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It's Time to Redesign Your Business with Manufacturing Analytics

MANUFACTURING ANALYTICS
Consumer demand has shifted dramatically in recent years, and manufacturers are trying to adapt to this shift. To maintain high product quality, minimize costs, and optimize supply chains, manufacturing analytics has become essential for manufacturers.

Manufacturing analytics is the process of gathering and analyzing data from various systems, equipment, and IoT devices in real-time to get essential insights.

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

Manufacturing analytics can assist in maintaining production quality, boost performance with high-profit returns, decrease costs, and optimize supply networks.

This article will outline manufacturing analytics and present a list of possible application cases. It will also highlight the benefits of manufacturing analytics for any shop floor or factory.

Manufacturing analytics: An Overview

With manufacturing analytics, we can streamline and speed up the entire process. Data interchange and automation helps in speeding up the production process. Manufacturing analytics uses predictive manufacturing, big data, Industrial IoT, network virtualization, and machine learning to produce better scalable production solutions.

Manufacturing analytics collects and analyses data from many sources via sensors embedded in machinery to identify areas for improvement. Data is collected and presented in an easy-to-understand structure to illustrate where difficulties emerge throughout the process.

In short, manufacturing analytics collects and analyses large volumes of data to reveal insights that might improve performance. Users can also obtain automated business reports to reply in real-time.


Why Manufacturing analytics is Vital for Leading Businesses

There are numerous benefits of manufacturing analytics that drive any company’s production and overall manufacturing business growth. The benefits of manufacturing analytics fall into three distinct categories as below.

It reduces the overall cost: Analytics may save a significant amount of money if used more efficiently. Labor costs are also reduced due to automation and semi-autonomous machinery. Similarly, preventive and prescriptive maintenance programs may save money while enhancing productivity.

It boosts profits for businesses: Manufacturers can respond swiftly to changes in demand using real-time insights in production, inventory management, and demand and supply forecasting. For example, assume the data indicates that they are approaching their maximum capacity. In such instances, they can increase over time, increase capacity, modify procedures, or tweak other production areas to adapt and maintain delivery times.

Other unforeseen benefits: There are several advantages to the increased capabilities enabled by manufacturing analytics. These benefits include lower energy use, safer environmental practices, fewer compliance failures, and more customer satisfaction.


Five Real-world Applications of Manufacturing Analytics

Predictive Maintenance  

A machine's analytics uses aggregate data from real-time detectors to anticipate when it needs to be replaced or functioning irregularly. This process helps predict machine failure or equipment defects.

Analytics can assist in determining a plant's capacity and how many products are produced by the unit in every production cycle, which is helpful in capacity planning. In addition, analytics may help determine the ideal number of units to create over time by considering capacity, sales predictions, and parallel schedules.

Predictive analytics solutions can automate maintenance requests and readings that shortens the procedure and reduce maintenance expenses. 

Product Development

Product development is an expensive process in manufacturing. As a result, businesses must invest in R&D to develop new product lines, improve existing models, and generate new value-added services.

Earlier, this approach was in place by repeated modeling to get the finest outcome. This approach can now be modeled to a large extent, with the help of data science and technologically superior analytics. Real-world circumstances can be replicated electronically using "digital twins" and other modeling approaches to anticipate performance and decrease R&D expenses.


Demand Forecasting

Many factors that might help in the plan significant capital expenditures or brief breakdowns can be explained using historical data and a few high-impact variable strategies. For example, consider the seasonality of products like ice cream. As a result, historical market data and a few high-impact factors can help explain numerous variables and plan major capital expenditures or short-term shutdowns.  

In addition to demand forecasting, predictive analytics incorporates advanced statistical techniques. With predictive analytics, a wide range of parameters, including customer buying behavior, raw material availability, and trade war implications, may be taken into consideration.

Warranty Analysis

Warranty support may be a load for many manufacturers. Warranties are frequently based on a "one-size-fits-all" approach that is broader. This approach introduces uncertainty and unanticipated complications into the equation.
Products may be modified or updated to decrease failure and hence expense by using data science and obtaining information from active warranties in the field. It can also lead to better-informed iterations for new product lines to minimize field complaints.


Managing Supply Chain Risks   

Data may be recorded from commodities in transit and sent straight from vendor equipment to the software platform, helping to enable end-to-end visibility in the supply chain.
Manufacturing analytics allows organizations to manage their supply chains like a "control tower," directing resources to speed up or slow down. They may also order backup supplies and activate secondary suppliers when demand changes.


