The Paradigm of Modern Manufacturing
We live and deliver our solution in a paradigm where different layers of manufacturing are developing through various stages of industrialization, automation, and digitization.
Due to time compressions, Industry 3.0, 4.0, and 5.0 often coexist within the same industrial park, frequently becoming stakeholders to one another. This coexistence depends on numerous parameters and factors and is crucial to consider when discussing general market trends.
Mature companies often position themselves as leaders, promoting and spreading trends while pushing “younger” companies by enforcing supplier or industrial compliance. At the same time solution suppliers and consultants must navigate this complex paradigm, providing solutions that connect all the links within the intricate product cycle.
Any solution should first and foremost satisfy customers’ needs. But sometimes it seems that technology advances ahead of these needs, creating gaps between primary requirements and the solutions that market leaders push to implement.
To once more synchronize with our environment and company pain points, we conducted our own research. We were not focusing on global plans or trends but instead asked our contacts about the nature of their current challenges. The research is not divided into personas, but we primarily engaged with the operational level to get an accurate picture of what is happening on the shop floor for manufacturing of different sizes.
That’s why we decided not to ask if they are planning to enhance the level of automation they currently have (spoiler – they are) but instead to identify the main values they see from that process and the most impactful factors they can highlight.
Main Research Results
What are the main values of automation?
The leaders in answers have been split between resource optimization (read: saving money) and meeting customer compliance (read: earning more money). While global trends and C-level discuss transparency, labor, and the role of sustainability, the main goals at the plant level still revolve around money.
If cost-saving is the primary reason for digitization, let’s examine where plants incur losses.
Which losses are the most impactful and cost production the most?
The top three areas for losses are unplanned equipment downtimes, quality defects, and inefficient maintenance which leads to equipment breakdowns. Unplanned downtimes can cause significant disruptions in production schedules, leading to delays and increased operational costs. Quality defects not only result in wasted materials and resources but also damage the company’s reputation and customer satisfaction.
These problems are not only costly but also challenging to predict and prevent without the right tools and strategies in place. Lots of these issues are caused by Inefficient processes, such as bottlenecks and miscommunication. Further, compounding it by reducing overall productivity and increasing labor costs. The operational teams are constantly looking for effective solutions to mitigate these losses and improve their production efficiency. That`s why we decided to learn where teams usually look for solutions.
What solutions do you believe will be most effective in addressing these challenges?
The most popular answers just confirm our assumptions in this case. The winner is real-time visualization and instant communication within departments. These two processes help to address the unplanned downtime issue and improve the pace and the smoothness of the flow in general.
Real-time visualization provides a clear picture of the production process, enabling quick identification and resolution of issues. Instant communication ensures that all departments are aligned and can respond rapidly to any changes or problems. Together, these solutions enhance the overall efficiency and effectiveness of the manufacturing process, leading to significant cost savings and improved product quality.
When we asked what else can be valuable for the production process or what has been probably missed, we got the following answer – Safety and Labor.
The global trend for labor resources tells us that in the next decade, it will be more and more challenging to find, educate, and retain shop floor-level personnel. The tools that allow the production process to be easy to use, safe, and cooperative become more relevant and important. Enterprises already can experience the issue of the ongoing shortage of skilled labor (https://www2.deloitte.com/us/en/insights/industry/manufacturing/manufacturing-industry-outlook.html), especially in some regions.
Embracing Digital Transformation
When it seems that your partners or competitors are thinking big while you’re still struggling with reducing downtimes or scrap, don’t worry – this is normal. Look for optimal solutions that allow you to track all processes and receive timely notifications; in this case, every minute or even second can matter. These solutions should not be always expensive or custom-made. That’s why AGW offers highly flexible systems that allow you to try them on one station first and then adapt and expand gradually. And besides technology itself is pretty complex, so innovation sometimes isn’t about inventing something new but about adapting existing solutions to multiple roles.
Robotics, AI, and VR are prevalent topics at any manufacturing trade show. Eventually, they will touch nearly every aspect of not just manufacturing but also our everyday lives. As the industry moves forward, it is crucial to remember that technology should not only advance but also align with the actual needs of the users. This alignment ensures that the solutions provided are not just innovative but also practical and beneficial.
Digital transformation simultaneously inspires and intimidates industry representatives and our customers, as it often entails significant process changes and costs in terms of both time and money. Through close collaboration with partners and continuous study of industry trends, we ensure our roadmap is aligned with the latest developments. Given all the challenges, needs, and values expressed by our customers, we strive to build our products with flexibility in mind.
Ultimately, aligning technology with the real-world challenges faced on the shop floor is essential for driving meaningful progress. Focusing on practical, cost-effective solutions will ensure that innovations provide genuine value. By remaining adaptable and responsive to these core needs, we want to bridge the gap between advanced technology and everyday operational demands and reduce the cost and the pain of the transformation.
