Article | December 30, 2021
Risk management in manufacturing has always been a top priority for manufacturers to avoid any unfortunate incidents. As a result, it is possible to create a more secure work environment for employees by conducting risk assessments and implementing remedies.
“If you don’t invest in risk management, it doesn’t matter what business you’re in, it’s a risky business.”
– Gary Cohn, an American Business Leader.
As of 2019, the worldwide risk management market was valued at $7.39 billion, and it is expected to rise at a CAGR of 18.7% from 2020 to 2027, according to allied market research.
Why is Risk Assessment Critical in Manufacturing?
The manufacturing industry must have a credible risk assessment and management plan to defend itself from any breaches. Risk assessment helps firms understand the dangers they face and their implications if their systems are compromised. Hence, risk assessment is very critical in the manufacturing industry.
Five Risk Assessment Principles
Identify hazards/risks - Employers must examine their workers' health and safety risks. Therefore, an organization must regularly inspect its employee’s physical, mental, chemical, and biological threats.
Identify who may be hurt and in what way – Identifying the personnel both full-time and part-time at-risk. Employers must also examine threats to agency and contract personnel, visitors, clients, and other visitors.
Assess the risks and act accordingly - Employers must assess the likelihood of each danger causing injury. This will evaluate and lower the chance at the working space. Even with all safeguards, there is always some danger. Therefore, employers must assess if danger is still high, medium, or low risk.
Get the Risks Documented - Employers with five or more employees must record the critical findings of the risk assessment in writing. In addition, register any risks identified in the risk assessment and actions to minimize or eliminate risk.
This document confirms the evaluation and is used to examine working practices afterward. The risk assessment is a draft. It should be readable. It shouldn't be hidden away. The risk assessment must account for changes in working techniques, new machinery, or higher work objectives.
5 Manufacturing Risks to Consider in 2022
Accidents at Work
Even if official safety policies and programs are designed, followed, and enhanced, manufacturers may endure workplace accidents and injuries. Risk assessment for workplace accidents assists in mitigating the negative impact on both employees and the organization.
Manufacturers have distinct issues regarding fuel handling and hazardous waste disposal in facilities. Sudden leaks or spills may be extremely costly to clean up and result in fines from state and federal agencies. Risk assessments for such plant accidents assist businesses in mitigating financial losses.
Essential machinery throughout the production process might fail at any time, incurring significant repair or replacement costs. Therefore, it's critical to recognize that business property insurance may not cover mechanical issues.
Risk assessment and prepayment solutions protect against equipment failures without interfering with typical company operations.
Supply Chain Disruption
Dependence on your supply chain may result in unintended consequences that are beyond your control. For example, if you experience downtime on the manufacturing line due to a supplier's failure to supply materials or parts, you risk losing revenue and profitability. If a disturbance to your supply chain poses a hazard, risk management can assist you in managing it more effectively by quickly identifying the risk and providing a suitable response.
Operation Temporarily Suspended
Depending on the severity of the weather event, a factory might be severely damaged or perhaps utterly wrecked. While major repairs or rebuilding are being undertaken, recouping lost income might be vital to the business's future profitability.
Risk assessment in this area enables your organization to budget for overhead expenditures such as rent, payroll, and tax responsibilities during the period of suspension of operations.
Risk management is critical in manufacturing because it enables manufacturers to comprehend and anticipate scenarios and create a well-planned response that avoids unnecessary overhead costs or delays in delivering the production cycle's final result. Manufacturing risks are undoubtedly not limited to the risks listed above and may vary according to the nature of the business and regional environmental conditions. Therefore, create a well-defined strategy to overcome threats in your business and be productive at all times.
How are manufacturing business risks classified?
In most cases, the business risk may be categorized into four types: strategic risk, regulatory compliance risks, operational compliance risks, and reputational risks.
Why should a manufacturer conduct a risk assessment?
