Intelligent

Manufacturing:The
Future of Production
An Overview Debarghya Jash May 12, 2024
Agenda
•Introduction to Intelligent Manufacturing
•Evolution of Manufacturing
•Key Concepts in Intelligent Manufacturing
•Technologies Enabling Intelligent Manufacturing
•Benefits of Intelligent Manufacturing
•Challenges in Implementing Intelligent Manufacturing
•Case Studies
•The Role of Artificial Intelligence
•The Internet of Things (IoT) in Manufacturing
•Digital Twins and Simulation
•Cybersecurity in Intelligent Manufacturing
•The Impact of Intelligent Manufacturing on Supply Chains
•Intelligent Manufacturing and Sustainability
•The Future of Work in Intelligent Manufacturing
•Skills and Training for Intelligent Manufacturing
•Intelligent Manufacturing and Global Competitiveness
•Intelligent Manufacturing in Different Industries
•The Role of Standards and Regulations
•Collaboration and Ecosystems in Intelligent Manufacturing
•Intelligent Manufacturing and Customer Experience
•The Role of Big Data in Intelligent Manufacturing
•Intelligent Manufacturing and Product Customization
•Conclusion
Introduction to Intelligent
Manufacturing

Let's start by defining some key concepts. Intelligent Manufacturing is

linked to the idea of the fourth industrial revolution (aka Industry 4.0).
The key Industry 4.0 components that make Intelligent Manufacturing
possible are artificial intelligence, machine learning, the Internet of Things
(IoT) and the cloud. Essentially, Intelligent Manufacturing is defined by
real-time communication between connected devices using embedded
sensors and cloud-based software, coupled with machine learning and
powerful data analytics, creating a more sophisticated level of visibility and
flexibility.
Ultimately, Intelligent Manufacturing is about a lot of little pieces that fit
together to create a much greater (and smarter) whole. Together, these tools
make it possible for manufacturers to operate in a way that's proactive
rather than reactive, and spend more time looking ahead.
Evolution of Manufacturing
The First Industrial Revolution began in the 18th century through the use of steam power and mechanisation of production. But in the 19th century, the invention of
electricity brought about the Second Industrial Revolution.

Henry Ford (1863-1947) took the idea of mass production from a slaughterhouse in Chicago and carried over those principles into automobile production. While
before one station assembled an entire automobile, now the vehicles were produced in partial steps on the conveyor belt - significantly faster and at lower cost.

The Third Industrial Revolution began in the ’70s in the 20th century through partial automation using memory-programmable controls and computers. This
later paved way for Industry 4.0,which is characterised by the application of information and communication technologies to industry.

Industry 4.0 builds on the developments of the Third Industrial Revolution. Production systems that already have computer technology are expanded by
a network connection and have a digital twin on the Internet so to speak. These allow communication with other facilities and the output of information about
themselves. This is the next step in production automation. The networking of all systems leads to "cyber-physical production systems" and therefore smart
factories, in which production systems, components and people communicate via a network and production is nearly autonomous.

Industry 4.0 has the potential to deliver some incredible advances in factory environments and has the power to change the way that people work. The digitalization of
the manufacturing environment allows for more flexible methods of getting the right information to the right person at the right time. The increasing use of digital
devices inside factories and out in the field means maintenance professionals can be provided with equipment documentation and service history in a timelier manner,
and at the point of use. Maintenance professionals want to be solving problems, not wasting time trying to source the technical information that they
need.The digitalization of manufacturing will change the way that goods are made and distributed, and how products are serviced and refined.
Key Concepts in Intelligent
Manufacturing
1.Smart 2.Automation 3.Real-time
factories and robotics data analytics
A cyber-physical The use of computers, The use of data and
system that uses control systems and related resources for
advanced information technology analysis as soon as it
technologies to to handle industrial enters the system
analyse data, processes and
drive automated machinery, replacing
processes, and manual labour and
learn as it goes. improving efficiency,
speed, quality and
performance.
Technologies
Enabling Intelligent manufacturing

