From Concept to Use Cases: Big Data Analytics in Manufacturing

FROM CONCEPT TO USE CASES
Big data analytics in manufacturing is all you need to improve your business's efficiency, quality, and productivity in today's data-driven industry. It helps you transform your business data into actionable analytics to make informed decisions on business processes and operations.

“Data is the new science. Big data holds the answers.”

– Pat Gelsinger, CEO at VMware

The significance of manufacturing industry data analysis is critical, and many manufacturers have recognized this and have started incorporating it into their manufacturing operations. According to Research and Markets, the manufacturing sector market was worth $904.65 million in 2019 and is predicted to grow to $4.55 billion by 2025.

In this article, we'll look at the importance of big data in manufacturing, its applications, and how some of the industry's major players are incorporating it into their manufacturing processes and operations.

Why Do Manufacturers Need Big Data?

Big data analytics in manufacturing helps manufacturers find new information and identify trends. This enables them to improve operations, increase supply chain efficiency, and identify variables that affect production.

Many leaders from the manufacturing industry recognize the importance of big data and have either started applying it to their business or are planning to do so.
  • According to a KRC research report, 67% of manufacturing executives considered investing in manufacturing data analytics, especially in the face of pressure to minimize costs in this volatile market.
  • According to MicroStrategy, 59% of organizations worldwide are using big data analytics.

Big Data: From the Past to the Future

Herman Hollerith invented the first punch card tabulating machine that marked the foundation of data processing. Hollerith's tabulating device was utilized to process data from the 1890 United States Census. Later that year, in 1911, he formed the Computing-Tabulating-Recording Company, which evolved into IBM. It is now based in Armonk, New York, with operations in more than 171 countries.

This international corporation develops computer hardware, software, and middleware, and provides hosting and consulting services in different sectors, ranging from mainframe computers to nanotechnology. The company is a significant research institution that has set the bar for the number of U.S. patents generated annually by a firm for the last 28 years (as of 2020). 

Companies Using Big Data Analytics 


Amazon

The enormous benefit of big data is its capacity to assist businesses in innovating and redeveloping their products. Essentially, big data has evolved to generate additional revenue streams by enabling innovations and product development. Before developing new product lines or redesigning old products, organizations begin by fixing as much data as possible.

How does Amazon make use of big data?
Most people are familiar with Amazon Fresh and Whole Foods Market. This is an excellent illustration of how big data can benefit the growth of innovation and product creation. Amazon uses big data analytics to get a foothold in a vast market. Amazon's experience in data-driven logistics enables the creation and achievement of more value. By focusing on manufacturing analytics, Amazon Whole Foods deciphers how customers purchase products and how suppliers engage with the store.

PepsiCo

Big data enables supplier networks to operate with increased precision, clarity, and insight. Suppliers achieve contextual insight throughout supply chains by utilizing manufacturing data analysis. Essentially, providers can overcome previous limitations using big data analytics.

How does PepsiCo leverage big data to optimize its supply chain?
PepsiCo is a consumer packaged goods company that depends mainly on massive amounts of data to operate its supply chain efficiently. The organization is committed to restocking the shelves of shops with the proper quantities and varieties of products. Clients give reports on their warehouse and point-of-sale inventory, which the company uses to reconcile and estimate production and shipment requirements. This way, the corporation guarantees that shops have the appropriate products, in the appropriate quantities, and at the appropriate times. Read our latest infographic to learn more about increasing the efficiency of your manufacturing business. 

Big Data in Manufacturing: Use Cases


Supply Chain Management

Big data allows manufacturers to track their products' actual position. The ability to track is one of the most important features offered by big data to manufacturers. Traceability is important since many products released by manufacturers are lost or hard to trace. Barcode scanners and radio frequency transmission equipment can set up a parcel's coordinates. These devices broadcast the product's location, pinpointing its exact location.

Identifying client needs is a challenge when predicting market trends. Big data assists by predicting client requests and assisting with product delivery timings. This type of forecasting can help businesses improve their profits and workforce by looking at their supply chain.

Production Management Once businesses have discovered market requirements, the same analytics for manufacturing can assist them in evaluating the volume of products necessary in the market. Previously, when big data analytics did not exist, businesses relied on human estimates, which frequently resulted in excess or insufficient production. This technique has been deemed obsolete because of its inaccuracy. Instead, organizations gain intuitive insights from the data they collect and analyze using big data analytics for manufacturing.

