Article | December 8, 2021
The new manufacturing industry outlook for 2022 is what businesses desire. Due to COVID-19, the sector has seen several ups and downs in recent years. But the industry overcame the most difficult situation by adopting innovations as their working hands.
But all this upgrading and digitalization in manufacturing isn't for everyone. Some manufacturers may struggle with this change, while others may not. So, taking into account all industry segments, we have compiled a list of potential manufacturing challenges for 2022.
“Many companies simply are not willing to change or think they are done once they make a change. But the truth is that technology, consumer demands; the way we work, human needs and much more are constantly changing.”
– Michael Walton, Director, Industry Executive (Manufacturing) at Microsoft
The summary of manufacturing industry challenges and industry outlook for 2022 are presented in the stats below.
According to the National Association of Manufacturers (NAM), four million manufacturing jobs will likely be needed over the next decade, and 2.1 million will likely go unfulfilled unless we motivate more people to pursue modern manufacturing occupations.
According to PTC, 70% of companies have or are working on a digital transformation plan.
According to Adobe, 60% of marketers feel technology has increased competitiveness.
The statistics show that while digitalization facilitates the process, it also poses several challenges that must be addressed in the coming years. Let's explore what obstacles manufacturers may face in 2022.
The Manufacturing Industry Challenges in 2022
The manufacturing business has had a difficult few years as a result of the current economic downturn, and 2022 may not be even that smooth. Thought, technology, and current trends make the operations of upscale manufacturers easier, but not everyone is on the same page.
Let's look at some of the manufacturing challenges that businesses will face in the next year.
Skilled Labor Shortage
The manufacturing industry is facing a workforce shortfall as a skilled generation prepares to retire. Industry experts say that by 2025, there will be between 2 and 3.5 million unfilled manufacturing jobs. As a result of the advancement of new technologies, manufacturing organisations are finding themselves with fewer personnel. They do, however, require individuals with a diverse range of abilities, such as mathematicians and analytic thinkers, to accomplish the tasks with precision.
Specific manufacturing tasks have been automated to save time and money. Industry has adopted machine sensors to capture large amounts of data. With this kind of innovation, the industry's job structure is changing and the desire to hire an untrained or trainable workforce is slowly fading in the industry. However, using augmented reality and virtual reality, manufacturers can easily train personnel for the job and save money.
Lack of Ability to Mine Data
Manufacturing is progressively using IoT. The majority of businesses have already installed or are planning to install Internet of Things machines. These smart machines let businesses collect data to improve production and conduct predictive maintenance. But getting data is a simple task. The difficult aspect is analyzing and aggregating data.
Despite possessing the machines, most companies lack the systems to analyze and retrieve the data recorded by the systems. In this way, the industries are missing a vital opportunity. The industry must improve data mining capabilities to make better decisions in real-time.
Using IoT for analytics and predictive maintenance is critical. Monitoring technologies can help the sector examine data quickly. It can also help predict an asset's maintenance period. As a result, the industry will move from replacement to predict and fix.
Self-service Web Portals That Is Extremely Detailed and Precise
Manufacturing businesses usually strive for on-time order delivery and optimum revenue. However, consumer self-service, which has been in the industry for a long time, has never proven to be a simple walk for clients. Clients are frequently required to pick up the phone and contact manufacturers in order to track their orders and receive delivery estimates. This is hardly the service one would expect from a manufacturer, even more so in today's digital era.
The term customers in manufacturing include partners, end-users, and subcontractors. These three clients have distinct requirements and concerns about collaborating with the manufacturer. Companies can better serve their customers if their partner and end-customer portals are linked to a central hub which we can mention as self-service web portals.
All of the information and updates they need about their orders will be available to them through this new system. They can track, accept and amend their tasks. They'll also use the self–service portal to contact the manufacturer.
In this way, manufacturers can better serve their customers. A system like this will ensure that all parties have access to timely information in a digital format.