Every manufacturing employment has risks for injury or illness. But risk evaluations can significantly minimize workplace injuries and illnesses. In addition, they assist companies in discovering strategies to reduce health and safety risks and enhance knowledge about dangers.
Article | December 23, 2021
Sustainable business strategiesare bringing significant financial and environmental benefits to manufacturers. Sustainable manufacturingcreates goods while minimizing environmental consequences and preserving energy and natural resources. In addition, sustainable production improves the safety of workers, the community, and the products they produce.
Allied Market Research projects that the worldwide renewable energy market will reach $1,977.6 billion by 2030, increasing at an 8.4% CAGR. As a result, we can conclude that many businesses are transitioning from traditional manufacturing to sustainable manufacturing.
It’s a good time to be a part of the renewable energy industry. New technologies are coming to market every day, and we work in an industry that is trying to solve an enormous challenge.
– Susan Stone, Chief Executive Officer at Ubiquitous Energy, Inc., in conversationwith Media 7
Though many organizations are pioneering the sustainable manufacturing approach, we have selected five of the most well-known companies making serious attempts to be sustainable manufacturing companiesby all means.
In addition to the list of sustainable manufacturing businesses, this article will discuss the advantages of sustainabilityand how organizations may become carbon neutral. So let's get started.
Top 5 Companies with a Sustainable Business Model
The following are five manufacturing businessesthat are investing in sustainable manufacturingmethodsacross their production processes to become more responsive to our mother earth.
The company is reducing its environmental effect by engaging with suppliers, taking climate action, and driving the shift to a circular economy. Climate change is a key concern for Philips. So they are rethinking their business strategies and decoupling economic development from environmental and social impacts.
They met their aim of becoming 100% carbon-neutral in their operations and procuring 100% of their power from renewable sources by 2020. They intend to obtain over 75% of their total energy usage from renewable sources by 2025 and to reduce CO2 emissions across their whole value chain to meet the 1.5°C global warming state.
Sustainability is profoundly embedded in SCHOTT's DNA. It derives from their distinctive business concept, which dates back to 1896. Their sustainability plan includes responsible governance, workers, society, environment, and climate.
“Regarding climate change, it is high time to act. Everyone must take responsibility – politicians, companies and society. We are ready to play our part. We want to become climate neutral by 2030.”
- Dr. Jens Schulte, Member of the Board of Management with responsibility for the “Zero Carbon” strategy program
Long-term thought and responsible behavior are guiding principles of SCHOTT, which is why they care about the environment and climate. They are entering a new era of sustainable management with their “Zero Carbon” strategic program.
Long term, they seek to eliminate fossil fuels as soon as technologyallows it. They are focused on the most energy-intensive stage of glass melting to create new solutions.
IKEA's low-cost furniture utilizes a lot of wood. But because the company employs sustainable forestry practices, your new minimalist nightstand didn't cost the globe a rainforest. The business is also investing heavily in solar and wind energy. This year, the corporation intends to increase its already significant expenditures in renewable energy, to reach 100% clean energy by 2020. It also leads in offering cleaner, greener products.
In addition to encouraging people to walk, this footwear manufacturer uses recycled aluminum frames in its headquarters in the Netherlands, and underground energy storage to reduce its carbon footprint. Moreover, it has implemented stringent emission regulations at all of its manufacturingfacilities and has cut its overall carbon footprint by around 80 % since the late 1990s. The company also sells the most environmentally-friendly soccer sneakers on the market.
Johnson & Johnson
According to the company, Johnson & Johnson has just begun transitioning a significant portion of its energy reliance to solar power in an effort to become the world's most socially responsible organization. Currently, it is the second-largest user of solar energy in the United States, with more than half of its power coming from environmentally friendly sources.
