Article | March 7, 2022
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.
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Article | November 20, 2021
Additive manufacturing in America plays a significant part in reviving the manufacturing industry and establishing the country as a leader in applying additive manufacturing technology. The United States was formerly the industrial leader, but it fell out of favor between 2000 and 2010 for many reasons, including recession and structural and financial instability.
In this challenging time, technology interventions such as additive manufacturing in the manufacturing business have allowed the industry to survive. As per the recent report by A.T. Kearney, the USA, the industry leader in manufacturing, has worked hard to reclaim its top position in manufacturing and has also been named the leader in additive manufacturing.
Let's look at which fields of America are utilizing the benefits of additive manufacturing technology to reclaim its position as the industry leader.
Additive Manufacturing in America
The manufacturing industry is gravitating toward additive manufacturing, sometimes known as 3D printing. The numerous advantages of additive manufacturing, such as the reduction of material waste, the reduction of prototyping time, the reduction of prototyping costs, the creation of lightweight objects, and the ease with which it can be implemented and recreated, are making it more popular around the world, including in the United States.
In the United States, the additive manufacturing and material industry is expected to be worth $4.1 billion by 2020. China is the world's second-largest economy and is expected to reach a projected market size of US$14.5 billion by 2027, with a CAGR of 27.2 percent from 2020 to 2027.
How does America Leverage the Additive Manufacturing?
US Airforce has launched research into 3D printing
The US Air Force has begun researching 3D printing replacement parts for old planes utilizing a 3D printing platform.
The project initiative credit goes to 3D Systems, Lockheed Martin, Orbital ATK, and Northrop Grumman. America Makes will observe the project in its third stage and be led by the University of Dayton Research. The Air Force Laboratory financed the Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS) program.
The US Air Force will investigate how the 3D printing technology may reproduce components for outdated aircraft. Using additive manufacturing, the replacement parts may be created faster and in smaller batches, with no minimum order quantity. In addition, applying additive manufacturing will reduce the aircraft ground time and eliminate the need for parts warehousing.
American Manufacturing Companies and Additive Manufacturing
3D Systems, Inc.
3D Systems is an additive manufacturing company. Their work goes beyond prototyping. The company's experts use their deep domain expertise in aerospace and healthcare industries to produce competitive additive manufacturing solutions. This global leader in additive manufacturing helps you define business needs, verify manufacturing flow, and scale manufacturing flow.
General Electric
GE has seen the benefits of additive manufacturing and its options for product design, such as the potential to build lighter, more vital components and systems. As a result, they created goods that are better performing, more sophisticated in design, and easier to produce.
Ford
Ford's advanced manufacturing center in Michigan is all about additive manufacturing. The company employs 3D printing extensively in product development and is looking to integrate it into manufacturing lines. As a result, additive manufacturing is now a critical aspect of the Ford product development cycle, enabling prototype parts and product engineering exercises.
Final Words
The American manufacturing industry has experienced a renaissance as a result of the advent of additive manufacturing. Additionally, it has built its national accelerator and leading collaborative partner in additive manufacturing, "America Makes," which is the largest manufacturing industryglobally in terms of revenue and operates in a variety of areas. However, it is mainly focused on 3D printing or additive manufacturing, which is undoubtedly reviving the country's manufacturing sector.
FAQ
What are the significant challenges in additive manufacturing?
Limitations in terms of size, consistency of quality, scalability, a limited variety of materials and high material costs, and limited multi-material capabilities are only a few of the prevalent issues associated with additive manufacturing technology.
Which company is leading in additive manufacturing technology in the USA?
3D Systems Corp. is the leading company in additive manufacturing technology with a revenue of $566.6 million.
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Article | April 1, 2022
Digital twin technology in the manufacturing industry is playing a vital role in evaluating current and future production line conditions to increase OEE, productivity, and business profitability. It has become the most critical component of industry 4.0 because it collects precise data about your manufacturing process and uses that data to help you make wiser decisions.
In other words, manufacturers can utilize digital twins to check and assess physical assets, processes, and systems in a virtual environment.
