Breaking it Down: Building Blocks of Smart Manufacturing

A Smart Manufacturing company is a manufacturer with fully integrated solutions which empower it to be highly flexible and responsive
to changing conditions, with self-healing systems. Those capabilities enable a company to reduce costs, generate more revenue, and

increase their competitiveness in their market.

So how does it all work, and where do these capabilities come from?

The Nine Blocks that Stack Up to Smart

There are 9 technologies or building blocks that stack up to create Smart Manufacturing.

  1. IoT (Internet of Things): Taking data from sensors on machines, moving it over the internet, and converting it to valuable information to help people make decisions and drive action.
  2. Automation and robots: Using robots and software to enable machines and people to work together more efficiently.
  3. Big data: Storing and using massive amounts of machine data for data analysis to gain insights about operations and machines.
  4. AI (Artificial Intelligence): Using software tools to build models and algorithms which can learn about niche areas of your facility to distinguish between normal and critical conditions.
  5. AR (Augmented Reality): Viewing models or images overlaid onto the real world on a mobile device.
  6. Additive Manufacturing: Creating objects from 3D models by joining materials layer by layer.
  7. Modeling: Portraying or defining aspects of physical world in digital form for gauging equipment status, simulating operations, or controlling live systems.
  8. Cyber Security: Applying old and new ideas of encryption, protecting attack vectors, and combining digital with physical security tactics to protect data in motion and data at rest.
  9. Cloud: Moving away from local, on-site servers towards 3rd parties like Amazon, Google to store, service, and process data.

Stacking the Blocks

Each of these technologies can deliver value on its own. However, companies can realize exponential value by combining the technologies.

Here are a few examples:

     Predictive Maintenance

  • Technologies: IoT + AI
  • Method: AI experts create a machine learning model. IoT pulls data from machines and channels it through the model to assess probability that a part or whole machine may fail within a certain period of time.
  • Benefits: Clear identification of critical maintenance windows, resulting in up to 50% cost reduction by addressing issues only when needed but before failure.

     Robot Assisted production

  • Technologies: Robots + Automation + IoT
  • Method: A “human assistant” robot is programmed to work alongside people to handle repetitive and mundane tasks or sets of tasks. The robot is pre-programmed to handle multiple task sets. Input from IoT data (such as production data further up or down the line) directs robot to change its tasking based on real-time production needs.
  • Benefits: Increased production with existing staff and reduced pressure to hire/replace workers.

     Data-driven quality control

  • Technologies: IoT + Automation + Big Data
  • Method: Set up machines to test products immediately after a certain stage of production. Automatically analyze that data relative to product quality standards. Based on results, either trigger alarms for humans to intervene or have the equipment modify its own behavior appropriately to meet the required standards.
  • Benefits: Earlier notification of equipment problems, earlier identification of product quality issues, reduced waste and rework. Increased production of product to standards.

Choosing the Right Blocks

Some of the most exciting benefits of Smart Manufacturing come from the myriad and creative ways that new technologies can be combined and implemented. To find the right combination requires effort: thoughtful planning, employee input, and focus. But even small and mid-size companies can increase their competitive position, with access to the same building blocks as larger manufacturers.