Machine Maintenance

When a company manufactures something, it intends to maintain its machinery, from how it currently runs to what changes are required to keep it working properly. These robots' sensors may continuously collect data. Device data helps firms determine when and how much maintenance a machine needs. Big data analytics can help manufacturers keep track of their machinery by assessing and improving their efficiency.

Daily Production

For a company to run properly, they must monitor their daily activities, production capacity, and financial performance. Big data analytics can help manufacturing organizations by giving intuitive insights from numerous sources. These sources include operating machines, databases tracking unit production, and employee records. This data can help corporations make profitable improvements.

Quality Assessment

Quality control is important in manufacturing since the products must be of the highest quality. Big data analytics can also help here by providing vital information about any changes in the development process.

Businesses recognize the need to utilize technological breakthroughs as manufacturing transforms. Big data analytics helps enterprises not only track and forecast market demands but also maintain quality measurements and standards. This ensures product quality and increases profitability for a manufacturer's products.

Final Word

We understand the significance of big data in manufacturing, and the sooner you start collecting data on your manufacturing processes, the sooner you can implement the latest advancements. Therefore, delve further into big data, data analytics, and data science services to assist your manufacturing organization in growing and blooming to the next level.

FAQ


Is data science the same as big data?

No, data science and big data are not synonymous. Big data collects varied and complicated data, whereas data science is a multidisciplinary area that tries to generate broader insights from data.

What purpose does data serve in manufacturing?

Manufacturing data provides a deeper insight into market trends, a complete grasp of client needs, and predicts future trends. In a nutshell, it includes everything necessary for manufacturing companies to maintain a competitive edge.

How are manufacturing data defined?

Manufacturing data refers to all data, information, materials, and documentation developed or generated in connection with the product’s manufacturing. This includes manufacturing and control data as well as additional data and documentation requested by or submitted to a Regulatory Authority.

Spotlight

Luminous Power Technologies (P) Ltd

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OTHER ARTICLES
Industrial 4.0

