Although failure provides instruction, when it comes to manufacturing technology, what matters is what actually works.
Every new technology begins at the end of the Gartner cycle. Manufacturers must wait patiently for new hardware and software to prove themselves. Next, it takes time to explore and understand the technology that appears to have value. Pilot use cases can be difficult to identify and implement.
However, once technology deployment is successful, doors of possibility open throughout the organization. Taking that first step, deploying that first technology, pays off well beyond its immediate benefits. This is when a digital transformation begins.
So here are our stories of 2024, chronicling the best manufacturing technology that delivers results and the leaders who are leading the way in digital.
5G can revolutionize manufacturing
Connected devices in a factory generate enormous amounts of data which, if processed correctly, provide invaluable insights into product quality, production efficiency and operational safety, among others. Limiting connectivity to wired Ethernet or WiFi restricts the ability to change the floor plan or track tools as they move around the factory. 5G technology definitely solves these problems, but as John Deere discovered, Having the right people to manage the technology is the biggest challenge to successfully using 5G.
Let employees lead the way on sustainability
Sustainability does not have to be about grandiose proposals and radical policy changes. Small improvements add up quickly. No one knows better how to save energy, reduce waste and leverage renewable energy in your factories than the operators closest to what’s happening on the ground. ABB has learned to empower employees to decide how best to execute sustainability efforts and launched a company-wide program to support their work.
Confident Operators Create Quality
How can a small business win jobs from manufacturers like Toyota? Demonstrate a commitment to quality and long-term accountability. HJI Supply Chain SolutionsThe manufacturing manager knows that operators make mistakes when instructions are unclear or when they encounter unforeseen circumstances. HJI’s new Manufacturing Execution System (MES) makes operational procedures clear and records every step of the manufacturing process to optimize cycle times. And if something goes wrong with the product, HJI can determine exactly where it needs improvement.
Digitalized Maintenance Creates Better Leadership
John Sedgwick, director of engineering and maintenance at Hexpol makes up Americaswanted each factory to follow the same corporate strategic plan. This involved introducing new standards, such as the adoption of a new computerized maintenance management system (CMMS). Sedgwick knew that passing the new agenda down from above was a recipe for failure, so he instituted a new leadership policy at the same time. Digital technology cannot solve problems alone. Humans must continue to be part of the equation.
Machine data can solve people’s problems
Management at AVPE Systems was convinced that productivity should be much higher than it was. They had no data to prove their point and installed a digital machine monitoring system to record real-time information on the condition of the machine. When they had to account for downtime, it became clear that AVPE simply didn’t have enough operators on the ground. And while the goal wasn’t to monitor operators, the data clearly showed that some operators lacked the skills to operate certain machines. A recruiting drive and new training programs brought productivity to where management knew it should have been all along.
Automation is also about data
Strand Products manufactures mechanical wire, cord and cable assemblies for highly regulated industries such as medical and military. Monitoring document control, SOPs and machine calibration are mandatory and not optional. And because the company is 100% employee-owned, Wes Prunckle, President and CEO, felt a responsibility to his employees to personally track accounting data, ledgers, quality and inventory. Adopting a new intelligent manufacturing system allows Prunckle to automate data processing and shift its focus to leadership where it belongs.
Integrate 3D printing into global workflows
Additive manufacturing is unlikely to become a mass production technology replacing injection molding or die casting. It does, however, have its place in large-scale operations, as evidenced by the way Baker Hughes exploits technology. A single 3D printing center in Houston, Texas, handles additive manufacturing demands for Baker Hughes factories around the world and is a mixed success by any measure.
Robots are worth the risk
Industrial robotics is well established as a practical and capable technology, but aimed at small businesses like custom kitchen cabinet makers. Manufacturerthe investment may still seem fragile. They don’t have the same risk tolerance. The financial implications of deploying a robot can be disastrous if the robots do not perform as advertised. Hubert Dubois, general manager, convinced the owners to trust his instincts and deploy the robots. It rewarded their trust by increasing productivity and quality.
Prepare the treats for the robot dogs
We have surely all heard of the quadruped robot Spot from Boston Dynamics. It is agile, reliable and can carry various payloads. Monitoring machine health and looking for acoustic or thermal anomalies may seem like mundane tasks for such advanced technology. But Nestle Purina learned that Spot was so good at his job that he achieved ROI in half the expected time. Good dog (robot)!