Industry 4.0 is merely not a buzzword in the manufacturing world but has become a reality, thanks to the world pandemic—COVID-19. The digital advancement, like manufacturing automation during this time, is almost equal to ten years, as businesses and consumers have shifted to the digital world. It has simplified the interactions and fastened every procedure.
This blog can help understand the use of AI in the manufacturing industry and different ways to include this latest technology into the traditional manufacturing process.
Shift to digital technology offers a wide range of benefits. Manufacturers need to implement it in crucial areas to become more resilient and improve features, such as forecasting, conditional maintenance, and communication. Applications of artificial intelligence to convert the present unit into a smart factory are:
Demand Planning and Forecasting
AI powered forecasting helps in reducing errors by more than twenty percent in supply chain networks. Enhanced accuracy leads to huge profits as lost sales are reduced significantly. The loss can be due to inventory out-of-stock and warehousing costs. The effect can range from acquiring production cost to delivery of finished goods.
Development and Maintenance
Manual maintenance is time-consuming and costly. It also holds the risk of malfunction and improper maintenance. It will hit on the production schedule; thus, decreasing productivity. Further, the use of AI in the manufacturing industry aids in predicting malfunction or prospective failure of machines.
Communication
The smart manufacturing system is not restricted to operational processes. It aids in detecting patterns from various sources, which improves communication between employees and customers. Latest technologies like AI bot help reduce the burden on employees and guide personnel in customer acquisition.
Application of the smart manufacturing system in your manufactory unit in the above-mentioned areas provides you with a set of benefits, such as
Defect Detection
Traditional assembly lines lack technology; hence, it becomes difficult to identify problematic areas. Manufacturing automation simplifies this complex process and helps in finding solutions that are long-lasting and effective. It also helps in saving tons of hours in quality control by reducing false positives.
Quality Assurance
The manufacturing sector requires high levels of precision and attention to detail. AI in the manufacturing industry helps in evaluation and establishing if an item has been produced perfectly. Image processing algorithms sort and process images, which the cameras placed in the strategic points along the factory floor collect.
Predictive Maintenance
Maintenance of production line and machinery equipment is one of the biggest expenses. A flawless operation impacts the production operation and guarantees maximum output. Hence, predictive maintenance has become a necessity, as the manufacturer would benefit by knowing when the potential failure would occur. It aids in reducing costs associated with unplanned downtime or production machinery and equipment. Thus, making the manufacturing unit a smart factory.
Human-Robot Collaboration
Many manufacturers prefer robots to work alongside human workers or in areas that are dangerous to human life. The use of robots helps in detecting and avoiding obstacles, at the same time working alongside human workers. Manufacturers can use them to work alongside humans or as a replacement for traditional workers.
Supply Chain Management
Smart manufacturing system can optimize warehouse management and logistic operations such as production, delivery and other similar operations. The technology helps in simplifying the detection of bottlenecks and errors.
Digital Twins
Many manufacturing units use digital twins (are a virtual representation of a physical product, process or system that a business uses to make model-driven decisions) for various tasks, even for product development and improvement of operational performance. Integrating hi-tech components to gather actual data and connecting with a cloud-based system will help in deep learning.
Inventory Management
This trending application of AI helps companies manage their inventory needs with ease. It also aids in preventing cash-in-stock and out-of-stack scenarios. It aids in better prediction of ingredient arrival and how the delay will affect the production.
Smart manufacturing systems use predictive analysis tools to estimate market demand by observing various critical factors. Hence, it will allow the manufacturer to produce high-in-demand inventory.
Customer Care
AI in the manufacturing industry includes tools such as chatbots and customer insights are popular with industries that directly deal with customers. With the use of technology for observing customers’ behavior, a manufacturing company will be able to answer their needs better. It provides a few benefits like quick customer response and personalized experience.
Cut in unplanned downtime and better-designed products are a few benefits of the use of AI in manufacturing industry. Seeking professional help will open up a new path and provide manufacturers with new paths leading to success.