Key Technologies
Enabling Intelligent
Manufacturing
Challenges in Implementing
Intelligent Manufacturing

i) Advance Technical Skills Gap – Running a smart factory requires highly skilled labour having adept knowledge of
technology and data handling.Industry week magazine reports 36% technical skills gap hurdles industries from reaping benefits
from investment in smart factory.
ii) Inaccurate Change Management –The success of smart factory initiation and implementation depends on the clear
delineation of requirements, definition of project scope and elaborate description of the procedures for management of change
throughout the various departments of factory operations.
iii) Insufficient Senior-level Input – Large-scale implementation is inevitable and inputs from all senior-level boards are
required for a successful implementation and business plan thereafter in a smart factory. With the change that affects each
department, some senior-level employees might be hesitant to provide sufficient inputs for effective smart factory
transformation.
iv) Unrealistic Expectations – Industry stakeholders and management might have personal opinions on the requirements and
expectations of smart factory implementation. In their vague understanding and perspectives, unrealistic scheduling of resources
and expectation of an overnight digital transformation can be challenging.
v) Opting the Wrong Technology Partner –Before picking a technology partner, make sure to assess the product offerings
and support they provide. Be sure that the technology partner has both, the operational and technical experience of implementing
smart factory and overseeing a project that suits your corporate culture.
Role of Artificial Intelligence
AI in the manufacturing industry plays a key role in
improving productivity, efficiency, and decision-making
processes. AI-driven predictive maintenance is used in
production to optimize maintenance schedules and minimize
downtime by analyzing equipment data to anticipate possible
faults.

Supply chain management is made more efficient by machine

learning algorithms, which estimate demand, control
inventory, and simplify logistics. Robotics with AI enables
automation on assembly lines, enhancing accuracy and speed
while adapting to changing production demands.

AI-powered QC systems find flaws more accurately,

guaranteeing consistency in the final product. It is also used in
smart manufacturing to monitor processes in real-time and
make immediate adjustments to maximize efficiency and
reduce waste.
The Internet of Things (IoT) in
Manufacturing
IoT encourages seamless connectivity of equipment, systems, and devices
involved in an operation. The concept of Smart Manufacturing is majorly driven
by the Internet of Things. When it comes to manufacturing, it is often known as
the Industrial Internet of Things or IIoT. More than 65% of first-mover
manufacturers find IoT essential in gaining a competitive advantage. By 2020,
total IoT spending is expected to mount to nearly $70B in Smart Manufacturing.
These studies are quite evident that technology is making advancements in the
industrial sphere where its applications directly, positively impact revenue. The
manufacturing industries where IIoT is expected to make prominent shifts are
machinery, automotive, food, and beverage, pharmaceuticals, etc.

The process of manufacturing encompasses different operations, products,

processes, components, people, machines, partners, activities, and information
systems. The entire supply chain and logistics are massively dependent on
decentralized production, a significant decrease in errors, rise in accuracy and
maximized throughput by automation of data influx. It is very important if we
are to witness a 50% reduction in the product development cost. It is, indeed, a
technological breakthrough of Industrial Internet of Things and the critical
success factor for a Smart Factory.
Digital Twins And Simulation
Digital twin in manufacturing is a virtual replica of a physical
product or space, including warehouse, factory floor layout,
machinery, or systems created using real-time data from sensors
and IoT devices. They represent digital replicas that give access
to the manufacturing facility for training, touring, and planning
without safety hazards, disruption risks, or travel.