Rewards of Adopting Sustainable Manufacturing Practices
Many businesses are seeking sustainabilityfor many reasons, including:
Reducesoperating expenses and waste
Respondsto new consumers and get a competitive edge
Buildspublic trust and protect brand and reputation
Createslong-term business viability
Recognizesand address regulatory constraints
What Can We Do to Make Sustainable Manufacturing a Reality?
Every business must support green energy projects. Here are some fundamental actions that every business should take to transform itself into a sustainable manufacturing organization.
Maximize the Efficacy of Fossil Fuels
In today's society, energy conservation is a win-win situation. Approximately half of the world's known oil reserves have been exhausted, which means we are near to the point of diminishing returns in terms of supply. As far as we know, there hasn't been a shortage of supplies. Shutting down unwanted equipment might help you save money immediately. Replace a single-speed motor with a variable speed or servo drive. Use a hydraulic pump with variable speed. Wind, solar, and hydropower can also be used to conserve energy.
Reduce or Eliminate Waste
Don't overindulge; merely take in what you need to get the task done. At this point, we may all agree that it's easy, but in the past, our primary focus was on reducing productioncosts or time to market. Whether we were wasting resources was unknown or irrelevant to anyone. Metal, paper, and packaging are all examples of industries where this is true. The potential for waste reduction may justify the purchase of highly accurate production equipment.
As a byproduct of manufacturing, metals may be easily recycled and used for new products. In addition, recycling metal saves money and energy since it uses less energy in the manufacturing process, allowing for a 60 % or more reduction in the energy needed to make new products.
Sustainable manufacturing practicesare making manufacturing industries more socially responsible and carbon neutral. This new manufacturing method is necessary for today's period because we must consider future generations while improving today's. Natural resources must be conserved before depleting, and we have nothing left to offer future generations. Responsible organizations have already used this sustainable approachin their manufacturing processes, and we anticipate that every company should consider this method to be more sustainableand environmentally responsible.
What is the difference between green and sustainable manufacturing?
The main difference between green and sustainable is that green addresses a single aspect i.e., environmental health, but sustainability addresses the entire system, including economic, social, and environmental aspects.
Which business is more environmentally friendly?
According to Corporate Knights, Alphabet, Tesla, and AstraZeneca were among the world's most sustainable companies in the Global 100 Index for 2021.
What are the four sustainability factors?
The word sustainability refers to programs, activities, and actions to preserve a resource. But it relates to four unique key areas. Human, social, economic, and environmental are the four pillars or factors of sustainability.
Article | December 6, 2021
Additive Manufacturing (AM) uses computer-aided design (CAD) or 3D object scanners to create accurate geometric features. In contrast to traditional manufacturing, which frequently involves milling or other processes to eliminate superfluous material, these are produced layer by layer, as with a 3D printing process.
The global additive manufacturing market is expected to grow at a 14.42 percent annual rate from USD 9.52 billion in 2020 to USD 27.91 billion in 2028, according to reports and data. Overall, the worldwide 3D printing industry is gaining traction due to various reasons, some of which are listed below.
Significantly, greater resolution
Reduced manufacturing costs as a result of recent technology breakthroughs
Ease of creating customised goods
Increasing possibilities for printing with diverse materials
Funding by the government for 3D printing ventures
Additive manufacturing is available or may be implemented in various procedures, which is the primary objective of this article. First, we'll look at the seven additive manufacturing processes and which one is the best to use. So let us begin.
“Don’t be afraid to go outside of your industry to learn best practices. There might be something that surprises you or inspires you to try in your line of work.”
– Emily Desimone, Director of Global Marketing at SLM Solutions
Additive Manufacturing Processes
There are numerous diverse additive manufacturing processes, each with its own set of standards. Here are the seven additive manufacturing procedures that many manufacturers consider based on their benefits from each process, or whichever approach best suits their product requirements.
This additive manufacturing process is quite similar to that of conventional inkjet printers, in which material droplets are selectively placed layer by layer to build a three-dimensional object. After completing a layer, it is cured with UV radiation.