Best Practices for Successful Digital Transformation in Industry 4.0

Article | September 21, 2023

Navigating the path to success by unveiling the best practices for thriving in Industry 4.0 through successful digital transformation. Embrace the data-driven decision-making and customer-centricity. The pursuit of successful digital transformation has evolved from a business strategy to a business necessity. It is a vital imperative for organizations striving to survive and thrive in an ever-competitive market. Within this paradigm shift, a journey unfolds that transcends the commonplace and ventures into the realms of strategic innovation. This best practices article is not just a standard guide but a roadmap to excellence. Explore the best practices that propel businesses into the forefront of Industry 4.0. Beyond the surface of technology adoption lies a deeper narrative, one of cultural transformation, stakeholder collaboration, and visionary leadership. Delve into the intricacies of data-driven decision-making, the agility that fuels progress, the relentless pursuit of knowledge, and the unwavering commitment to the customer experience. Each of these elements forms a crucial thread in the tapestry of successful digital transformation. Through compelling case studies and real-world examples, draw inspiration from industry leaders who have not merely embraced change but have harnessed it to redefine their future. 1. Make confident decisions with Digital Twin Combining the physical and digital realms enables seamless integration of the entire value chain, from design to production, while optimizing with continuous data flow. A digital enterprise can harness the limitless power of data by obtaining valuable insights to make quick and confident decisions and to produce best-in-class products through efficient production. The Digital Twin approach integrates the entire product lifecycle with the factory and plant lifecycles and performance data. The end result is a continuous, open cycle of product and production optimization. The digital twin is a comprehensive digital representation of a product or process throughout its entire lifecycle. By creating a digital twin, companies can achieve significant value, such as faster time-to-market for new products, improved operational efficiency, reduced defects, and exploring new business models to drive revenue growth. With the digital twin, companies solve physical issues more efficiently by detecting them early on and accurately predicting outcomes. It empowers them to design and build superior products and ultimately enhance customer satisfaction by better serving their needs. By adopting smart architecture design, companies can continuously realize iterative value and benefits at an accelerated pace. Manufacturing, automotive, aviation, and other industries have adopted digital twins to boost productivity and efficiency. By 2025, the manufacturing industry is predicted to reach a market size worth over six billion U.S. dollars. 2. Vertically Network Various Units in Enterprise Vertical integration in a Digital Enterprise involves the convergence of IT and OT (Information Technology and Operational Technology) to enable seamless data flow from the shop floor to the top floor. The vast amount of data generated by field devices and control units on the shop floor is vital in the context of Industry 4.0, where intelligent data utilization and communication are paramount. Vertical integration generates a comprehensive solution by integrating IT systems at various hierarchical manufacturing and production levels. These hierarchical levels include the field level (interface with the production process via sensors), the control level (machine and system regulation), the production process level (to be monitored and controlled), the operations level (production planning and quality management), and the enterprise planning level. Vertical integration allows for improved communication and collaboration across different departments within the organization. This leads to better coordination, streamlined operations, and increased efficiency across the entire manufacturing ecosystem. A study by the Boston Consulting Group found that companies with a high level of vertical integration were 16% more productive than those with a low level of vertical integration. 3. Horizontally Integrate the Processes in Lifecycle The concept of horizontal integration in a Digital Enterprise ensures smooth data flow throughout the entire value chain. This integrated approach enables the digitalization of the complete value chain, spanning from design and production to service and recycling. By establishing seamless horizontal integration, it eliminates information silos and creates connections that encompass all aspects, from product innovation and manufacturing to product usage and beyond. Horizontally integrated companies focus on their core strengths and partner to support the value chain. Horizontal integration helps information flow between plant-level Manufacturing Execution Systems (MESs) when a company's manufacturing sites are spread out. This allows production sites to quickly share manufacturing data, such as unexpected delays, breakdowns, and inventory levels. Automated cooperation is crucial to supply chain integration in both the upstream (production processes and downstream (the process of bringing the finished products to market) supply and logistics chains. The integration lets a corporation automatically switch production duties between locations. A study byMcKinseyfound that companies that engaged in horizontal integration in the digital age saw their market share increase by an average of 10%. 4. Upgrade Digitalization using Automation Automation catalyzes growth by streamlining operations, breaking down silos, and promoting cross-functional collaboration. With reduced errors and increased efficiency, businesses can scale their operations with fewer resources, fostering a climate of innovation. This increased productivity allows employees to focus on more creative and challenging tasks, leading to higher motivation and engagement. Furthermore, automation provides a better customer experience, essential in today's digital-savvy market. By automating processes, businesses ensure quick access to customer information, leading to increased satisfaction. Lowering costs and expenditures is another significance enabling businesses to eliminate waste, save time, and conserve resources by automating data entry, approval workflows, and financial procedures. Additionally, automation enables efficient management of decentralized global teams from a central hub, further contributing to cost savings. Automation aids in enhancing security measures and simplifying compliance procedures. Businesses proactively identify vulnerabilities and ensure compliance with ever-changing regulations by automating data-intensive tasks. 