Article | October 20, 2021
Additive manufacturing has advanced significantly in recent years and is currently used in nearly every area to improve both products and processes in the manufacturing business. As a result, manufacturers have been more imaginative and innovative in offering relevant products to their target customer group due to this technological advancement.
Mr. Matt Mong, a prominent business executive, also mentioned in one of his Media7 interviews,
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, VP Market Innovation and Project Business Evangelist at Adeaca
The use of additive technology provides several advantages, including creating unique shapes and low production costs. In addition, the increasing application of additive manufacturing technologies is accelerating the growth of the additive manufacturing market. According to recent research conducted by Metal AM, the value of additively produced components is expected to increase by 15% annually from $12 billion in 2020 to $51 billion in 2030. Thus, additive marketing is the way forward for all industries.
This article will cover the top five industries that utilize additive manufacturing and are advancing their businesses every day by overcoming the prevailing challenges such as production errors, downtime, and skilled labor shortage with the benefits of additive manufacturing.
Five Industries Utilizing Additive Manufacturing
Though additive manufacturing or 3D printing has penetrated almost all the industries, we have picked up a few of the prevailing industries that have started using additive manufacturing and excelling in it.
Additive Manufacturing in Aerospace
Aerospace has always been the first sector to adopt new technology. Precision is critical in this sector, as a failure of any component is not an option in aerospace. In aircraft production, dimension, weight, and temperature tolerance are critical, and additive technology provides every solution around this. As a result, additive manufacturing has evolved into a critical technology that adds value throughout the supply chain for prominent aircraft firms like Airbus, GE, Boeing, and TTM.
Additive Manufacturing in Healthcare
Healthcare or medical is one of the industries that is maximizing the benefits of additive manufacturing. Technology enables the medical sector to be more innovative, accurate, and capable of offering the most excellent medical solutions available today. It enables medical practitioners to rehearse before procedures and medical researchers to study functioning human tissues for basic biological research. In addition, it is utilized to fabricate tissues and organoids, surgical instruments, patient-specific surgical models, and bespoke prostheses. Thus, additive technology has altered the face of medicine, elevating it to a more sophisticated and solution-oriented state.
Additive Manufacturing in Architecture
As with other industries, additive manufacturing reshapes the architectural and construction sectors by eliminating conventional industrial barriers such as production time and cost, material waste, and design constraints. By utilizing 3D printing, designers can now quickly construct and demonstrate how structural parts will function and appear when combined. It also assists designers in seeing how the plan will seem subsequent execution.
Additive Manufacturing in Manufacturing
Nowadays, additive manufacturing, or 3D printing, is a significant part of the manufacturing process. For example, rather than fabricating a product from solid blocks, additive manufacturing may build a three-dimensional model utilizing fine powder, various metals, polymers, and composite materials as raw materials for constructing a 3D model with a three-dimensional printer.
Additive Manufacturing in Education
Additive manufacturing is reshaping the educational industry by introducing a new teaching trend and transforming the classroom experience for students. It is being used in various disciplines, including engineering, architecture, medicine, graphic design, geography, history, and even chemistry. They may produce prototypes, three-dimensional models, and historical objects, among other things. Thus, technology enables learners to get more practical information about their respective courses directly on the floor.
How has General Electric (GE) been pioneering the use of Additive Manufacturing for 20 years?
GE's primary competency is additive manufacturing (3D printing), and the company has made significant investments in the technology. It utilizes additive technology to manufacture a range of components for aviation and other sectors. This article will look at one of their manufacturing case studies and how additive technology enabled them to get the desired result from the end product.
CASE STUDY: OPTISYS
Optisys modified a vast, multi-part antenna assembly into a palm-sized, lighter, one-piece additive metal antenna. The antenna's aluminum material was chosen because of its surface conductivity, low weight, corrosion resistance, and stress and vibration resistance. Optisys was able to break even on machine acquisition within one year after acquiring its first Direct Metal Laser Melting (DMLM) equipment by utilizing additive technologies. (Source: General Electric)
Benefits and Outcomes
Non-recurring expenditures were reduced by 75%.
Weight loss of 95%
The size was reduced by 80%.