Meeting the Deadline for the Project
Product launch timelines are extremely demanding, tight, and stringent. Every project in the assembly line is about cost, time, and quality. Ultimately, these projects are rigorous and well-controlled. Manufacturers who fail to meet deadlines risk losing millions in potential revenues and sales.
Due to rigidity and stringent control, companies are less able to change project scopes or make adjustments as projects develop. The majority of initiatives begin with a design commitment. As new facts or change criteria emerge, adjustment flexibility decreases. This can be aggravating for a team that expects high-quality results. Deadlines are always a constraint.
Effective Business Digital Marketing Strategy
An industry's key digital transformation challenges are driving leads, sales, and MRR through digital channels. Many manufacturing organizations struggle to efficiently use marketing channels like paid media, enterprise SEO, local SEO, content strategy, and social media. In our opinion, one of the most significant issues these organizations have is their digital experience, website design, and overall brand presentation. They can't ignore them if they want to keep enjoying the manufacturing revival.
Visibility of the Supply Chain
Manufacturers must respond to the growing demand from customers for greater transparency. In order to meet customer demand across the customer experience and product lifecycle, they must first understand that precise and real-time visibility throughout the supply chain is essential.
All details must be taken into consideration by the manufacturers. They must be aware of any delays in the arrival of products on the market. Keeping abreast of such developments would give them a leg up in terms of adjusting or rectifying the situation.
Manufacturing industry challenges have long been a part of the industry. However, industry leaders and professionals have always confronted and overcome any challenges that have come their way. The year 2022 will also be a year of achievements, setting new records, and growth for the manufacturing industry, since it will be a year in which it will develop solutions to all of the aforementioned challenges.
What is the future of manufacturing?
Manufacturers should start using AI, block chains, and robotics today. The combination of these new technologies will reshape manufacturing. A new workforce capable of augmenting these technologies is developing and will become the future of manufacturing.
How will automation affect manufacturing in 2022?
When applied properly, automation can greatly assist manufacturing. These benefits include shorter production times, faster and more efficient work than human labor, and lower production costs.
How is the manufacturing industry’s market likely to upsurge in the future?
According to BCC Research, the global manufacturing and process control market is expected to grow at a CAGR of 6.3 percent from $86.7 billion in 2020 to $117.7 billion in 2025.
"name": "What is the future of manufacturing?",
"text": "Manufacturers should start using AI, block chains, and robotics today. The combination of these new technologies will reshape manufacturing. A new workforce capable of augmenting these technologies is developing and will become the future of manufacturing."
"name": "How will automation affect manufacturing in 2022?",
"text": "When applied properly, automation can greatly assist manufacturing. These benefits include shorter production times, faster and more efficient work than human labor, and lower production costs."
"name": "How is the manufacturing industry’s market likely to upsurge in the future?",
"text": "According to BCC Research, the global manufacturing and process control market is expected to grow at a CAGR of 6.3 percent from $86.7 billion in 2020 to $117.7 billion in 2025."
Article | May 10, 2021
Jason Spera, picture left, recently shared his vantage of the changes for factory floor automation in 2021. Jason is CEO and Co-Founder, Aegis Software. Spera is a leader in MES/MOM software platforms for discrete manufacturers with particular expertise in electronics manufacturing. Founded in 1997, today more than 2,200 factory sites worldwide use some form of Aegis software to improve productivity and quality while meeting regulatory, compliance and traceability challenges. Spera's background as a manufacturing engineer in an electronics manufacturing company and the needs he saw in that role led to the creation of the original software products and continue to inform the vision that drives Aegis solutions, like FactoryLogix. He regularly speaks on topics surrounding factory digitization, IIoT, and Industry 4.0. Contact Jason on LinkedIn.
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"
Article | January 3, 2022
Production planning and control are critical components of any manufacturing organization. It helps organizations with the regular and timely delivery of their goods. Furthermore, it allows manufacturing businesses to increase their plant’s efficiency and reduce production costs.