97% of IT managers feel process automation is necessary for digital transformation. 5. Implement Additive Manufacturing The adoption of Additive Manufacturing (AM)technologies has prompted the evolution of innovative business models that emphasize environmental perspectives. AM has emerged as a transformative solution within the smart manufacturing industry, offering numerous advantages, such as improved labor, energy, and material optimization, enabling companies to respond to changing market demands effectively. AM is particularly time-saving and cost-effective for small-batch complex geometries products, allowing for non-traditional mass customization and shortening the product development cycle. It encourages changes in sustainable business models, including integrating recycled materials, increasing component attributes, and enhancing product lifecycle. AM’s sustainable benefits have garnered significant attention, focusing on reducing waste, optimizing material consumption, and shortening supply chains. Using layer-by-layer production, AM is considered less wasteful than traditional subtractive methods. It also facilitates the creation of products with extended lifecycles through repair, refurbishment, and remanufacturing, promoting sustainability and environmental responsibility. Study data estimates that the cost savings that can be achieved with Industry 4.0 transformations is 50%. 6. Choose the Appropriate Technology The success of digital transformation endeavors hinges on the careful selection of technologies to invest in. Avoid investing in the latest technology just for the sake of digitization, and refrain from rushing into numerous significant changes simultaneously, which may overwhelm employees. Instead, opt to gradually replace legacy systems and synchronize technology with business objectives through the implementation of new procedures. Here’s what Airbus did. Case Study: Airbus Airbus is the market leader in aeronautics and aerospace products and services worldwide. The organization needed a user-centric digital transformation solution to optimize its data analytics, technology, and machine learning tools, but this proved difficult. Later, it embraced open-source technology and consolidated its 15 tools onto a user-friendly platform. In ten months, this helped produce 290,000 visits and 2,200,000 page views. Additionally, the company's service center is now managing 30% fewer incidents. 7. Adapt Company for a Change Digital transformation does not demand extensive technical expertise from management and employees; rather, it necessitates a shift in mindset. By embracing this new mindset and leveraging technology solutions to automate processes for both customers and employees, rapid growth can be achieved within the organization as well as in the external market. To facilitate this transformation, it is essential to identify areas that require change, enhance transparency, and foster a culture of collaboration within the organization. By taking these steps, an organization can effectively prepare for the changes brought about by digital transformation. Case Study: Honeywell The Fortune 100 manufacturer operates in industries such as aerospace and building technology. To improve product quality and make it easier to apply digital strategies, it cut its operations from eight markets to six. Early in its transformation journey, it established a digital transformation group in the company that led digital innovations like data-driven product offerings, IoT-connected devices, and advanced industrial process control. Honeywell Intelligent Wearables eliminated the need for expert site visits, empowered workers to continue learning, improved their performance, and effectively shared their knowledge with peers by connecting field workers with remote advice. In 2018, Honeywell's share price grew from $95 to $174, and revenue went from $40 billion to $43 billion. 8. Integrate Digital Transformation into Business Goals Establish a strong connection between the digital transformation journey and the company's goals. Define the specific achievements to accomplish through digitization efforts. By aligning digital transformation initiatives with business objectives, a company can enhance its effectiveness in completing tasks, retaining existing employees, attracting new talent, and successfully overhauling company culture. Case Study: Cummins Cummins, a manufacturer of diesel and alternative fuel engines and generators is an example of a company that has capitalized on the increased demand for environmentally friendly products. Microsoft cloud compliance opportunities boost data security and IP protection. Microsoft has been one of the world's foremost technology companies for decades. Satya Nadella shifted the company's revenue model away from desktops and accelerated the transition to cloud computing. Cummins now uses Microsoft 365 for information management and collaboration to create a new workplace culture. Cummins' 58000 employees work cross-functionally and globally to stay ahead. Cummins relies on Microsoft 365 for strict security, data management and delivery, and compliance. Final Thoughts Successful digital transformation in Industry 4.0 requires a strategic and holistic approach beyond technology adoption. It demands a cultural shift, stakeholder collaboration, and a clear vision of the desired outcomes. To achieve successful digital transformation in Industry 4.0, organizations must adopt best practices that encompass technological, cultural, and strategic dimensions. Data-driven decision-making, agility, continuous learning, and a customer-centric approach are key elements in this transformative journey. By prioritizing these practices, businesses can navigate the complexities of digital transformation, drive innovation, and stay competitive in the dynamic landscape of Industry 4.0.