In this article, we will discuss some of the major applications of digital twin technology in the manufacturing industry. Additionally, we also have a look at how this technology helps businesses increase their ROI.
Digital Twin Technology Applications
Product Development
Product development is a long and intricate process. For example, it might take up to six years to develop and launch a new automobile model. The shift from the previous model to the new model must be seamless. A minor error during this process might have a detrimental effect on the brand's value and revenue. A digital twin software enables the integration of data between previous-generation models and the new concept's digital representations. Additionally, twinning facilitates communication between product designers, end users, and other stakeholders. When it comes to product testing, having digital twin platforms eliminates the need to wait for performance data from car trials to determine the product's performance and quality.
Design Customization
As consumers become more intelligent, and demand personalized items in a timely manner, the manufacturing industry will become increasingly competitive. According to an Industry Week Special Research Report on the future of manufacturing, industrial enterprises of all sizes place a premium on process improvement and customer relationship strengthening, while small businesses focus on addressing customer demand for product customization. To assist in the customization process, manufacturers use Twin Design Customization, which enables the virtual design and re-design of goods prior to generating a physical product that fully meets consumer specifications.
Shop Floor Performance Improvement
The shop-floor digital twin concept helps businesses to be proactive as the system is capable of identifying anomalous situations. This demands attention and process improvements prior to them escalating into a real problem or standstill.
Predictive Maintenance
Individual digital twin examples for equipment or manufacturing processes can detect deviations that indicate the need for preventative repairs or maintenance prior to the occurrence of a serious problem. Additionally, they can aid in the optimization of load levels, tool calibration, and cycle times.
Can Digital Twin Boost Business Revenue?
According to a recent study by Juniper Research, revenue from digital twins (a virtual representation of a connected physical product, process, or service throughout its lifecycle) will reach $13 billion by 2023. This is an increase from an estimated $9.8 billion in 2019, representing an average annual growth rate of 35%. The study also discovered that increased deployments of advanced sensors for data collection and technological advancements such as machine learning, artificial intelligence, and high-performance computing are enhancing the benefits of digital twins.
So, how does a digital twin help your company's ROI?
The digital twin improves transformation efficiency by providing platforms and technologies that simulate the impact of process changes in your supply chain – in a safe, secure, and digitally isolated environment – using real-time scenario modeling generated parallel with live supply chain operations. More than a visualization, a digital twin can help accelerate innovation, foster consensus, and save time and money by iteratively modeling changes, testing how components or systems operate, and inexpensively troubleshooting malfunctions in a virtual world.
Final Words
The digital twin platforms benefit manufacturing organizations across all verticals, including supply chain management, manufacturing operations, and logistics. Thus, technology is accelerating and enhancing the manufacturing industry to obtain more positive results and, in turn, increase its efficiency and, as a result, its return on investment. The digital twin will gain popularity as businesses learn to use it to their advantage. According to a 2020 analysis conducted by Research and Markets, up to 89% of all IoT platforms will incorporate digital twins by 2025. Thus, the future of digital twins is bright, and we may witness increased use of digital twins in the next few years.
FAQ
How digital twin help businesses?
Digital twins can help businesses make better data-driven decisions. Businesses utilize digital twins to understand the state of physical assets, respond to changes, optimize operations, and add value to systems.
How does digital twin save money?
A digital twin can save time and money by iteratively modeling modifications, testing component or system functionality, and resolving faults in virtual reality.
What are the essential components of digital twin technology?
The concept of the digital twin is composed of three unique components: the physical product, the digital or virtual product, and the linkages between the two.
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Article | March 4, 2022
Cyber manufacturing is a term that refers to a modern manufacturing system that allows for asset management, reconfiguration, and productivity maintenance in a way that is easy to see and use.
Industry 4.0 anticipates an era of enormous opportunity for innovation and prosperity. Additionally, it introduces new risks and challenges in today's manufacturing cyber scene.
“Cybersecurity is starting to become more prevalent within organizations, so opportunities to grow in this industry will never end if you have the correct drive and determination.”
