Article | March 22, 2022
Manufacturing analytics, or real-time manufacturing analytics, is the process of collecting, cleansing, and analyzing data from machines to forecast their future use, prevent failures, forecast maintenance requirements, and identify areas for improvement.
“The goal is to turn the data into information and information into insight.”
- Carly Fiorina, ex CEO of Hewlett-Packard
Manufacturing data incorporates all structured and unstructured information collected manually or through software from machines and humans throughout the manufacturing process, up to the point at which a product is launched to the market.
In this article, we will look at the use cases of data analysis in manufacturing and some of the start-ups from the U.S. that are helping manufacturers gather their real-time manufacturing analytics.
Data Analysis in Manufacturing: Use Case Analytics
Forecasting demand is highly dependent on historical data on supply levels, material costs, purchase trends, and customer behavior. Manufacturers can use analytics to accomplish the following:
Define the products to be manufactured in a time frame
Define products that are no longer in stock
Determine the quantity of products to be manufactured
Forecast sales prospects
Forecasting demand enables manufacturers to manage inventory, purchase materials, and optimize storage capacity based on data. Additionally, manufacturing industry data analysis provides insight into:
The sales-to-inventory ratio indicates the average inventory value over net sales.
Days in inventory refers to the time a manufacturer retains before selling a product.
Gross margin return on inventory (GMROI) is a term that refers to the amount of gross margin a manufacturer receives for each dollar invested in inventory.
Data collected from various manufacturing machines, tools, and devices, as well as information about operations and the gears required for the machines, can be analyzed to:
Predict when a machine will require maintenance based on the amount of time and the operations in which it has been used.
Identify and resolve operational anomalies caused by or will result in machine failure.
Prevent downtime by scheduling machine breakdowns, repairs, and replacements in advance.
Utilizing analytics can assist manufacturers in determining the actual cost of a product based on the costs of materials, labor, machines, and tools used or purchased during the manufacturing process. Additionally, manufacturers can optimize prices based on data about competitors, market trends, consumer behavior, and purchase history. Additionally, analytics can assist in setting dynamic prices that are determined by demand, supply, competition, and subsidiary product prices.
Analytics for Manufacturing as a Service: Three U.S.-based Startups
Uptake offers predictive analytics solutions powered by artificial intelligence for various industries. It provides a compass, which allows organizations to optimize work orders and scout. This allows users to analyze data and custom alerts and radar to get failure and anomaly detection solutions. Failure prediction, noise filtering, situational analytics, and detecting changes in operational behavior are just a few of the features that these systems offer to their customers today. The product, by Uptake, is intended for use in various industries like mining, construction, fleet management, manufacturing, aviation, government, and oil and gas.
Seeq is a leading provider of industrial data analytics solutions. Its big data analysis solutions help in the analysis and comprehension of industrial process data (IPD) more effectively and quickly than typical alternatives. Reduced analysis time, quicker relationship discovery, ERP and other system connectivity, support for business intelligence (BI) tools such as Excel, Tableau, SAS, and MATLAB, and collaboration support are some of the features.
Sight Machine provides a platform for manufacturing applications that utilize digital twins. It provides solutions for continually analyzing images captured by industrial cameras, sensor data, and data from manufacturing systems to improve product quality and operations. It provides real-time visibility and actionable data for every part, machine, line, and plant manufacturing process. Its clientele includes Nike, Sony, Nissan, and Google, to name a few.
Big data analytics in manufacturing assists businesses in identifying the parameters that have a direct effect on production. Additionally, modifying the target process helped businesses increase productivity by 50%.
McKinsey estimates that when analytics are used in design-to-value workflows and projects, manufacturers' gross margins can increase by as much as 40%. Manufacturing analytics can help with design-to-value, supply chain management, and after-sales support. Real-time manufacturing analytics enables manufacturers to optimize their overall production.
Why is data critical in manufacturing?
Big data helps manufacturers understand their customers' needs and wants better. To launch a new product or upgrade an old one, data is required to make it appealing to customers and assess the risks of competition.
What is production analysis?
Production analysis visualizes production output and helps assess production losses and associated costs.
What is predictive manufacturing?
Predictive manufacturing uses descriptive analytics and data visualization to provide a real-time perspective of asset health and reliability performance.
Article | November 1, 2021
Manufacturing processes will undergo significant transformation in 2022 as a result of advanced manufacturing technology. The changing manufacturing industry is full of digitization to improve processes, products, productivity, and business revenue.
Manufacturers must realize the advantages of advanced manufacturing and learn to enhance their production processes to increase their manufacturing plant's productivity. Once you understand the heart of your business and where to integrate technology, you're halfway to success.
The manufacturing industry's top professionals have also recognized the technology shift and are supporting upskilling in the manufacturing business. Mr. Matt Mong has said in his interview with Media7,
“Once you start to look at yourself in the right way and realize that projects are at the core of your business, it is easy to see how you should use technology to support your business.” – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca
Importance of Advanced Manufacturing
Adopting innovative manufacturing technologies has several advantages that grow its acceptance and relevance among manufacturers across industries. The following are the most significant advantages of advanced manufacturing.
Amplifying the product and process quality
Improvement in productivity
Encourages new ways to innovation
Decreases production time
Considering the factors above that contribute to the production process becoming more efficient, productive, and revenue-generating, advanced manufacturing will continue to dominate the manufacturing business in 2022.