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DigiKey Announces Global Partnership with Super Low Power IC Provider Ambiq

PR Newswire | November 01, 2023

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PR Newswire | November 03, 2023

BizLink, a leading provider of connectivity solutions worldwide, uses a method for creating physical prototypes with computer-aided design (CAD) data. This so called 'Rapid Prototyping' enables development times to be shortened, costs to be lowered and innovative ideas to be realised more quickly. BizLink's Automation & Drives business unit will showcase one of these solutions at the sps trade fair in Nuremberg, Southern Germany, which takes place from 14 to 16 November. In the development and production of individual injection moulded parts, a large part of the cost and time is spent on providing the appropriate tools. That is why BizLink uses Rapid Prototyping for sample parts in the development phase of overmoulded connection components. The principal objective of this technology involves testing and validating design concepts, functionality and features before there is any investment in series production. Through Rapid Prototyping, BizLink thus reduces development costs and time-to-market for overmoulded components and its reinforced innovative cable systems for factory automation. Rapid Prototyping involves applying layer upon layer of materials or bonding them to one another with 3D printing to make the desired object. This makes it possible to quickly adapt the design as changes can easily be made in the CAD data and the prototype can then be reprinted. It also allows, for example, the spatial conditions during fitting and operation under real-life conditions to be assessed, letting the findings thereby acquired be incorporated in product improvement before a tool-maker has even started his or her job. 3D printing technology can furthermore make valuable contributions to quality assurance while development is ongoing. If, for instance, parts being tested must be scrutinised to limit failure mechanisms along functional boundaries, it helps to be able to quickly create a matching testing device for such investigations. In some cases, such devices also facilitate good reproducibility, meaning that dependable component qualifications can also be carried out in this way. Other applications involve trialling numerous production resources and tools as well as handling aids that are, with respect to their function and ergonomics, initially tested as a 3D-printed specimen and improved repeatedly so that they can later be reproduced in a more robust version made of metal, for example. Rapid prototyping is versatile and has long been a proven tool for BizLink in the innovation process to bring new products to market faster and more effectively. Visitors to sps can convince themselves of these advantages through application examples in the Nuremberg exhibition halls from November 14 to 16, 2023 in Hall 2, Stand 431.

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Manufacturing Technology

DigiKey Announces Global Partnership with Super Low Power IC Provider Ambiq

PR Newswire | November 01, 2023

DigiKey, a leading global commerce distributor offering the largest selection of technical components and automation products in stock for immediate shipment, announced that it has partnered with Ambiq to distribute their ultra-low power semiconductors globally. Through the new partnership, DigiKey is now stocking Ambiq's Apollo4 Blue Plus. With one of the lowest dynamic powers for microcontrollers currently on the market, the new SoC allows designers of next-generation wearables and battery-operated smart devices to accelerate their innovation. said David Stein, vice president, semiconductors at DigiKey. DigiKey is pleased to add Ambiq to our core supplier line card. As a leader in low-power SoC solutions, Ambiq has raised the bar with their new MCU & SoC, and we're excited to support designers, engineers and builders globally as they work with these innovative solutions to accelerate progress. [Source:PR Newswire] The Apollo4 Blue Plus is a 4th generation system processor solution built upon Ambiq's proprietary Subthreshold Power-Optimized Technology (SPOT®) platform. The device's complete hardware and software solution enables current and future battery-powered endpoint devices to achieve a higher level of intelligence without sacrificing battery life. The Apollo4 Blue Plus with Bluetooth Low Energy has more than enough compute and storage to handle complex AI algorithms and neural networks, always-on voice recognition, and display capability for smooth graphics. "Ambiq shares the same value of meeting and exceeding customer's expectations with DigiKey," said Mike Kenyon, vice president of sales and business development at Ambiq. "We're excited to partner with DigiKey to offer our portfolio of ultra-low power, AI-enabled semiconductor solutions to help ease the customer's search for the best electronic components in one place." About Ambiq Ambiq's mission is to develop the lowest-power semiconductor solutions that enable intelligent devices everywhere to drive a healthier, cleaner, and more productive world. Ambiq has helped leading manufacturers worldwide develop products that last weeks on a single charge (rather than days) while delivering a maximum feature set in compact industrial designs. Ambiq's goal is to take Artificial Intelligence (AI) where it has never gone before in mobile and portable devices, using Ambiq's advanced ultra-low power system on chip (SoC) solutions. Ambiq has shipped more than 200 million units as of March 2023. About DigiKey DigiKey, headquartered in Thief River Falls, Minn., USA, is recognized as the global leader and continuous innovator in the cutting-edge commerce distribution of electronic components and automation products worldwide. We get technical by providing more than 17.2 million components from over 2,800 quality name-brand manufacturers with an industry-leading breadth and depth of product in stock and available for immediate shipment. DigiKey also supports engineers, designers, builders and procurement professionals with a wealth of digital solutions, frictionless interactions and tools to make their jobs more efficient.

