Today’s revolution is the digitisation of the manufacturing industry, powered by advancements such as the Industrial Internet of Things (IIoT), robotics, augmented reality, and artificial intelligence. These next-generation technologies help to improve productivity and safety, reduce downtime and increase energy efficiency. Read on to learn how some of these tools work when applied to industrial environments, and how they can benefit businesses now and in the future.
The Industrial Internet of Things
IIoT is formed by connected devices, sensors and computers which collect and analyse data in manufacturing environments; helping to reduce waste and inefficiencies. Machine-to-machine communication (M2M) and sensors create an environment where IIoT can prosper. Businesses are already using IIoT and automation to monitor internal environments of production facilities and minimise energy use to lower manufacturing costs. By using devices like smart helmets to communicate with manufacturing equipment, safety and working conditions can also be improved. Industry 4.0 is the heart of smart manufacturing, allowing large amounts of data to be stored and processed in the cloud. This means whether they’re on or off-site, manufacturers will be able to monitor, maintain and adjust equipment with complete accuracy without stopping production. This is assisted by open source devices and software, which enable greater control and flexibility over processes through the use of computer programming. This is because the software has source code that anyone can inspect, modify, and enhance – the code computer programmers can manipulate to change how a program or application works. IIoT is changing the industrial landscape in many ways, and its impact will only continue to increase.
Robotics is on the rise
Robots are becoming an increasingly popular way of completing dangerous or repetitive tasks without human involvement. Not surprisingly, the International Federation of Robotics (IFR) predicts that more than 1.7 million new industrial robots will be installed in factories worldwide by 2020. IIoT enables robotic hardware to be smarter, faster, and more aware. Combined with sensors, a mobile robot could, for example, identify when a worker is in the area and slow or stop production to allow for input. This type of robot, known as cobot, collaborates with humans and one another to work more intelligently. There’s an expansive range of robots available – from basic arms to autonomous vehicle-mounted machines. They’re becoming more common in some of the world’s major manufacturing industries, including food and beverage, pharmaceuticals, aerospace and construction. Automation with robotics enables a level of accuracy and productivity beyond human ability. Plus the new generation of robotics is not only much easier to program, but easier to use, with capabilities like voice and image recognition.
Augmented reality in real life
With Industry 4.0 and intelligent manufacturing, more consideration is being given to the value of augmented reality (AR) for industrial applications. New tools are enabling companies to create and test scenarios in the virtual world – simulating the design process and assembly line prior to a product being created. AR has the potential to recharge the manufacturing industry by connecting workers with equipment and allowing them to interact with sensor data. The technology aims to produce efficient operations by reducing production downtime, quickly identifying problems and keeping processes running. This can be achieved through AR glasses which overlay virtual reality onto the real world. With this, engineers can see renderings of bolts, cables, part numbers and instructions on how to assemble a specific component. It’s also possible to use AR-enabled mobile apps to scan QR codes to view live video, graphics, images, or use it to repair machines. Many manufacturers have begun to explore the benefits augmented reality can offer in an industrial environment, a trend that has nowhere to go but up as AR hardware and software improves.
Artificial intelligence and machine learning
Artificial intelligence (AI) systems show information relating to a machine’s condition and productivity, as well as detect irregularities and make it possible to learn from experience and perform humanlike tasks. Meanwhile, machine learning is a subfield of AI which uses statistical techniques to give computers the ability to ‘learn’ with data. Machine learning is much faster than humans, as it can analyse immense amounts of data in real-time and turn it into actionable improvements; helping speed production and lower costs by avoiding errors. With AI and machine learning, manufacturers can use more of their production capacity and optimise the best possible combination of machines, staff, and suppliers. The technology can also be used in cobots, allowing for a robot to not only safely work alongside humans, but also be easily reprogrammed for new tasks – unlike traditional industrial robots which rely on extensive programming for each action. One of the greatest benefits is increased uptime and productivity from predictive maintenance. With AI integrated with industrial robotics technology, machines can monitor their own accuracy and performance and signal when maintenance is needed to avoid expensive downtime. The use of AI and machine learning can enhance performance across all areas of a supply chain including warehousing, transportation, customer feedback, production, and packaging.
What the future holds
With half of the manufacturers in the region expected to have smart factories by 2022, it’s evident the landscape of industrial automation is changing.