VAT Photo Polymerization
This procedure employs a technology called photo polymerization, in which radiation-curable resins or photopolymers are utilized to ultraviolet light to generate three-dimensional objects selectively. When these materials are exposed to air, they undergo a chemical reaction and solidify. Stereo lithography, Digital Light Processing, and Continuous Digital Light Processing are the three primary subcategories.
Binder jetting is a process that deposits a binding agent, typically in liquid form, selectively onto powdered material. The print head deposits alternating layers of bonding agent and construction material and a powder spreader to create a three-dimensional object.
S. Scott Crump invented and patented material extrusion in the 1980s using Fused Deposition Modeling (FDM). The continuous thermoplastic filament is fed through a heated nozzle and then deposited layer by layer onto the build platform to produce the object.
Powder Bed Fusion
Powder bed fusion procedures, particularly selective laser sintering, were the pioneers of industrial additive manufacturing. This approach melts the powdered material and fuses it using a laser or electron beam to form a tangible item. The primary kinds of powder bed fusion are direct metal laser sintering, selective laser sintering, multi-jet fusion, electron beam melting, selective laser melting, and selective heat sintering.
Sheet lamination is a catch-all term encompassing ultrasonic additive manufacturing, selective deposition lamination, and laminated object manufacturing. All of these technologies stack and laminate sheets of material to form three-dimensional objects. After the object is constructed, the parts' undesirable areas are gradually removed layer by layer.
Directed Energy Deposition
Directed energy deposition technology employs thermal energy to melt and fuse the materials to form a three-dimensional object. These are pretty similar to welding processes, but are much more intricate.
Which Additive Manufacturing Process is best? Why?
Based on three fundamental factors, additive manufacturing techniques are categorized into seven types. First, the way material is solidified is determined first by the type of material employed, then by the deposition technique, and finally by how the material is solidified.
The end-user often chooses an additive manufacturing technique that best suits his requirements, followed by the explicit material for the process and application, out of the seven basic additive manufacturing processes.
Polymer materials are commonly used in AM techniques because they are adaptable to various procedures and can be modified to complicated geometries with high precision. Carbon-based compounds are used to strengthen polymers. Polymers, both solid and liquid, have been widely used due to the variety of shapes, formability, and end-use qualities available. Wherever the light-activated polymer contacts the liquid's surface, it instantly solidifies.
Photo polymerization, powder bed fusion, material jetting, and material extrusion are the most common additive manufacturing procedures for polymers. The materials employed in these processes can be liquid, powder, or solid (formed materials such as polymer film or filament).
How BASF is Using Additive Manufacturing
BASF is a chemical company. BASF, one of the world's major chemical companies, manufactures and provides a range of 3D printing filaments, resins, and powders within its extensive material portfolio.
The company, well-known in the 3D printing sector, has formed major material agreements with several 3D printer manufacturers, including HP, BigRep, Essentium, BCN3D, and others.
BASF went even further in 2017 by establishing BASF 3D printing Solutions GmbH (B3DPS) as a wholly-owned subsidiary to expand the company's 3D printing business. In addition, BASF stated last year that B3DPS would change its name to Forward AM.
BASF's role in the 3D printing business, however, is not limited to material development. BASF has made several investments in 3D printing companies over the years, including the acquisition of Sculpteo, one of the significant French 3D printing service bureaus, last year.
BASF sees 3D printing as having a bright future. With the growing popularity of professional 3D printers, all of these systems will eventually require robust, high-quality polymer materials to perform at their best – and BASF has been paving the way to becoming one of the leading solution providers.
All additive manufacturing procedures are unique and helpful in their way. Still, some have additional advantages over others, such as the material used, highresolution, precision, and the ability to build complicated parts. Because of these added benefits, photopolymerization, material jetting, powder bed fusion, and material extrusion are preferred over others. Therefore, choose the AM process that is best suited to your manufacturing business and will assist you in achieving the desired final product output.