Part-to-part reduction of 100-to-1
Cycle duration shortened from 11 to 2 months
5 product lines were created for AM, a new market growth
Additive manufacturing benefits a wide variety of businesses. Industries must recognize the advantages of additive manufacturing and begin using the technology in their manufacturing processes to cut production time and costs while increasing product accuracy. This game-changing expansion of the additive manufacturing market across several industries is upgrading both products and production processes.
How do you define additive manufacturing?
Additive manufacturing (AM), more generally referred to as 3D printing, is a ground-breaking manufacturing technique that enables the creation of lighter, more robust components and systems. As the name implies, additive manufacturing is adding material to an item to create it.
Is additive manufacturing the same as 3D printing?
Both terms are interchangeable. Additive manufacturing and 3D printing manufacture components by connecting or adding material from a CAD file.
Which companies specialized in additive manufacturing?
American Additive Manufacturing, Forecast 3D, Sciaky, Inc., 3 Axis Development, Inc., Jonco Industries, Inc., Polyhistor International, Inc., and Caelynx, LLC are renowned companies for additive manufacturing in the United States of America.
"name": "How do you define additive manufacturing?",
"text": "Additive manufacturing (AM), more generally referred to as 3D printing, is a ground-breaking manufacturing technique that enables the creation of lighter, more robust components and systems. As the name implies, additive manufacturing is adding material to an item to create it."
"name": "Is additive manufacturing the same as 3D printing?",
"text": "Both terms are interchangeable. Additive manufacturing and 3D printing manufacture components by connecting or adding material from a CAD file."
"name": "Which companies specialized in additive manufacturing?",
"text": "American Additive Manufacturing, Forecast 3D, Sciaky, Inc., 3 Axis Development, Inc., Jonco Industries, Inc., Polyhistor International, Inc., and Caelynx, LLC are renowned companies for additive manufacturing in the United States of America."
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.
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'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.
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.
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.
"name": "What are the significant challenges in additive manufacturing?",
"text": "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."
"name": "Which company is leading in additive manufacturing technology in the USA?",
"text": "3D Systems Corp. is the leading company in additive manufacturing technology with a revenue of $566.6 million."
Article | December 8, 2021
An agile manufacturing strategy is one that places a strong priority on responding quickly to the needs of the customer, resulting in a major competitive advantage.
It is a captivating method to build a competitive work system in today's fast-moving marketplace. An agile organization must be able to adapt quickly to take advantage of limited opportunities and rapid shifts as per client demand. Agile manufacturing is gaining favor among manufacturers due to its several benefits, including increased work productivity and good control over the final deliverable. Furthermore, the shorter time to market is expanding the global market for enterprise agile transformation services.
According to Market Watch, with a CAGR of 17.9% from 2019 to 2026, the US enterprise agile transformation services market is predicted to reach $18,189.32 million by 2026.
So why is agile manufacturing gaining traction? What challenges do manufacturers encounter when implementing agile manufacturing, and how have industry leaders like GE, Adobe, and Accenture effectively implemented agile methodology in their organizations and become the best examples of agile manufacturing? In this article, we'll take a closer look at each point.
What Is the Importance of Agile Manufacturing?
The term "agile manufacturing" refers to the use of a variety of different technologies and methodologies in the production process. In order to meet market standards and criteria, organizations must be able to adapt quickly and effectively to their customers' needs by bringing agility to manufacturing. To ensure the quality of products and the cost of production are kept to a minimum, agile manufacturing helps firms to regulate their end product.
Because it immediately addresses the needs and worries of the clients, it is an effective strategy as well. By using this method, firms may better understand the market and use it to their advantage by creating products that meet the needs of their customers.
Challenges While Adopting Agile Methodologies on a Project
When we talk about agile challenges when implementing it on any project, some will be routine and some will be unique. So, let's get a quick grasp on the agile challenges.
Communication about the project: Clear communication between the development team and the product owner is critical throughout the project development life cycle. Any miscommunication can have an impact on the product's quality and the end result of the entire process.
Managing the day-to-day operational challenges: Throughout the project, daily minor or large operations play a significant impact on the overall project output. Any obstacles encountered when working on everyday chores should be resolved immediately to avoid any delays or halts in the process.
To make it function, you'll need experience: Any inexperienced product owners, scrum masters, or individuals new to the agile approach may have a negative impact on the project's expected output.