– Joe Boyle, SEO of SaltDNA
Numerous manufacturing organizations are experiencing an increase in cyber-attacks on control systems used to oversee industrial processes. Some of these systems may include programmable logic controllers and distributed control systems, as well as embedded systems and industrial Internet of Things (IoT) devices.
To help you develop a strong and secure manufacturing operation, this article will outline the multiple sorts of cyber-attacks in manufacturing and how you may improve manufacturing security. Let's begin with the importance of cybersecurity in the manufacturing industry.
Why is Cybersecurity in Manufacturing Crucial?
From January to March of 2019, the number of ransomware attacks in the manufacturing industry has increased by 156%. This is a big change, so it's important to have strong cyber security in the manufacturing process. Wherever software is in use, there is a high probability of cyber-attacks. The manufacturing industry is digitizing itself with cutting-edge technologies connected via the internet and various software. Therefore, the manufacturing industry is particularly vulnerable to cyber-attacks.
The following are some of the key reasons why manufacturers should prioritize manufacturing cybersecurity:
Increase in the use of IoT devices in the industry
Increase in the cost of data breaches
Increase in the number of cyber-attacks across industries
Increase in the severity of cyber-attacks
Increase in the use of widely accessible hacking tools
Increase in the use of remote workers
Five Major Types of Manufacturing Cyber Attacks
Ransomware
Due to the rising value of ransomware, cybercriminals have switched their attention away from selling personal and financial data. Unfortunately, industrial companies stand to lose a lot. Until the hacker's demands are met, this malware locks files on a network and makes them impossible to use.
If a ransom (typically millions) is not paid, threat actors may sell or leak important data. Until the ransom is paid, ransomware users render the company's network inaccessible. This strategy works well for attackers in the manufacturing industry because downtime is costly, and no manufacturer would like to encounter it for a long time.
Ransomware assaults generally occur on weekends or holidays to maximize damage before the attack is realized. This allows hackers to wait in comfort during a busy manufacturing period. Manufacturing enterprises are a desirable target for numerous reasons. A wide network of OT devices and a long supply chain make many endpoints and security flaws.
Phishing
Phishing is the most common type of network assault. Phishing emails are frequently used to gain access to a target firm to carry out further detrimental assaults or acts. For instance, in 2016, a CEO sent an email to a global solar panel manufacturer’s employee.
The email claimed that precise information about internal employees was required. The employee transmitted the data without confirming it. The CEO received the information. Unfortunately, the CEO was a cybercriminal, and the employee was phished, disclosing firm secrets. Perhaps the next generation of thieves will commit even more advanced and sophisticated penetrations and attacks.
Phishing attacks are characterized by the following characteristics:
Emails with malicious attachments
Emails with hyperlinks that differ from well-known websites and are misspelt
Emails with an attention-grabbing title or content
Emails from an unusual sender
Urgent orders or to-do items
Supply Chain Attacks
In the manufacturing business, no single firm can complete the entire production cycle. It must rely on several manufacturers' parts and components to complete the manufacturing and assembly of the entire product. As a result, numerous parties should coordinate to ensure an effective production process. This technique introduces the risk of supply chain attacks.
Numerous criminals utilize supply chain hacks to steal critical data and intellectual property rights from manufacturers. If a malicious attacker gets permission from the manufacturer's partner to access their network, they may steal critical information or data, and even essential manufacturing records, wreaking havoc on the business.
Additionally, manufacturers' external software or hardware poses security vulnerabilities, and there is a danger of attack along the equipment and system supply chain. Most products are developed using open-source or closed-source components, yet all these components have some level of security vulnerability.
The following are common indicators that your network has been compromised by a third party:
Incorrect usernames and passwords are used to access software systems
Strange redirects to unknown websites
Pop-up advertisements
Ransomware messages
Software freezes or crashes
IoT Attacks
As the intelligent transformation of manufacturing continues to progress, the Internet of Things' role in facilitating this process becomes increasingly critical. Manufacturers can optimize production processes more effectively and precisely by utilizing various IoT devices. For instance, businesses track assets, collect data, and perform analysis using IoT sensors embedded in devices. These sensors continuously monitor the various operating parameters of the equipment and critical data to enable automatic recovery and minimize maintenance downtime.
