IBM: the potential of smart manufacturing
As the world rapidly evolves as industry 4...
Manufacturing Global gains insight into the potential Industry 4.0 can provide to the manufacturing industry.
As the world rapidly evolves as industry 4.0 continues to innovate the business world, companies are experiencing an unprecedented amount of information and insights.
This is no different for the manufacturing sector. Over the last decade, low-cost sensors and high tech analytics have been providing manufacturers with new levels of visibility, resulting in increased production and reduced downtime.
IBM highlights that now with the addition of artificial intelligence (AI) and cognitive manufacturing, “industry 4.0 is creating a whole new realm of possibilities” for companies to improve their operations from their suppliers to the factory floor and customers.
IBM stresses that It is no understatement that the transformations being seen within the sector are anything short of revolutionary. The leverage of high volume data combined with advanced tools in order to improve business functions is providing significant benefits. With smarter manufacturing, plant operations will see increased efficiency, fewer failures, greater outputs, increase productivity, happier customers, optimised assets and inventory, and improve equipment and processes. In smart manufacturing, solutions learn and interpret patterns and related outcomes, which will improve fault predictions, security and productivity over time.
However, according to a study on AI in the industrial sphere conducted by the company, 1 TB of production data is created daily by an average factory, however, less than 1% is actually being analysed by manufacturers. Therefore although the potential of industry 4.0 is there, a vast majority find themselves with vast amounts of data, but limited insights.
It is also important to remember that with this increased insight, companies need to have the ability to execute a remedy to mitigate any issues. Something which IBM says “will set successful industry 4.0 solutions apart from previous systems.”
In today's manufacturing, many challenges can be categorised as disruption, the core of this disruption is the sectors shift from an aligned value chain of few suppliers and geographical restrictions to one that is fragmented, dynamic, uncertain and global
Image: IBM global challenges then and now
Although the potential of globalisation provides more opportunities it also comes with its challenges, ones which continue to increase as time goes on. With competitors, customers and suppliers coming from all over the world, manufacturers face varying challenges including political disruption and climate change.
Political issues can lead to currency fluctuations which can increase costs or decrease profits
Privatisation and coming under government control can lead to insatiable global markets
The efficiency of ports, varying standards and enforcement of customs can cause trading barriers
Material costs, wages, quality standards and many other variables can also complicate the manufacturing process
Changing environmental legislation can impact manufacturing standards between countries, provinces, states or cities
Erratic weather patterns can lead to downward pressures on prices and margins as well as delays
New customer dynamics are increasing challenges for manufacturers. Today customers want a personalised experience instead of a standard product, which is disrupting the standardisation of operations to drive efficiency and productivity, that the sector has been striving to establish over the decades.
Manufacturers now need to work to balance efficiency with client demand. IBM states that a successful manufacturer will leverage industry 4.0 tools to drive efficiency and productivity while maintaining customisation, quality and fast delivery.
As industry 4.0 evolves at high speed, manufacturing talent needs to keep up with this level of evolution. Currently, in this increasingly digital, global and customisable world, industries are facing a shortage of IT professionals, with “67% of IT decision-makers in a 2019 Frost & Sullivan Global Survey stated that their digital transformation has been hampered by a lack of in-house technical expertise. While another 59% said that “hiring and retaining qualified IT staff” was a top challenge.”
In addition to new talent, the manufacturing industry is also facing the challenge of a retiring workforce while lacking the volume of new talent.
Many of these challenges have one thing in common, a need to gather vast amounts of data, interpret the data and apply the finding in real-time. IBM states that information has a direct correlated effect on efficiency.
Image: IBM key benefits of industry 4.0
The technology available to the factories of the future is vast and varied. It is important that manufacturers define their challenges and the solutions they need to combat the challenges in order to successfully leverage industry 4.0.
Image: IBM the digital technologies available in manufacturing
Leading solutions within the industry will be able to provide a level of enterprise asset management (EAM), to improve the reliability and performance of assets across the operations. On average an hour of downtime costs US$100,000, as a result, 71% of executives are looking to reduce this as a core KPI, while 50% report challenges related to unplanned machine downtime. By harnessing industry 4.0 technology to gain sophisticated insights, downtime can be reduced by up to 50% and increase maintenance costs by 25%.
Process industries face complexities when it comes to suppliers, components and feedstock that can be highly variable. As a result, manufacturers need to be adaptable, however, these multiple variables can make it hard to optimise operations, by leveraging industry 4.0 technology companies can increase their ability to predict various outcomes and make business decisions based on analytical insights.
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IMF: Variants Can Still Hurt Manufacturing Recovery
After a year of on-and-off manufacturing in the US, UK, and the eurozone, demand for goods surged early last week. Factories set growth records in April and May, suppliers started to recover, and US crude hit its highest price point since pre-COVID. As vaccination efforts immunise much of the US and UK populations, manufacturers are now able to fully ramp up their supply chains. In fact, GDP growth could approach double-digits by 2022.
Now, the ISM productivity measure has surpassed the 50-point mark that separates industry expansion from contraction. Since U.S. president Biden passed his US$1.9tn stimulus package and the UK purchasing managers index (PMI) increased to 65.6, both sides of the Atlantic are facing a much-welcomed manufacturing recovery.
Lingering Concerns Over COVID
Even as Spain, France, Italy, and Germany race to catch up, and mining companies pushed the FTSE 100 index of list shares to a monthly high of 7,129, some say that UK and US markets still suffer from a lack of confidence in raw material supplies. Yes, the Dow Jones has made up its 19,173-point crash of March 2020, and MSCI’s global stock index is at an all-time high.
Yet manufacturers around the world realise that these wins will be short-lived until pandemic supply chain bottlenecks are solved. If we keep the status quo, consumers will pay the price. In April, inflation in Germany reached 2.4%, and across the EU’s 19 member countries, overall prices have increased at an unusual pace. Some ask: Is this true recovery?
IMF: Current Boom Could Falter
Even as Elon Musk tweeted about chip shortages forcing Tesla to raise its prices, UK mining demand skyrocketed; housing markets lifted; and the pound sterling gained value. The International Monetary Fund (IMF), however, cautioned that manufacturing recovery won’t last long if COVID mutates into forms our vaccinations can’t touch. Kristalina Georgieva, Washington’s IMF director, noted that fewer than 1% of African citizens have been vaccinated: “Worldwide access to vaccines offers the best hope for stopping the coronavirus pandemic, saving lives, and securing a broad-based economic recovery”.
Across the globe, manufacturing companies are keeping a watchful eye on new developments in the spread of COVID. Though US FDA officials don’t think we’ll have to “start at square one” with new vaccines, the March 2021 World Economic Outlook states that “high uncertainty” surrounds the projected 6% global growth. Continued manufacturing success will in large part depend on “the path of the pandemic, the effectiveness of policy support, and the evolution of financial conditions”.
Mathias Cormann, secretary-general of the Organisation for Economic Co-Operation and Development (OECD) concurred—without global immunisation, the estimated economic boom expected by 2025 could go kaput. “We need to...pursue an all-out effort to reach the entire world population”, Australia’s finance minister added. US$50bn to end COVID across the world, they imply, is a small investment to restart our economies.