What are the benefits of additive manufacturing?
AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability.
What is the major challenge in additive manufacturing?
Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing.
What are the steps of additive manufacturing?
The additive manufacturing steps are divided into four steps as below,
Step1 - Design a model with CAD software
Step4 - Post-processing
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"text": "AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability."
"name": "What is the major challenge in additive manufacturing?",
"text": "Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing."
"name": "What are the steps of additive manufacturing?",
"text": "The additive manufacturing steps are divided into four steps as below,
Step1 - Design a model with CAD software
Step2 - Pre-processing
Step3 - Printing
Step4 - Post-processing"
Article | December 10, 2021
IoT in the manufacturing industry introduces a superior technology that is coming up as a blessing for the industry. Manufacturers are enjoying one-of-a-kind benefits and returns on their reinvestments in IoT. Benefits such as enhanced productivity, work safety, reduced downtime, cost-effective operations, and more such benefits of IoT in manufacturing make it more and more popular with each passing day.
The global IoT market is estimated to reach a value of USD 1,386.06 billion by 2026 from USD 761.4 billion in 2020 at a CAGR of 10.53 percent over the forecast period of 2021-2026. So the whole worldwide market of IoT has a bright future in the following years.
“As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity.”
– Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca
Let’s check out below some exciting facts about IoT in manufacturing and see how IoT makes a difference in the manufacturing industry.
IoT in Manufacturing: Some Interesting Facts
According to PwC, 91% of industrial/manufacturing enterprises in Germany invest in "digital factories" that use IoT solutions.
According to the International Federation of Robotics (IFR), China employs more industrial robots than any other country (many of which are connected to the internet in some way).
According to IoT Analytics, the industrial sector spent more than $64 billion on IoT in 2018 and expects investment in Industry 4.0 to reach $310 billion by 2023.
According to the Eclipse Foundation, most IoT developers are focused on developing smart agriculture systems (26%), while industrial automation is another big focus area (26%). However, home automation is dwindling in popularity, accounting for just 19% of projects.
How Does IoT Work for the Manufacturing Industry?
The Internet of Things (IoT) is a network of interconnected devices that communicate with one another and with other networks. While IoT-enabled devices are capable of various tasks, they are primarily employed to collect data and carry out specific tasks. The implementation of the Internet of Things in manufacturing is often referred to as the IIoT, or Industrial Internet of Things.
IoT makes use of 'smart' devices to collect, process, and act on data. These intelligent devices are equipped with sensors and other software that enable them to communicate and exchange data inside the network.
IoT-enabled equipment gives crucial real-time data that enables manufacturers or machine operators to make informed decisions. So, how does it function in practice?
Sensors capture data from the system and transfer it to the cloud, where it can be analyzed.
The data is transferred to the quality assurance system.
The data that has been analyzed is forwarded to the end-user.
How the IoT is Improving Manufacturing Business Operations
The Internet of Things (IoT) has numerous benefits for the manufacturing industry. We'll go over some of the significant benefits that the Internet of Things brings to the manufacturing business.
Energy Efficiency Solutions
Energy is a high cost in manufacturing. Unfortunately, the current industrial energy infrastructure can only track excessive energy consumption.
The utility bills include the factory's energy consumption records. But, unfortunately, nobody can break down energy consumption to the device level and find out the underperforming pieces. Some energy usage monitoring tools exist, but they only provide partial data, making system analysis difficult.
IoT can help by giving device-level energy data. The sensors will detect any underperforming devices in the network and alert you so you can take action. As a result, the technology can help you reduce energy waste and find other ways to save it.
Data is required to determine trends and quality of production at a manufacturing facility. It also helps manufacturers plan and anticipates changes. These forecasts can help with inventory management, employment, cost control, and other operational procedures. Thus, IoT technology makes it easier to foresee and optimize customer requirements.