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Manufacturing Technology

Rockwell Automation Invests in Momenta Fund for Sustainable Tech

Rockwell Automation | November 08, 2023

Rockwell Automation invests strategically in Momenta's Industry 5.0 Fund, focused on resilient, sustainable, and human-centric industrial operations. The Industry 5.0 Fund promotes a transition from shareholder to stakeholder value, emphasizing sustainability and empowering individuals with technology to make informed decisions. This partnership positions Rockwell Automation to gain early access to innovative technologies that have the potential to disrupt industrial markets and enhance sustainability while supporting startups at the forefront of digital transformation in energy, manufacturing, smart spaces, and supply chains. Rockwell Automation, a global leader in industrial automation and digital transformation, has made a strategic investment in Momenta's Industry 5.0 Fund. The Industry 5.0 Fund, with an initial capital of $100 million, supports startups dedicated to advancing resilient, sustainable, and human-centric industrial operations. Switzerland-based Momenta launched the fund in cooperation with the EU Commission to promote research and innovation in line with the Commission's Industry 5.0 initiative. The fund aims to transition industries to focus on stakeholder value over shareholder value, emphasizing sustainability and empowering people with information and technology for decision-making. Targeting entrepreneurs in Europe and North America who are at the early stages of development and are at the forefront of the digital revolution in energy, manufacturing, smart spaces, and supply chains, the Industry 5.0 Fund will provide them with venture capital funding and direct value creation. Rockwell Automation is an anchor investor in the fund, allowing the company early access to cutting-edge technologies that can disrupt industrial markets and enhance sustainability. The investment aligns with Rockwell's strategy for inorganic growth and provides valuable insights into next-generation technologies driving digital transformation. Cyril Perducat, Senior Vice President and Chief Technology Officer of Rockwell, expressed excitement about partnering with Momenta to support startups poised to disrupt the industry while expanding human potential. He emphasized the intrinsic benefits of adopting technology that benefits all stakeholders. Ken Forster, a founding partner at Momenta, expressed his appreciation for Rockwell Automation's investment in their Industry 5.0 fund. He acknowledged that Rockwell Automation played a defining role in industrial automation and digital transformation within North America. Under the leadership of an impressive team, they had also been extending their global influence. Ken noted that Momenta's primary focus for the past decade had been investing in companies that drive industrial impact. He further mentioned that they couldn't have found a better partner for the Industry 5.0 fund than Rockwell Automation.

Read More

3D Printing

BizLink counts on Rapid Prototyping with the help of 3D printing technology

PR Newswire | November 03, 2023

BizLink, a leading provider of connectivity solutions worldwide, uses a method for creating physical prototypes with computer-aided design (CAD) data. This so called 'Rapid Prototyping' enables development times to be shortened, costs to be lowered and innovative ideas to be realised more quickly. BizLink's Automation & Drives business unit will showcase one of these solutions at the sps trade fair in Nuremberg, Southern Germany, which takes place from 14 to 16 November. In the development and production of individual injection moulded parts, a large part of the cost and time is spent on providing the appropriate tools. That is why BizLink uses Rapid Prototyping for sample parts in the development phase of overmoulded connection components. The principal objective of this technology involves testing and validating design concepts, functionality and features before there is any investment in series production. Through Rapid Prototyping, BizLink thus reduces development costs and time-to-market for overmoulded components and its reinforced innovative cable systems for factory automation. Rapid Prototyping involves applying layer upon layer of materials or bonding them to one another with 3D printing to make the desired object. This makes it possible to quickly adapt the design as changes can easily be made in the CAD data and the prototype can then be reprinted. It also allows, for example, the spatial conditions during fitting and operation under real-life conditions to be assessed, letting the findings thereby acquired be incorporated in product improvement before a tool-maker has even started his or her job. 3D printing technology can furthermore make valuable contributions to quality assurance while development is ongoing. If, for instance, parts being tested must be scrutinised to limit failure mechanisms along functional boundaries, it helps to be able to quickly create a matching testing device for such investigations. In some cases, such devices also facilitate good reproducibility, meaning that dependable component qualifications can also be carried out in this way. Other applications involve trialling numerous production resources and tools as well as handling aids that are, with respect to their function and ergonomics, initially tested as a 3D-printed specimen and improved repeatedly so that they can later be reproduced in a more robust version made of metal, for example. Rapid prototyping is versatile and has long been a proven tool for BizLink in the innovation process to bring new products to market faster and more effectively. Visitors to sps can convince themselves of these advantages through application examples in the Nuremberg exhibition halls from November 14 to 16, 2023 in Hall 2, Stand 431.

Read More

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