The Future of Smart Manufacturing: The Way Forward

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February 27, 2023 - by Synoptek

Digital transformation in manufacturing refers to integrating digital technologies into all aspects of manufacturing processes, from design to production and supply chain management. Digital transformation in manufacturing aims to leverage data and technology to help manufacturers:

Optimize their operations
Increase transparency
Improve efficiency
Reduce costs
Increase quality
Enhance the customer experience
Enhance their competitiveness

The Smart Manufacturing Imperative

The global smart manufacturing market size will be worth $658.41 billion by 2029 from $277.81 billion in 2022 at a 13.1% CAGR. But adopting the smart factory model depends on whether it makes sense for your facility or business model, which can be done through an in-depth assessment.

Some manufacturers may find upgrading machines, retraining workers, or installing security systems prohibitive. But most companies claim that technology transformation has helped them significantly grow their product/service portfolios and enhance customer experience. A study by the Everest Group states that manufacturing and distribution companies have realized a satisfactory strategic and cost impact. According to researchers, companies in this sector have demonstrated a 44% overall technological impact.

All aspects of the organization should be involved in the decision to transition to a smart factory. Everest group’s findings for technology investment priorities say that the manufacturing and distribution industry leads the way for investments in emerging next-generation technologies. Over 40% of manufacturing and distribution firms are investing in big data and IoT.

Current State of Manufacturing: The Challenges

Despite the many doors that smart manufacturing opens, there are several challenges that the manufacturing and distribution industry faces in its technology transformation initiatives, including:

The scarcity of internal talent knowledgeable about digital technologies essential for transformation.
Organizational resistance, which slows down the transformation process, especially if employees resist changes that need to be made to the traditional ways of working.
Companies lacking a clear vision for their digital transformation journey, making it difficult for them to progress in their initiatives.
A defective funding model can be a major challenge where companies may not have the necessary budget to implement new technologies, or they may not be investing enough to sustain their endeavors.
The lack of executive support can result in a roadblock to digital transformation- because.

Companies that successfully navigate these challenges will be better positioned to thrive in a rapidly changing digital world. This adds to the increasing need for automation and adopting new technology, as well as the scope of having service consultants resolve conflicts cost-effectively.

Technologies Poised to Carve the Future of Manufacturing

In the past, technologies in pilot or development stages have now moved into the next phase to deliver results on demand. Let’s look at the leading technologies that are poised to carve the future of manufacturing:

Artificial intelligence (AI), Machine Learning (ML)

AI and ML will revolutionize ways manufacturing processes are carried out via:

Predictive maintenance: AI and ML algorithms can predict when a machine is likely to fail, enabling manufacturers to perform preventative maintenance and avoid costly downtime.
Inventory management: They can analyze sales data and predict inventory levels, enabling manufacturers to optimize operations and reduce waste.
Quality control: AI and ML models can identify and classify defects in real-time, reducing the need for manual inspection and improving product quality.
Supply chain optimization: AI and ML can analyze data from various sources to optimize supply chain operations, such as reducing lead times, reducing costs, and improving customer satisfaction.
Personalization: AI and ML can also help personalize products and customer experiences, enabling manufacturers to differentiate themselves and increase customer loyalty.

Augmented Reality (AR)

Manufacturing and industrial software development tend to use monolithic architectures and applications- which are rigid and complex, requiring manual installation and scheduled downtime for changes or updates. Incorporating advanced AR technology into shop floors and assembly processes can increase efficiency, reduce costs, and boost overall production. AR simplifies complicated processes by positioning the right information at the right time. It also creates a real-time hybrid environment bridging cyber-physical IoT and the real world.

Advanced Analytics

Manufacturers looking to handle the vast amount of data that has always been available for use can. The data from operational systems, supply chain, and customer feedback is used to understand & improve performance & efficiency, reduce costs, and improve customer satisfaction. It can be exploited for the benefits of advanced analytics to identify gaps in existing processes.

Creating insights from data will be a key focus area for manufacturers globally. Then these observations can then be used to optimize operations, production, supply chain, vendor management, product performance, delivery of goods, services, and customer management. It can also improve quality, efficiency, and turnover.

For instance, predictive analytics can help organizations optimize production schedules and reduce waste. In contrast, prescriptive analytics can provide recommendations for better decision-making and process improvements and help analyze customer data to understand purchasing patterns and preferences. This can, in turn help them develop targeted marketing campaigns and improve customer engagement.

IoT

As sensors expand across territories, IoT is catching up with digitization like wildfire, and edge clouds are acquiring front-row positions in factories. The following are the ways IoT will transform manufacturing in the future:

Product/Organizational Performance: IoT devices and sensors can be integrated into products for real-time performance monitoring & potential problems identification. This helps companies make necessary adjustments to improve product reliability and reduce warranty costs. IoT can also deliver real-time data and analytics, enabling organizations to optimize operations, improve production processes, and enhance product quality. Using smart sensors and devices in manufacturing, logistics, and supply chain management can reduce downtime and improve efficiency, in addition to gathering valuable customer feedback to improve product design and features.
Supply Chain: IoT technologies can enable real-time tracking and monitoring of products in the supply chain. This optimizes inventory management, improves delivery times, and reduces product damage or loss risk. The technology can also enable the sharing of data between suppliers, manufacturers, and distributors, leading to improved collaboration and streamlined processes.
Delivery: Smart sensors and devices in transportation and logistics can enable real-time tracking of shipments, reducing the risk of product damage or loss and improving delivery times. IoT can enable the use of drones and autonomous vehicles for delivery. This will lead to the enhanced delivery speed and reduced delivery costs.