The Internet of Things (IoT) uses sensors to gather data about assets' health and productivity. In addition, it uses advanced analytics to give actionable information. These are presented on an appealing dashboard connected to your smart device. This allows for predictive maintenance to be used in the manufacturing industry.
Superior Product Quality
Every manufacturer is determined to produce a high-quality product at a low cost. Therefore, a minor quality modification can have a significant influence on the manufacturing firm.
Customer happiness, waste reduction, sales, and profit can all benefit from high-quality products. But making high-quality products isn't easy.
The Internet of Things (IoT) can assist you in this endeavor. Poorly set, calibrated, and maintained equipment are some of the main reasons for low-quality products. Worst of all, many small things sometimes go ignored as the final product seems perfect. Quality tests show the product is fine, but your consumers start having problems after a couple of months.
Imagine the resources needed to identify and correct the problem. Sensors in an IoT network detect even minimal tweaks in setup and alert operators. The team might momentarily stop production to address the issue before the production cycle gets complete.
Rapid and Informed Decision-Making
The IoT can dramatically improve organizational decision-making. It unlocks vital data about network equipment performance and delivers it to the right person.
Managers and field operators can use this data to improve plant processes and overall production.
In addition to these significant benefits, IoT in manufacturing can help manufacturers improve their manufacturing operations and construct a unit that meets the vision of the smart factory of 2040. The future beyond IoT would be the icing on the cake for all of us, as technology has always amazed us.
Imagine the day when IoT and AI merge, and the virtual gadgets controlled by IoT are the next major milestone. Then, the ideal combination of robotics, AI, and VR may reduce the manufacturing plant size and cost while increasing the output to a level that is unimaginable and unattainable as of now.
Airbus Improved Production Efficiency with Its Factory of the Future Concept
It's a massive task for a commercial airliner to be assembled. The expense of making a mistake throughout making such a craft can be significant, as there are millions of parts and thousands of assembly phases. Airbus has established a digital manufacturing effort called Factory of the Future to optimize operations and increase production capacity. The company has installed sensors on factory floor tools and machinery and supplied workers with wearable technologies, such as industrial smart glasses, to reduce errors and improve workplace safety. The wearable allowed for a 500% increase in efficiency while eliminating nearly all mistakes in one process named cabin seat marking.
While the benefits of IoT devices have long been a topic of discussion among technology enthusiasts, the incorporation of IoT in manufacturing is creating a new buzz in the industry. The benefits of IoT in manufacturing, such as remote analysis of operations, processes, and products, are assisting manufacturers in establishing a more productive manufacturing unit. As a result of these benefits, IoT use in manufacturing is accelerating. Recognize the IoT's potential and take a step toward incorporating it into your manufacturing operation in 2022.
What is the Industrial Internet of Things (IIoT)?
IIoT stands for Industrial Internet of Things. It uses data to improve industrial efficiency. To enhance industrial performance, it uses embedded sensors, cloud data, and connected devices.
Why is the IoT changing manufacturing?
Real-time monitoring of machines and accurate reporting for better decisions are possible through IoT. This improves business strategies and project control. Thus, the Internet of Things has a significant impact on the profitability of any manufacturing company.
How does the IoT transform the way we do business?
We can use data collected by IoT devices to improve efficiency and help organizations make better decisions. They tell organizations the truth, not what they hope or believe.
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"text": "IIoT stands for Industrial Internet of Things. It uses data to improve industrial efficiency. To enhance industrial performance, it uses embedded sensors, cloud data, and connected devices."
"name": "Why is the IoT changing manufacturing?",
"text": "Real-time monitoring of machines and accurate reporting for better decisions are possible through IoT. This improves business strategies and project control. Thus, the Internet of Things has a significant impact on the profitability of any manufacturing company."
"name": "How does the IoT transform the way we do business?",
"text": "We can use data collected by IoT devices to improve efficiency and help organizations make better decisions. They tell organizations the truth, not what they hope or believe."