Top Five Technologies That Are Advancing Manufacturing in 2022
To better understand the current trends in manufacturing technology, let us comprehend the technologies that are advancing the manufacturing industry. Additionally, discover how these technologies help manufacturers to advance their manufacturing processes.
Cloud computing in manufacturing is used for marketing, product development, inventory management, and productivity management. It stores software and commercial data via internet connections. Cloud computing is becoming a prevalent technology because it enables manufacturers to improve communication and manage the entire production cycle effectively.
According to MarketsandMarkets' study, the global cloud computing market will also increase to 832.1 billion dollars by 2025, growing at a 17.5 percent annual rate in the following years.
Benefits of Cloud Computing
Fewer technical issues when compared to traditional software use
Cost savings because no in-house servers are required
Cloud computing enables easy scalability for your developing firm
Cloud computing provides centralized control and access from any device
How did McDonald's use AWS cloud computing services to transform their customer service?
Additive manufacturing enables the fabrication of lighter, more sophisticated designs that would be impossible or prohibitively expensive to fabricate using conventional dies, molds, milling, and machining techniques. Rapid prototyping is another area where additive manufacturing thrives.
As a result, it is gaining a grip in the manufacturing business. According to Statista's market research, the additive manufacturing industry is worth approximately 12.6 billion US dollars in 2020 and is predicted to increase at a compound annual growth rate of 17% until 2023.
Benefits of Additive Manufacturing
Reduces material waste
Simplifies manufacturing processes
Additive manufacturing enables on-demand production
Increases supply chain flexibility
The finished product can be made close to the end customer
Robots are used in manufacturing to automate repetitive tasks, resulting in a more efficient assembly line. Humans and robots work together on a variety of things as well during the production of various products. Many jobs are hazardous or necessitate many supplies, which could be harmful to the human workers themselves. So, in such instances, robots play a significant role in executing manufacturing operations.
Robotics' increasing application in production is transforming it into a necessary component of industrial processes in the future. According to Mordorintelligence's study, the robots industry was worth USD 27.73 billion in 2020 and is predicted to reach USD 74.1 billion by 2026, growing at a CAGR of 17.45 percent between 2021 and 2026.
Benefits of Robotics
Increased productivity when compared to traditional manufacturing
Consistent speed and quality during goods production
Increased workplace safety for all employees at the manufacturing plant
Aids in more efficient use of floor space
Internet of Things
The Internet of Things allows devices to interconnect with one another and exchange data. The IoT connects assets to processes, systems, and people in manufacturing. This enables improved process integration, increased efficiency, and the advancement of manufacturing to the next transformation phase, Industry 4.0.
According to Mordorintelligence's market research, the global IoT market is estimated to reach USD 1,386.06 billion in 2026, up from USD 761.4 billion in 2020, a CAGR of 10.53 percent over the forecast period of 2021 to 2026.
Benefits of Internet of Things
It contributes to increased energy efficiency by identifying and optimizing underperforming devices
It monitors all processes and parameters to determine when to replace specific components
It improves product quality by analyzing and correcting issues at any stage of the manufacturing process
It reduces downtime by detecting and alerting production line personnel to problems
It enables more informed decision-making by unlocking
Virtual reality enables plant managers to mimic manufacturing processes and assembly line layouts to discover potentially harmful scenarios. Additionally, virtual reality can immerse an employee in a future workstation and then capture their movement to assess task feasibility and proficiency. As a result, the usage of virtual reality in manufacturing is increasing daily and is widely seen as the industry's future.
According to market research firm markets and markets, the worldwide virtual reality industry is estimated to rise by USD 20.9 billion by 2025, expanding at a 27.9 percent compound annual growth rate from 2020 to 2025.
Benefits of Virtual Reality
Enables a more thorough examination of the product's design
Enables the gathering of feedback on future items before they are launched in the real world
In recent years, advanced manufacturing technology has helped the manufacturing industry become more efficient, precise, and goal-oriented. As a result, manufacturers are eager to upgrade their current manufacturing facilities to state-of-the-art facilities. As a result, manufacturing companies would become more competitive and an integral industry component if they implement cutting-edge technologies.
How do you define advanced manufacturing?
Product and process improvement through inventive use of new technology is called advanced manufacturing.
Which sectors are utilizing cutting-edge technology?
Aerospace, Medical, Electronics, Transportation, Energy, and Consumer Product Production Companies are the top businesses or sectors that use cutting-edge technologies with sophisticated manufacturing.
What is the difference between conventional manufacturing and advanced manufacturing?
Traditional manufacturing adds value to attain the goal. Traditional manufacturing adds value to attain the goal. But, on the other hand, advanced manufacturing covers production methods in specific industries like aerospace, medical, pharmaceutical, etc.
Article | June 28, 2021
Manufacturing journalist Thomas R. Cutler visited the remarkable and magnificent country of Uganda.
Foreign investment is coming into the country and that is a good thing; it is not however, enough. To tap into this workforce corporate citizenship and contribution is essential. Just as I underestimated the stamina needed to climb the mountain to experience the gorillas, the role of transforming Uganda requires a careful, well-thought approach.
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
"name": "What are the benefits of additive manufacturing?",
"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"