Final Words

Businesses should adapt to changing times. Using analytics in manufacturing has altered the business industry and spared it from possible hazards while boosting production lines. Industry 4.0's route has been carved. Manufacturing analytics is the key to true Industry 4.0, and without it, the data produced by clever IoT devices is meaningless. The future is data-driven, and success will go to those who are ready to adopt it. The faster adoption, the sooner firms go ahead of the competition.


FAQ


How can data analytics help manufacturers? 

Data analytics tools can help manufacturers analyze machine conditions and efficiency in real-time. It enables manufacturers to do predictive maintenance, something they were previously unable to accomplish.


Why is data so crucial in manufacturing? 

Data helps enhance manufacturing quality control. Manufacturers can better understand their company's performance and make changes by collecting data. Data-driven manufacturing helps management to track production and labor time, improve maintenance and quality, and reduce business and safety concerns.


What is Predictive Manufacturing?

Predictive manufacturing uses descriptive analytics and data visualization to offer a real-time perspective of asset health and dependability performance. In addition, it helps factories spot quality issues and takes remedial action quicker by eliminating the waste and the cost associated with it. 

Spotlight

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Dexter Magnetic Technologies provides comprehensive magnetic solutions including the design, engineering and manufacturing of complex magnetic circuits, permanent magnets, magnetic assemblies, electromagnetic systems, as well as finished products serving specific market needs.

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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. 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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. 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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. 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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.

Read More

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Read More

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Wuhan, the epicenter of the outbreak, is considered a crucial hub in the middle of China, a place of high importance for the production of automobiles, electronics, optics, and fiber optics. Wuhan and surrounding cities in the Hubei province are currently on a government-imposed quarantine at a scale the world has never seen before, some Chinese officials have referred to the situation as warlike.

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Making digitalization work for you requires an understanding of your manufacturing ecosystem. Standards - such as ISA-95 - only guide you on a journey to more deeply comprehend the workings of your unique process for manufacturing your products. A batch manufacturing ecosystem often includes campaign management. Campaign management is not mentioned in ISA-95, which only speaks generally of order processing.

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Nexa3D Plans to Acquire Essentium for Broadened Capabilities

Nexa3D | November 07, 2023

Nexa3D, an ultrafast 3D printing leader, has taken a substantial step in staking its leader position in the industrial additive manufacturing space by signing a LOI to acquire Essentium, a manufacturer of HSE 3D printers and materials, adopted for high requirement, precision applications in aerospace, defense, and military. With this acquisition, Nexa3D will add high-speed extrusion (HSE) to its current product portfolio. The acquisition would broaden capabilities, diversify revenues, and expand addressable markets for the fast-growing 3D printing company. Avi Reichental, Co-founder, Chairman, and CEO of Nexa3D, stated that they are looking forward to welcoming the Essentium team to Nexa3D’s family. The acquisition will be a testament to their unwavering commitment to pushing the boundaries of 3D printing technology. He continued that by joining forces with Essentium, they aim to create synergies to deliver unmatched value to their customers. Together, they will drive ultrafast additive manufacturing innovation and provide even more powerful solutions for manufacturers seeking to achieve their production goals. Essentium, known for its variety of materials portfolio, true independent dual extruders (IDEX) and award-winning high-speed extrusion 3D printers, has provided solutions for complex polymer production applications 5 to 15 times quicker than other competing extrusion technologies. Essentium’s commitment to reliability and innovation has made it a go-to choice for manufacturers worldwide. Nexa3D has rapidly emerged as a leader in the 3D printing space, delivering excellent production solutions for businesses across various sectors. Best known for its ultrafast 3D printers, from desktops to the factory floor, its technology has redefined the possibilities of 3D printing production, enabling unparalleled productivity, material flexibility, and accuracy. Adopted by around 1200 customers all over the world, its printers have become the go-to solution for high-throughput production applications. This acquisition is expected to close by the end of this year or as soon as practicable afterward. Both Essentium and Nexa3D are committed to ensure a smooth transition and for maintaining uninterrupted services to existing and prospective customers. About Nexa3D Nexa3D is committed to the sustainable digitization of supply chains, driven by its relentless pursuit of advancing additive manufacturing. The company engineers ultrafast polymer 3D printers, capable of delivering remarkable productivity gains, up to 20 times greater, to professionals and businesses of varying sizes. Innovative partnerships with renowned material suppliers, combined with an open materials platform, serve as the catalyst for unlocking the full potential of additively manufactured polymers, particularly in volume production. Nexa3D leverages automated software tools, employing process interplay algorithms that optimize the production cycle.