Increased security risks occur because of the proliferation of various IoT devices in manufacturing plants. IoT devices have networking capabilities and can be easily connected to a network. Typically, manufacturers' IoT, industrial control, and office networks are not adequately isolated. They can get into the industrial control network through public flaws or zero-day attacks on IoT devices. They can then launch malicious attacks on critical production equipment, which can stop production and cause processing accidents.
Insider Threats
Most manufacturing cyber attacks are carried out by outsiders, but nearly 30% originate from insiders or those with access to the company. As with external hackers, these attacks are frequently motivated by financial gain. However, some employees or former employees attack a business out of rage or dissatisfaction.
Internal threat actors do not require network access. They can access sensitive data by leveraging their existing knowledge or credentials. A threat actor is more likely to carry out an attack invisibly and undetected with pre-existing credentials. Unfortunately, former employees can typically access this information if passwords or entry methods are not changed to prevent such attacks.
Because of the increased use of personal devices and remote work, employees can unintentionally be the cause of an internal breach. Most businesses were unprepared for the regulations that would accompany a global pandemic. As manufacturing companies looked for ways to stay afloat by maintaining employees remotely, few had the necessary technological equipment to keep each employee as safe as the company's employees.
Many home-based employees discovered that working from home was not easy, as the line between personal and work time became increasingly blurred and eventually vanished. For hackers, these home networks and the use of unprotected personal devices have opened a new avenue for obtaining sensitive data from large andsmall businesses.
How to Mitigate Manufacturing Cyber Attack
Make Sure Your Software Is up to Date
Install software patches to prevent attackers from exploiting known issues or vulnerabilities. Numerous operating systems include an automatic update feature. If available, ensure that this option is enabled.
Utilize Current Antivirus Software
Install software patches to prevent attackers from exploiting known issues or vulnerabilities. Numerous operating systems include an automatic update feature. Ensure that this option is enabled if it is available.
Make Use of Strong Passwords
Set up password rules. A stolen or default password is used in 63% of confirmed data breaches. Create strong passwords that are difficult to guess and use unique passwords for each program and device. Experts advise using passphrases or passwords of at least 16 characters.
Make Use of MFA Tool
MFA validates a user's identity using at least two identification components. This stops attackers from taking advantage of weak authentication mechanisms, which lowers the risk of someone getting into your account even if they know the login credentials.
Train Employees on Security Awareness
Security awareness training unites employees, eliminates risks and events, and protects both the company and the employees. Employees should also be taught how to look for and deal with threats like phishing.
Final Word
Industry 4.0 is all about smart technologies that operate with the help of the internet. It increases the probability of manufacturing equipment and software being hacked. Therefore, while you intend to create a smart environment in your manufacturing facility, you must take the necessary cyber security measures.
The strategies mentioned in this article to mitigate the cyber-attacks will ensure that you take every precaution to keep the working environment safe. There are many ways to protect your manufacturing business from cyberattacks. The techniques and the types of attacks described in this article will help you know what to opt for and which attacks to look for in your manufacturing business.
FAQ
What are the most common cyber security threats?
Phishing attacks are the most common cyber security threats that employees fall for. With the advancement of phishing attacks, many employees lack the knowledge necessary to spot a phishing email. Additionally, many employees have poor cyber security practices, such as using the same password for work and personal devices, which is also one of the reasons for rising phishing attacks.
What are the cyber security challenges in Industry 4.0?
Smart factories are vulnerable to the same types of attacks as conventional networks, including vulnerability exploitation, malware, denial of service (DoS), device hacking, and other typical attack tactics.
What is CPS in manufacturing?
CPS (Cyber Physical Systems) are defined as designed systems that are comprised of and reliant on the seamless integration of computer algorithms and physical components.
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