Blockchain

Blockchain technology can benefit the manufacturing and distribution industry in several ways via its transparency, immutability, and security capabilities. The benefits include:

Improved Traceability: Blockchain technology provides a secure and transparent record of all transactions in the supply chain. This enables manufacturers and distributors to track the origin of raw materials, the manufacturing process, and the distribution of finished products.
Better Inventory Management: With blockchain technology, manufacturers and distributors can track inventory in real-time, reducing the risk of stock shortages and overstocking.
Increased Supply Chain Efficiency: By streamlining processes, blockchain technology can help reduce errors, eliminate duplicate efforts, and facilitate the supply chain, resulting in reduced costs and improved operational efficiency.
Improved Product Safety: By easily tracking and verifying the safety of products, blockchain reduces product recalls and the risk of fraud.

Increased Trust and Collaboration: Blockchain technology also allows for secure and transparent sharing of information between different stakeholders (manufacturers, suppliers, distributors, customers) in the supply chain leading to improved trust and collaboration.

Cybersecurity

Cyber threats such as hacking, malware, phishing, and other cyber-attacks could disrupt operations and compromise sensitive information. To strengthen security posture, manufacturers will be found investing in several cybersecurity tools and technologies, including:

Firewalls: They are the first line of defense against cyber-attacks and can be customized to meet the specific needs of the manufacturing industry.
Encryption: It protects sensitive data and prevents unauthorized access to confidential information.
Identity and Access Management (IAM): These solutions help manufacturers control who has access to sensitive information and ensure proper permissions are in place for critical systems access to be available for authorized personnel only.
Network Segmentation: It helps prevent the spread of malware by limiting access to critical systems and data.
Endpoint Protection: Antivirus software helps protect individual devices from malware and other cyber threats.
Vulnerability Management: This helps manufacturers identify and prioritize security weaknesses in their systems, to take proactive measures to prevent attacks.

Digital Transformation in Manufacturing: Predictions for 2023

Aside from the evolution of established technologies like additive manufacturing, IoT, and so forth, the world can expect innovations or new game-changing strategies to come into play. It is rare for giant leaps to occur; technological development moves incrementally in its usual course.

Optimal technological development opens up new possibilities and paves the way for rapid and fundamental change, new theories and hardware, and conceptual thinking. And that’s how the manufacturing technology world is expected to progress in 2023.

The Industry 4.0 revolution will become even more widespread in the coming year. This will lead to the creation of smarter and more efficient processes. This also results in increased collaboration between different parts of the supply chain. Other aspects that will be redefining the Manufacturing and Distribution industry in 2023 include:

Emphasis on Cybersecurity: By 2025, the cost of cybercrime will cross the $10 trillion mark, while Gartner predicts 45% of global organizations will be impacted by cyber threats. As technology becomes more integrated, there will be a greater focus and increase in investment to protect sensitive data and systems.
Growing Acceptance of Servitization: For traditional manufacturing industries, the transition from selling products to selling services can be challenging, as it requires a change in mindset and business models. Overall, the acceptance of servitization is expected to continue to grow as companies look for new and innovative ways to meet the changing needs of their customers.
Recession Proofing: If it happens, the recession will check the industries’ preparedness to handle backlogs and talent gaps and manufacturers’ ability to deliver on their promises. In the coming year, an industry that thrives on in-person involvement will find ways to compensate by finding flexibility through compensation, flexible working hours, etc. Although the sector may slow down for a short period, we expect the downtime to be used for much-needed improvements towards recession-proofing the business- optimizing processes, clearing backlogs, and finding talent.
Investment in AI and Machine Learning: AI and ML will continue to attract major investment – and will be used to improve decision-making, optimize processes, and enhance customer experiences.
Increased Automation and Robotics: The trend of automation and the use of robots will continue to grow – helping manufacturers improve production efficiency, reduce costs, and increase accuracy.
Increase in Direct-to-Consumer (D2C) Sales: More companies will bypass traditional retail channels to sell their products directly to consumers. This will result in the growth of online sales, home delivery services, and mobile-based sales.

The Need for Technology Consulting Service Providers

Technology consulting service providers play an important role in helping organizations navigate the complex and rapidly evolving world of technology. They provide expert guidance and support in strategy development, implementation planning, process optimization, and technology selection.

A third-party consultant brings extensive expertise to get things done without disrupting the flow of a well-functioning business. Using automation, AI, Big Data, Data Analytics, and IoT, these consultants can help organizations provide remote technician support, enable integration between siloed systems, and capture real-time machine information to gauge performance. Consultants can also schedule timely preventive maintenance for machines and transform shop floor outcomes.

Uncover the Potential of Powerful Digital Transformation in Manufacturing

Data-driven transformative technologies are fundamentally reshaping manufacturing and product design. This is opening new ways to maximize operating profits and achieve sustainability. They will continue to empower companies to increase competitiveness and improve the process of digital transformation in the Manufacturing and Distribution Industry’s bottom line.