Data and AI Solutions for Modern Day ManufacturingBlog by Glorious Insight
With digital transformation and technological revolution, AI has entered into all aspects of our lives and businesses. Almost all the industries are undergoing a technological shift with data and ai being the key drivers and manufacturing is not an exception. In fact, manufacturing is probably one industry that is utilizing the maximum potential of AI technology to optimize its operations and gain a significant improvement in outcomes. Studies have shown that 22-25% of businesses already have AI incorporated into their products and processes.
Technology-driven factories, formally known as smart factories 4.0, have experienced a remarkable boost with more friendly ties with the environment. Reduced downtime, faster transitions, better efficiency, enhanced product design and quality, and unparalleled workers' safety are a few well-recognized aspects that have radically progressed with AI.
Many manufacturing giants are heavily investing and increasingly relying on ai in the manufacturing industry to optimize their processes. Glorious Insight is committed to providing easy-to-use efficient AI solutions with machine learning that can put you much ahead of your competition. AI systems are only as useful as we can utilize the data. For that reason, we incorporate manufacturing analytics in AI-based automation and provide our clients deeper insight into product management, market trends, supply chain, and other critical aspects to draw useful conclusions from for improvement of business processes.
Digitization has made the market more volatile than ever. The customers’ demands and expectations are constantly changing forcing manufacturers to pivot their processes to adapt design, material, production, and packaging.
AI provides an edge to the manufacturing companies, that is essential to grow and adapt to these ever-changing demands. Studies have shown that the inclusion of AI is going to see the massive growth of 12% to 13% in the manufacturing market in the near future.
√ The challenge for the manufacturing industry
The manufacturing industry has been facing several challenges to maximize capacity and related to the supply chain. Manufacturers across the industry struggle to deliver quality and value products to the customer while pacing up the production processes. Despite having power manpower at hand, it becomes difficult to increase throughput and match up with the growing market demands.
This led to the major shift towards digitization. With technology coming into the picture manufacturers are now able to fully utilize the skills and knowledge of their people. Customers are drifting towards technology-based products that are mostly automated and accurate. This resulted in an explosive growth in the variety of products. To address this transformation, companies have to implement 'get it right the first time' strategy in production. This calls for including ai in the manufacturing industry. There is no room for errors and no time to waste in rectification and re-production.
Along with quality and variety, customers also demand cost-effectiveness. This means everything that is done in a manufacturing company must be done with maximum efficiency. To achieve this objective, cost-efficiency becomes inevitable which can only be achieved by mindful automation, precision in processes, and maximum utilization of resources. The emphasis the need for ai for manufacturing to ensure on-time and on-budget delivery of finished goods to the customer.
Major challenges that bothered the industry can be compiled in the following points.
• Demands for rapid and customized production
• Handling a wide range of products and numerous and diverse customer-base together
• The shorter time frame for production
• Revenue volatility
• Need for increased capacity and supply chain
• Flexible, adaptive, on-floor processes and continuous learning
• Maximum efficiency
• Upgrading conventional techniques
Despite automation to a certain extent, companies could not deliver a hundred percent efficiency. For instance, hard-code algorithms to identify good and defected items on the assembly line failed to adapt to the changes in products. This increased the percentage of false positives considerably, reducing efficiency and increasing cost. This is where the role of data and ai in manufacturing is realized and an industry shift triggered.
√ Introduction of AI as a game-changer
ai in manufacturing is considered a living digital technology that can adapt, learn, and grow with the changing market. Supporting manufacturing analytics helps industry leaders to overcome the challenges and support the evolving business needs and customers' expectations.
Many feared that the introduction of AI in the field will diminish the role of people. However, the reality is quite the opposite. People still remain the most valuable asset for manufacturers and are empowered with the capabilities of intelligent technology. They are enabled and encouraged to implement maximum innovation and creativity, boost productivity, and draw the highest job satisfaction.
Combining the power of data and ai with cloud-based architecture took the industry to new heights. By exploiting the advantages of machine learning and computer vision, companies could surmount the challenges and gain significant improvement such as:
• More efficient automation of processes
• Reduced error and early detection if there is any
• Scalable learning
• Greater value roles for skilled staff
• Company data leveraged to its fullest capacity
With the help of AI, identifying opportunities for improvement becomes easier allowing companies to constantly evolve their processes. This transition to AI-based automation has been rewarding for everyone including manufacturers, employees, partners, and customers. Nearly 55% of business executives assert that they have already achieved higher productivity with AI and data solutions. Companies are now producing more cost-effective batches, customizing on a just-in -time scale, and utilizing more efficient supply chains to map the market demands.