Digital Twins can be used for –

•Immersive, low-risk training

•Dimensionally accurate space planning
•Intuitively locating maintenance and repair
documentation
•Global site visits and inspections without travel
•Welcoming tours and guests virtually
Cybersecurity in Intelligent Manufacturing
Manufacturing advancements bring forth unprecedented opportunities for improving innovation and efficiency. However, it can be a double-
edged sword. Emerging manufacturing technologies heavily depend on IoT, AI, and Digital Twins consequently exposing these advanced
manufacturing environments to heightened cybersecurity vulnerabilities.
The Impact of Intelligent
Manufacturing on Supply Chains
Studies suggest that AI and Machine Learning (ML) technologies can deliver unprecedented value to supply chain and
logistics operations. According to McKinsey, 61% of manufacturing executives report decreased costs, and 53%
report increased revenues as a direct result of introducing AI in the supply chain.
 By implementing AI in supply chain and logistics, supply chain managers can enhance their decision making by
predicting building-up bottlenecks, unforeseen abnormalities, and solutions in order to streamline production scheduling
that otherwise tends to be highly variable.Furthermore, AI in supply chain can also lead to accurate predictions and
quantification of expected outcomes across different stages of the schedule enabling the scheduling of more optimal
alternatives as and when such interruptions occur during execution.
 AI-lead supply chain optimization software amplifies important decisions by using cognitive predictions and
recommendations on optimal actions.This can help enhance overall supply chain performance. It also uncovers possible
implications across various scenarios in terms of time, cost, and revenue. Also, by constantly learning over time, it
continuously improves on these recommendations as relative conditions change.
 Having a cognitive AI-driven automated platform offers a single virtualized data layer to reveal the cause and effect, to
eliminate bottleneck operations, and pick opportunities for improvement. All of this using real-time data instead of
redundant historical data.
 Cognitive automation that uses the power of AI has the ability to sift through large amounts of scattered information to
detect patterns and quantify tradeoffs at a scale, much better than what’s possible with conventional systems.
The Impact of Intelligent
Manufacturing on Supply Chains
 When supply chain components become the critical nodes to tap data and power the machine learning algorithms, radical
efficiencies can be achieved. The value is realized through the application of machine learning in price planning.The increase or
decrease in the price is governed by on-demand trends, product life cycles, and stacking the product against the competition.
This data is priceless and can be used to optimize the supply chain planning process for even greater efficiencies.
 When applied to demand forecasting methods, AI & ML principles create highly accurate predictions of future demand. For
example, forecasting the decline and end-of-life of a product accurately on a sales channel, along with the growth of the market
introduction of a new product, is easily achievable.Similarly, ML & AI in supply chain forecasting ensures material bills and
PO data are structured and accurate predictions are made on time. This empowers field operators to maintain the optimum levels
required to meet current (and near-term) demand.
 AI in supply chain and logistics provides real-time tracking mechanisms to gain timely insights including the optimal times by
where, when, and how deliveries must and should be made.Such powerful multi-dimensional data analytics further aids in
reducing unplanned fleet downtime, optimizing fuel efficiencies, detecting and avoiding bottlenecks. It provides fleet managers
with the intelligent armor to battle against the otherwise unrelenting fleet management issues that occur on a daily basis.
 AI in supply chain and logistics helps streamline the ERP framework to make it future-ready and connect people, processes, and
data in an intelligent way. Finally, when AI is correctly implemented on ERP and related data systems, data becomes more
receptive and event-driven over time, while processing greater amounts of data, to intelligently learn, quantify, rank, and
prescribe remedies proactively and more frequently over time.
Intelligent Manufacturing and
Sustainability
Intelligent manufacturing offers opportunities for green technology innovation at a low cost, helps eliminate outdated
equipment, and improves pollution efficiency, which is essential for environmental protection.

Sustainable manufacturing is the creation of manufactured products

through economically-sound processes that minimize negative
environmental impacts while conserving energy and natural resources.
Sustainable manufacturing also enhances employee, community and
product safety.