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Lean Manufacturing

CMTC Helps George T. Hall Company with Lean, Quality and IT Services

California Manufacturing Technology Consulting (CMTC) | September 11, 2023

California Manufacturing Technology Consulting (CMTC) has played a pivotal role in boosting the business of control solutions provider George T. Hall by delivering Lean, Quality, and Information Technology services. This collaboration has transformed George T. Hall's operations, leading to increased productivity, certifications, and substantial cost savings. CMTC's collaboration with George T. Hall resulted in several significant outcomes. George T. Hall expanded its workforce, doubling service demand and estimated increased sales of $1.5 million, along with cost savings exceeding $2.5 million. Capital investments of $1.9 million were made to enhance products, equipment, information systems, software, training, and other resources. The need for operational enhancements drove the partnership between CMTC and George T. Hall, overcoming pandemic-related setbacks and strategic growth during a challenging business environment. George T. Hall, founded in 1932, started as a small distributor and has evolved into a full-service control solutions provider. The company operates in various industries, including pharmaceuticals, food and beverage, renewable energy, mining, and wastewater, serving clients across California and beyond. George T. Hall initially faced challenges during the COVID-19 pandemic, causing a slowdown in its business growth. Recognizing the need for strategic improvements, the company engaged with CMTC in June 2020. The key areas of focus included Lean and continuous improvement, quality management systems, and the implementation of a new ERP system, Acumatica. Implementing Acumatica ERP system replaced multiple disparate systems, improving productivity and visibility. The company achieved ISO 9001 certification and was recognized as one of 2023's Best Places to Work in Orange County. These efforts aimed to streamline processes, enhance productivity, and provide unified access to critical information. George T. Hall's transformative journey, facilitated by CMTC's services, underscores the value of strategic improvements in business operations. The company's achievements, including certifications, workforce expansion, increased sales, and cost savings, reflect the positive impact of these enhancements on its overall performance and competitiveness. About CMTC California Manufacturing Technology Consulting (CMTC) is a non-profit organization dedicated to delivering technical support, workforce development, and consulting expertise to small and medium-sized manufacturers across California. CMTC's operations are conducted through various cooperative arrangements with both federal and state government entities, most notably with the Hollings Manufacturing Extension Partnership (MEP) of the National Institute of Standards and Technology (NIST), a department within the Commerce sector, specifically for the State of California.

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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.

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Additive Manufacturing

Nexa3D Plans to Acquire Essentium for Broadened Capabilities

Nexa3D | November 07, 2023

Nexa3D, an ultrafast 3D printing leader, has taken a substantial step in staking its leader position in the industrial additive manufacturing space by signing a LOI to acquire Essentium, a manufacturer of HSE 3D printers and materials, adopted for high requirement, precision applications in aerospace, defense, and military. With this acquisition, Nexa3D will add high-speed extrusion (HSE) to its current product portfolio. The acquisition would broaden capabilities, diversify revenues, and expand addressable markets for the fast-growing 3D printing company. Avi Reichental, Co-founder, Chairman, and CEO of Nexa3D, stated that they are looking forward to welcoming the Essentium team to Nexa3D’s family. The acquisition will be a testament to their unwavering commitment to pushing the boundaries of 3D printing technology. He continued that by joining forces with Essentium, they aim to create synergies to deliver unmatched value to their customers. Together, they will drive ultrafast additive manufacturing innovation and provide even more powerful solutions for manufacturers seeking to achieve their production goals. Essentium, known for its variety of materials portfolio, true independent dual extruders (IDEX) and award-winning high-speed extrusion 3D printers, has provided solutions for complex polymer production applications 5 to 15 times quicker than other competing extrusion technologies. Essentium’s commitment to reliability and innovation has made it a go-to choice for manufacturers worldwide. Nexa3D has rapidly emerged as a leader in the 3D printing space, delivering excellent production solutions for businesses across various sectors. Best known for its ultrafast 3D printers, from desktops to the factory floor, its technology has redefined the possibilities of 3D printing production, enabling unparalleled productivity, material flexibility, and accuracy. Adopted by around 1200 customers all over the world, its printers have become the go-to solution for high-throughput production applications. This acquisition is expected to close by the end of this year or as soon as practicable afterward. Both Essentium and Nexa3D are committed to ensure a smooth transition and for maintaining uninterrupted services to existing and prospective customers. About Nexa3D Nexa3D is committed to the sustainable digitization of supply chains, driven by its relentless pursuit of advancing additive manufacturing. The company engineers ultrafast polymer 3D printers, capable of delivering remarkable productivity gains, up to 20 times greater, to professionals and businesses of varying sizes. Innovative partnerships with renowned material suppliers, combined with an open materials platform, serve as the catalyst for unlocking the full potential of additively manufactured polymers, particularly in volume production. Nexa3D leverages automated software tools, employing process interplay algorithms that optimize the production cycle.

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