√ AI-based ecosystem for the manufacturing industry
The impact of ai in manufacturing is clearly visible and motivates all big and small companies to go for this major technological transition. However, the task needs technological proficiency along with domain expertise. For that reason, it is advisable to team up with the masters of the field to implement the AI solutions the right way. Companies need to associate with solution providers who can understand their needs and create a customized AI-based system that leads to the best outcomes.
The solution must extract the maximum potential of companies' data and adaptively improve the processes. While automating critical high-accuracy tasks, it should provide valuable insight into each step for continuous enhancement.
Implementing ai for manufacturing is a complex task. Glorious Insight provides manufacturing analytics solutions that incorporate the ideal mix of components. Our solutions include analytics technology, big data technology, cloud technology, and domain knowledge. We emphasize on analytics, as it is the heart of every AI solution and unleash the value of other elements.
Our experts pick the best in big data technology that creates a master pool of information and cloud architecture that forms a solid base for the solution. Having worked with many companies including industry leaders, our team is well-versed in the domain and in-depth understanding of the processes, challenges, and requirements. With the most suitable elements, glorious insight creates a powerful ecosystem for data and ai solutions that bring compelling improvements for manufacturing companies in all aspects.
√ Areas in manufacturing that AI is transforming
In the present day and age, more than 90% of seasoned manufacturing executives appreciate the role of data and ai in the manufacturing industry. They believe that smart factories have much higher productivity and authority with smart working. Experts acknowledge the impact of ai in manufacturing and suggest that the industry is likely to achieve a 35-40% increase in labor productivity by the end of this decade. They also believe that the manufacturing industry can see a 43-46% increase in GVA (gross value added) with the help of AI. The key areas in manufacturing that are experiencing radical enhancements including the following.
• Quality assurance
Product manufacturing can result in minute flaws that are often unnoticeable by naked eyes. Computer vision provides a super-sensitive vision to identify such microscopic flaws. Glorious Insight provides AI solutions that constantly monitor the production line and identify any imperfection. These systems can mark the product and generate alerts to initiate further actions. Automation of the entire process using AI dramatically reduce time and cost by early identification of defects.
• Failure mode prediction
To identify a problem and derive a viable and effective solution, having detailed information is a must to enable the right conclusions. Manufacturing processes are often complex. While analyzing a particular situation, it is common to overlook small details and misinterpret the fundamental cause of failure.
Products that look perfect can break down soon after first use while those that look flawed can perform well. Our perception of testing products and looking at defects is biased and unclear. ai in the manufacturing industry can utilize a large pool of information on how a product should be tested and performance using data analytics. This enables the system to accurately identify the problem area for efficient resolution.
• Predictive maintenance
Advanced analytics and technologies such as sensors are embedded in manufacturing machines to sense alerts and initiate resolving procedures. Predictive analytics uses machine learning to reduce unplanned downtimes of the machinery saving plenty of time, effort, and money.
• Flexible generative product designing
AI-based design systems use generative algorithms to produce several design outputs based on the given parameters and design goals. The algorithms are machine learning-enabled to learn from each iteration and optimize processes to develop the most suitable design for the product. The systems can generate hundreds of designs for every product. Human experts then can choose from these numerous options, a design that is most efficient and closest to customers' requirements.
• Environmental impact
The manufacturing industry has been ill famous for adversely affecting the environment. Release of various harmful chemicals increased production of plastic, and the high energy consumption is some of the factors leading to environmental degeneration.
Many global environmental leaders have accepted that the role of data and ai in manufacturing has significantly reduced energy consumption and the release of waste. AI has led to the development of a reformed manufacturing industry that is eco-friendly and highly energy-efficient.
• Price forecast
One of the most tricky tasks in manufacturing is estimating the price of the raw materials and determining the price of the finished goods. The price of the material is often fluctuating. For instance, a company using stainless steel to make its products needs to consider the price of stainless steel components such as nickel or ferrochrome. AI systems are provided with intelligence using machine learning algorithms to study the price pattern and deduce the possible rate with precision.
