This image illustrates a factory with smart technology. The image represents the benefits of smart manufacturing.

3 Vital Benefits of Smart Manufacturing

3 Vital Benefits of Smart Manufacturing

There’s an extensive list of smart manufacturing benefits and many ways that smart manufacturing can add value to a company. Today, there is a “smart” everything and manufacturing companies are not getting left behind on this trend. Technology continues to advance at a quick pace in the 21st century. We have smartphones, smart TVs, but that’s old news at this point. Now we have smart lightbulbs, smart toasters, smart dental floss dispensers. Yeah, I’m not kidding, go ahead and look it up yourself.

10-15 years ago, you didn’t need to have a smartphone. It was cool to have and useful to a lot of people, but you weren’t weird or behind the times if you didn’t have one. Flash forward to today, you are completely lost without a smartphone. Can’t do a quick google search from your pocket-sized computer? Can’t check your email? Get directions anywhere in the world? We can’t live without these things today. Smartphones started as a cool option for people that wanted to spend a little extra money, now nobody can function without them.

Old phone showing how the world has changed into a "smart" everything.My point being, the world is getting digitized, the world is getting “smart.” The manufacturing sector is no exception. Many manufacturers still choose to ignore the benefits of smart manufacturing, IIoT, and Industry 4.0, and those are ones that will get left behind. Just like that big, bulky Nokia 3310 you used to carry around.

In this article, I will go over a few key benefits of smart manufacturing that you should be implementing in your factory today so that you can “future proof” your company.

1. Increased Plant Floor Efficiency with Real-time Data

Every manufacturer needs to focus on increasing efficiency. Nobody has a completely perfect process, or anywhere near one. There will always be places to squeeze out more throughput, increase capacity, cut back on downtime, etc. Manufacturers need to have a continuous improvement mindset. Be proactive about making improvements on the plant floor, and establish that type of culture among the company.

  • Make Quick Decisions and Take Action

It’s really hard to make improvements that actually help when you don’t have much substance or information to base your decisions on. Furthermore, it’s tough to measure success without seeing the numbers. How do you really know if the adjustment you made helped or not? If it did help, how much did it help?

This is where smart manufacturing benefits you and can step in to lend a hand. IIoT and manufacturing analytics systems are smart manufacturing solutions that are equipped with the ability to deliver real-time data. Real-time data gives you the substance to make quick decisions and then act on those decisions to make quick adjustments on the plant floor. Then, measure the success instantly with, again, real-time data.

  • Don’t Get Stuck in the Past

Don't get stuck in the past, focus on the future.

Think about how long this process would take as well as the accuracy if you had to have someone manually gather basic data on the plant floor, and deliver that basic, hopefully accurate data to a decision-maker in a somewhat timely manner. Sort of? hopefully? That data is getting there many hours, if not a couple of days later.

This is one of the major benefits of smart manufacturing, this process can be streamlined. These types of solutions are what the “trendy” manufacturers are turning to. As I said previously, some other manufacturers are willingly choosing to ignore these advancements in technology. Soon, it won’t be “trendy”, it will be the standard. Companies will either have to adapt and change to the new ways of manufacturing, or they will watch competing companies continue to grow past them. There is always someone out there willing to do your job better, cheaper, and faster, and today, the tools are readily available for people to take advantage.

Just like the smartphone example. Yes if you have a “dumb” phone, you could drive to a gas station, buy a map, and then go find where you are trying to go. Or, with a smartphone, you could type your destination address in and be on your way in 10 seconds. It’s the same concept with smart manufacturing.

data delivered instantly in real-time, nobody walking around the shop floor handing out information, gathering information, no operators stopping work to write down their data during a shift. Not only is this a slow and inefficient process, but it’s also poor communication, how often does that data get to anybody else on the plant floor? especially in a timely manner for that data to actually be useful.

2. Seamless Communication

Our second key smart manufacturing benefit is communication. This is one that not many people really talk about or make a big deal about. However, smart manufacturing revolutionizes the way people communicate with workmates, customers, machines, and data.

This image illustrates communication, seamless communication is one of the key smart manufacturing benefits.

Here’s why this is so important. Wasted time and wasted motion = lost production and an efficient process. This goes against lean principles, and every manufacturer should strive to become a lean manufacturer. Strive to eliminate waste and create a highly efficient environment. Smart manufacturing can have a large impact on a variety of different communication scenarios such as:

Machines to Employees:

  • Machines deliver data in real-time, constantly delivering information to operators and other employees. This information is instantly made available to each person within the company. 

Employees to Machines:

  • Employees and operators can consume real-time data to make a data-driven decision and make adjustments on the plant floor. 

Sales team to Customers: 

  • When customers call for an update on their job or a progress update, the sales representative can look at the data in real-time and give the customer an extremely accurate data-based answer with detail on how much is done, how much is left, and when they can expect delivery. With every metric being updated in real-time. 

The communication benefits of smart manufacturing are tremendous and will undoubtedly save you a headache here and there, create a more knowledgeable staff, and improve customer relationships.

Before you start tracking these types of processes, you likely don’t realize how much time and money you could be saving. We have come across clients that have told us that they have people in the company that are consistently spending half of their day running around the plant floor trying to find a certain order for a customer. What a waste of valuable time!

With a smart manufacturing IIoT / Manufacturing analytics solution, you can give customers accurate real-time adjusted numbers instead of giving a rough estimate based on your best judgment, or going to run around the shop floor to deliver an answer a few hours later.

Efficient processes = more production, more production = more time for more clients, good communication = happy customers, happy customers = return customers, and all of this = more revenue in less time.

3. Smart Manufacturing Creates more JobsThis picture illustrates the workforce problems in manufacturing.

Some people will say that automation is going to take over human jobs in manufacturing and that IIoT is going to turn everything into an automated process putting everyone out of work. This is not the case at all. While it is true that there are some jobs that will likely be largely handled by machines, IIoT and smart manufacturing creates more jobs.

It’s no secret that there is a shortage of skilled employees in the manufacturing sector. The industry is filled with a lot of people closing in on retirement. Furthermore, there isn’t a large number of young people that want to go into the manufacturing industry. What do young people want? Tech jobs (source). There is a lot of young people that want to do something related to tech. That is where everything is headed, technology drives our world today. Correspondingly, what will all of these smart manufacturers need? They will need people to fill these new jobs created by smart manufacturing and smart factories. See where I’m going here?

Manufacturers will have new needs for people who can work with new technology, software, and data.

So, no, smart manufacturing and IIoT are not going to take away manufacturing jobs. It is creating new, different jobs, jobs that might be more appealing to the younger generation. These new jobs will help boost up the manufacturing workforce, which desperately needs the help.

These three benefits of smart manufacturing are huge, and they are shaping the future of the industry. Start implementing them today. Put yourself ahead of the curve and don’t get stuck in the old ways of manufacturing.