramount in manufacturing. Substandard products have severe and negative repercussions. These are product recalls, loss of sales, and great harm to a firm’s reputation.
Supply Chain:
Having dependable supply chains is important in achieving manufacturing goals. This ensures that raw materials and components are delivered on schedule. Close ties with suppliers assist ameliorate any likely disruptions.
Material Acquisition:
The presence of quality materials is a primary building block to the manufacture of strong products. Reliable supplier partnerships provide provision for diversification and uniformity. Quality of materials has an effect on the quality of the products.
Work Processes:
Lean production methods are still the basic requirements in today’s manufacturing. Such methods look at the efficiency of the processes and the reduction of waste. Such a strategy is demonstrated by Toyota, which has positioned itself as one of the best manufacturers in the world.
Man & Machines in Manufacturing
Machines and technology can replace workers but not fully. Creative activities, skilled worker and problem-solving are essential and will always be required for resolving intricate problems.
The Human Factor:
The uniqueness of the manual laborer comes around with strong intuitive and creative sense towards a particular task in the manufacturing process. They are more flexible when it comes to handling challenges that may not have been mechanised. The COVID-19 pandemic provided ideal proof of this flexibility.
During dust, economies relied on their employees’ abilities and versatility. Employees scaled production to supply critical requirements such as masks and ventilators. It even brought out the true nature of human potential.
Workforce Development:
There are appreciable returns to be gained from spending on employee training. Ergonomic work environments are a boost to productivity and the mood of employees. The World Economic Forum attests to the effectiveness of this strategy.
Firms that place an emphasis on the development of their workforce have good results to show. They record up to twenty percent improvement in general efficiency.
Examples of Success
There are some companies that have a tendency of doing better than their technology focused rivals because they remain committed to basic principles. There is a good case of a small manufacture in Germany.
All this company need to maintain was lean and quality control with processes. They were able to achieve impressive results without having to doll out a great deal of money on sophisticated technological capabilities. Their approach led to 30% waste reduction with increased production speed.
This bare truth of human existence has been made evident through their victory. Manufacturing discipline is still based on proper fundamentals which secure manufacturing advancement.
IV. Technology Improves Precision
For a better output, technology needs to be integrated effectively on manufacturing systems. It increases the level of sophistication in terms of precision, speed and also volume.
Predictive Analytics: Ge utilizes AI to forecast when equipment will fail.
Automation: Robotics enhance the level of effectiveness of repetitive assembling processes.
These tools are best used where they form working parts of pre-existing systems. They are the foreign assistive technologies that should not supersede human capabilities.
Avoiding Overreliance
Dependence on automation may also decrease the expected returns in some instances. Machines cannot conceive any modifications to implemented protocols unless a human is there to intervene.
The production issues faced by Tesla bring to bear this sort of scenario. The company encountered long lead times in 2018 because it had an automated production line that was too advanced for the company. Elon Musk, the company CEO, admitted later on that “There is some value to having a factory that is not too automated.”
Balance is Crucial
The best manufacturers are those that are able to achieve some level of equilibrium. They integrate automation and the brains of humans.
BMW is an ideal illustration of such a method. Robots perform monotonous routines. The key inspections of quality are controlled by skilled workers. This hybrid model preserves efficiency while ensuring that flexibility is maintained.
V. Case Study: Rapid Manufacture
More than everything else at Rapid Manufacture, we hold the basics of manufacturing in high regard. We apply technology in the right way in order to make superior products. Our method seems to provide client oriented solutions.
We strive to provide answers for actual manufacturing problems. The solution is a blend of accuracy and practical approaches.
Flexible Options in Different Volumes
To satisfy market requirements, we have flexible manufacturing options. It should be noted that our capabilities include:
Rapid Prototyping
We employ cutting-edge equipment and technology in order to provide our customers with rapid prototypes. This helps the clientele to cut down the period of product development. The capabilities of the firm include:
- Production capacity: 20–500 pieces
- Lead time: 10 business days
- Goal: Shortening the product development time.
Low-Volume Production
We have a niche in specialized or low-batch production. Our techniques consist of:
- Techniques: Vacuum casting and CNC machinery
- Production capacity: 500–1,000 pieces
- Lead time: 15 business days
High Volume Production
We develop optimum processes for mass production. The methods used are:
- Plastic injection moulding and sheet metal fabrication
- Production capability: 1000 and above pieces
- Lead time: 20 business days
- Conclusion
With the current trend of smart technology, it is not enough to just understand the new technology and implement it in your processes.
To succeed, the following must be in place:
- Assurance for Quality
- Supply chain efficiency
- Availability of skilled labor
- Purposeful organization of new technologies
We offer services from rapid prototype development to mass production. Our aim is to ensure that your ideas about manufacturing will be realized accurately and effectively.