Elements of Sustainable Manufacturing

Manufacturing cost – or the amount used to manufacture the product;

Power consumption – the amount of energy used to produce;
Waste management – how the waste is disposed, re-used, or recycled;
Operational safety – how it ensures the safety of production process;
Personnel health – how it ensures that workers in the operations aren’t at
risk;
Environmental friendliness – how it ensures that the product is not
environmentally harmful.
The Future of Work in Intelligent
Manufacturing
The future of work in manufacturing is a nuanced interplay between technology and human expertise. As automation and AI
reshape the industry, it's imperative for manufacturers to not only invest in cutting-edge technologies but also their most
valuable asset—their workforce. First, we talk about how AI can enable smart manufacturing as follows -
• Predictive Maintenance Precision: AI algorithms analyze equipment data to predict when machinery is likely to fail. This enables
proactive maintenance, reducing downtime and extending the lifespan of machines.
• Energy Efficiency Optimization: AI analyzes energy consumption patterns in manufacturing processes. It can identify opportunities for
energy savings, contributing to both cost reduction and environmental sustainability.
• Supply Chain Intelligence: AI enhances supply chain management by predicting demand, optimizing inventory levels, and identifying
potential disruptions. This results in streamlined operations, cost savings, and improved customer satisfaction.
• Real-time Decision-Making: AI processes data in real-time, enabling quick and informed decision-making. This is particularly valuable
in fast-paced manufacturing environments where swift responses to changing conditions are critical.
• Customization at Scale: AI facilitates mass customization by analyzing customer preferences and production capabilities. This enables
manufacturers to tailor products to individual customer needs without compromising efficiency.
• Collaborative Design Assistance: AI assists in the design phase by providing insights and suggestions. It can analyze design iterations,
considering factors like material efficiency, cost-effectiveness, and manufacturability.
• Regulatory Compliance Assurance: AI systems can monitor manufacturing processes to ensure compliance with industry regulations
and standards. This reduces the risk of non-compliance, associated fines, and reputational damage.
Skills and Training for Intelligent
Manufacturing
Next, we must talk about the importance of the following skills to manuever in the era of Industry 4.0 as
a worker -
1. Digital Tools - We want to be able to hone your abilities to use new systems, technologies, platforms, and software for digital data and AI
tools.
2. Programming Manufacturing Devices – As technology and artificial intelligence continue to develop, there is less of a need for
employees to operate and manually run machines. Instead, the needs of the factory have shifted to employees who can program machines
and manufacturing devices.
3. Robotic Monitoring - Robotics skills could include the ability to program or repair robotic systems, program automated systems, and
monitor robotic and machine performances over time.
4. Critical Thinking, Problem Solving and Communication - Human skills like communication,complex problem solving and critical
thinking are required to analyze and solve problems in the workplace, quickly resolve issues, troubleshoot problems, and respond to
developments or complications with accuracy.
4. Lean Manufacturing – We must know when to take a step back and evaluate the big picture processes in place to think more strategically
about the processes in use, and find opportunities to make them smoother and more efficient. Learning about lean manufacturing can help to
find and eliminate areas of waste in a factory without sacrificing product quality.
5. Creative Product Design - Creativity in the manufacturing workplace is important, especially when it comes to designing new products.
Intelligent Manufacturing in
Different Industries
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Timeline
Summary
References

 https://www.researchgate.net/figure/Key-enabling-technologies-of-Industry-50_fig4_353555332
 https://www.collidu.com/presentation-intelligent-manufacturing
 https://www.fogwing.io/smart-manufacturing/smart-factory-implementation/
 https://www.wildnettechnologies.com/role-of-iot-in-smart-manufacturing-iiot/
 https://1drv.ms/p/s!Ai7Wt-F04lcNhWRr0ev5xZUrTlh8?e=9DMqCJ
 https://www.epa.gov/sustainability/sustainable-manufacturing#:~:text=Sustainable%20manufacturing
%20is%20the%20creation,employee%2C%20community%20and%20product%20safety.
 https://www.linkedin.com/pulse/future-work-manufacturing-adapting-automation-ai-taha-j--lru5f
Thank you