• Customer satisfaction
A large amount of customer data gets accumulated every day. It can be used to derive decisions for product quality, production frequency, feature demands, and other aspects to align production with customer requirements. Data analytics can capture, filter, segregate, and analyze the data to simplify its enormity and present it in a highly interactive and attractive form. The combined power of AI and data analytics provides new dimensions to decision making.
√ Steps for a successful AI implementation for manufacturing
The success of ai in manufacturing highly depends on the utilization of data. AI technology uses real-time information from each production process and enables more informed decision-making. It improves product quality and makes the processes more profitable. As the market trends, customers' requirements, and product quality parameters keep fluctuating, AI allows human experts to constantly monitor the system and adapt to the decisions.
Glorious Insight enables AI-powered manufacturing for the new age industry 4.0. We deliver systems that scale up decision quality, process efficiency, and customer service. Implementing AI solutions takes the following 4 steps.
• Build a data-enabled foundation for machine learning
The basis of automation is data analytics and data connectivity. The key to a successful machine learning implementation is the timely and accurate analysis of massive data that is generated by different machines and processes. Real-time data analytics gives an edge to the AI and ML systems with significant insight into operations optimization.
• Robust IT infrastructure
Gather, analyzing, and using huge volumes of data in real-time and deploying artificial intelligence for inferences, decisions, and actions need a solid customized infrastructure. Cloud-based architecture is a must to cope with the wide range of data sources, gigantic datasets, and the need for super connectivity.
• Filling the skill gaps
The transformation that comes with ai in the manufacturing industry necessitates constant learning for staff. Employees must be retrained and reskilled to cope with technological advancement. Glorious Insight provides user-friendly AI solutions and prefers to include familiar technologies or technologies with familiar interfaces for simplified usage.
• Long-term planning
Transformation to AI and automation is a constantly evolving process. It takes several years to reach a fully automated AI-based working. Manufacturers need to prepare for a long-term transition process that keeps evolving with time and adapts to continuous business growth.
√ Adapting to changing market with AI
The impact of ai in manufacturing is not limited to the processing of the production floor. It is the central pillar for the industry 4.0 revolution that is transforming the industry comprehensively. Along with production, AI also optimizes the supply chain and market research that helps the companies to move from responsive thinking to a strategic mindset.
Data and AI can conduct a holistic analysis of various factors such as geography, demography, customer behavior, politics, socio, and macroeconomic factors, etc. It helps in accurate market estimation and optimization of operations. With the help of internal and external data analytics and intelligent automation, manufacturers can foresee upcoming challenges and ensure quality products and services in any condition. It also helps in inventory control, staffing, raw material management, and energy consumption.
√ Implementing an AI-based manufacturing solution with Glorious Insights
Using data and ai for manufacturing automates several complicated tasks and provides useful signals that drive fact-based decision making. From equipment performance and product quality to services and monetization, advanced AI and data analytics unlocks new opportunities and insight across the manufacturing industry.
Glorious Insight is equipped with state-of-the-art technology and domain experts who carefully design and strategically implement AI and data solutions. We deliver solutions that allow you to achieve your production and profitability goals with greater efficiency. We make deliberate efforts not only to get the right technology, but also to reduce complexity, increase margins, reduce risks, and find and create innovative income sources for our clients. Some key advantages that you can draw by collaborating with us for AI and Data solutions are:
• Predictive maintenance resulting in cost reduction
• More efficient supply chain
• Improved quality control
• Accurate prediction of RUL (remaining useful life)
• Consumer-focussed production
• Better human-robot interaction
Our embedded AI capabilities are based on powerful platforms and solutions. This gives confidence to our clients to predict, prevent, identify, and resolve issues related to quality and reliability. Our system extracts useful data from diverse sources and delegates deeper insight into it to govern your productivity improvements. Our systems provide anytime anywhere control and decision making that can be extended across the enterprise in no time.
Gone are the days when humongous datasets and artificial intelligence were a part of the fiction. With over 80% of businesses accepting artificial intelligence to be a strategic priority, technologies like data analytics and AI have turned these concepts to reality. These world-changing technologies are leading the revolution of the manufacturing industry.
Companies must begin a systematic implementation and development of AI and data-driven solutions to survive and remain relevant in the industry 4.0, the next generation industrial system. Utilizing the full potential of industry data and using intelligent solutions can help you overcome all the challenges and lead the new frontier.