Numerous software and tools for production scheduling and planning are available on the market, including Visual Planning, MaxScheduler, and MRPeasy, which assist manufacturing organizations in planning, scheduling, and controlling their production.
According to KBV Research, the manufacturing operations management software market is anticipated to reach $14.6 billion by 2025 globally, expanding at a market growth of 10.2 percent CAGR during the forecast period.
So, what exactly is production planning and control?
Production planning is an administrative process within a manufacturing business. It ensures that sufficient raw materials, personnel, and other necessary items are procured and prepared to produce finished products according to the specified schedule.
Scheduling, dispatch, inspection, quality control, inventory management, supply chain management, and equipment management require production planning. Production control makes sure that the production team meets the required production targets, maximizes resource utilization, manages quality, and saves money.
“Manufacturing is more than just putting parts together. It’s coming up with ideas, testing principles and perfecting the engineering, as well as final assembly.”
– James Dyson
In oversize factories, production planning and control are frequently managed by a production planning department, which comprises production controllers and a production control manager. More significant operations are commonly monitored and controlled from a central location, such as a control room, operations room, or operations control center.
Why Should You Consider Production Planning?
An efficient production process that meets the needs of both customers and the organization can only be achieved through careful planning in the early stages of production. In addition, it streamlines both customer-dependent and customer-independent processes, such as on-time delivery and production cycle time.
A well-designed production plan minimizes lead time, the period between placing an order and its completion and delivery. The definition of lead time varies slightly according to the company and the type of production planning required. For example, in supply chain management, lead time refers to the time required for parts to be shipped from a supplier.
Steps in Production Planning and Control
The first stage of production planning determines the path that raw materials will take from their source to the finished product. You will use this section to determine the equipment, resources, materials, and sequencing used.
It is necessary to determine when operations will occur during the second stage of production planning. In this case, the objectives may be to increase throughput, reduce lead time, or increase profits, among other things. Numerous strategies can be employed to create the most efficient schedule.
The third and final production control stage begins when the manufacturing process is initiated. When the scheduling plan is implemented, materials and work orders are released, and work is flowing down the production line, the production line is considered to be running smoothly.
The fourth stage of manufacturing control ascertains whether the process has any bottlenecks or inefficiencies. You can use this stage to compare the predicted run hours and quantities with the actual values reported to see if any improvements can be made to the processes.
Production Planning Example
Though production planning is classified into several categories, including flow, mass production, process, job, and batch, we will look at a batch production planning example here.
Manufacturing products in batches is known as "batch production planning." This method allows for close monitoring at each stage of the process, and quick correction since an error discovered in one batch can be corrected in the next batch. However, batch manufacturing can lead to bottlenecks or delays if some equipment can handle more than others, so it's critical to consider capacity at every stage.
Consider the following example of batch production planning:
Jackson's Baked Goods is in the process of developing a production plan for their new cinnamon bread. To begin with, the head baker determines the batch production time required by the recipe.
He then adjusts the bakery's weekly ingredient orders to include the necessary supplies and schedules the weekly cinnamon bread bake during staff downtime.
Finally, he creates a list of standards for the bakery staff to check at each production stage, allowing them to quickly identify any substandard materials or other batch errors without wasting processing time on subpar cinnamon bread.
Running a smooth and problem-free manufacturing operation relies heavily on a precise production planner. Many large manufacturing companies already have a strong focus on streamlining their processes and making the most of every manufacturing operation, but small manufacturing companies still have work to do in this area. As a result, plan, schedule, and control a production that will enable you to run your business in order to meet its objectives.
What is the difference between planning and scheduling in production?
Production planning and scheduling are remarkably similar. But, it is critical to note that planning determines what operations need to be done and scheduling determines when and who will do the operations.
What is a production plan?
A product or service's production planning is the process of creating a guide for the design and manufacture of a given product or service. Production planning aims to help organizations make their manufacturing processes as productive as possible.