Various project contributors' buy-in: Inadequate training, a lack of motivation to show up from project participants, keeping customers in the loop, and a lack of departmental management are some of the problems that may hinder the accurate implementation of the agile methodology. The presence of one or more of these obstacles in any business or project may jeopardize the agile methodology and its total output.
Though there are many online training courses and books available on how to integrate agile practices into your project, each organization's scenario is unique, as are the challenges they encounter. As a result, handling the situation with experienced personnel that have a can-do attitude is what is required to make it work.
Following that, we'll look at some manufacturing business agile examples and how they've successfully implemented agile methodology in their organizations.
Agile Manufacturing Examples
We'll look at one of the most well-known industrial examples of agile manufacturing that has successfully implemented the methodology and achieved great outcomes. Take a peek at it.
One of the most popular agile manufacturing examples in performance management revamps is Adobe. When Donna Morris was Senior Vice President of People Resources in 2012, she thought the annual performance evaluation and the stack-ranking process were bureaucratic, paperwork-heavy overly complicated, taking up too many management hours for the company. Aside from this, she discovered that it set barriers to joint efforts, creativity, and development.
The Adobe team ditched annual performance reviews and encouraged managers and employees to regularly discuss performance via a system called “Check-in.” Adobe has reduced voluntary turnover by 30% and increased voluntary departures by 50% since making the transition. Moreover, the company saved 80,000 management hours annually.
General Electric famously overhauled its performance management system in 2015, paving the path for other global firms to follow in the electronics industry. Annual performance evaluations and the infamous rank-and-yank performance rating system (ranking employees and regularly eliminating the bottom 10%) had GE decide they needed to update their performance management system. The annual appraisals lasted a decade longer than the ranking system. They are now a more agile organization.
Instead of directing employees to attain goals, managers now guide and coach them. GE also decided to deploy an app they designed called PD@GE to facilitate regular employee feedback and productive performance discussions.
Using the app, each employee establishes priorities and solicits feedback. They can also give real-time feedback. Employees can request a face-to-face meeting at any time to discuss transparency, honesty, and continuous improvement.
These traits will not arise quickly and will require motivation and commitment for self-growth.
According to Accenture's previous system, employees who perform well tend to be the most narcissists and self-promoters. Accenture wanted to revamp their system and reward genuine employees. So they started using on-going performance conversations while focusing on performance development.
Because it required employees to compete with coworkers who may have had a different position, Accenture decided that forced ranking was illogical. The new system is more centered on the employee and aims to assist them in becoming the best version of themselves.
Agile manufacturing is a way to get the finest results and exceed client expectations on every project. Businesses are benefiting from agile manufacturing because it improves the end product and helps them better utilize their resources. The necessity of agile manufacturing in business is vital, and organizations must overcome the challenges they encounter while applying the agile approach to any of their projects in order to reap the benefits of agile production.
How does agile manufacturing help businesses?
An agile manufacturing process enables organizations to respond to client requests with flexibility when market conditions change, as well as regulate their intended production while preserving product quality and minimizing costs.
What is an agile organization?
Unified alignment, accountability, specialization, transparency, and cooperation are key elements in an agile organization. To guarantee these teams can work efficiently, the organization must maintain a solid environment.
What are the core elements of agility?
Individuals and interactions over processes and tools are the four values of the Agile Methodology. A working program is preferable to in-depth documentation. During contract negotiation, the customer's cooperation is valued.
"name": "How does agile manufacturing help businesses?",
"text": "An agile manufacturing process enables organizations to respond to client requests with flexibility when market conditions change, as well as regulate their intended production while preserving product quality and minimizing costs."
"name": "What is an agile organization?",
"text": "Unified alignment, accountability, specialization, transparency, and cooperation are key elements in an agile organization. To guarantee these teams can work efficiently, the organization must maintain a solid environment."
"name": "What are the core elements of agility?",
"text": "Individuals and interactions over processes and tools are the four values of the Agile Methodology. A working program is preferable to in-depth documentation. During contract negotiation, the customer's cooperation is valued."
Article | January 12, 2022
Real-time manufacturing analytics enables the manufacturing base to increase its efficiency and overall productivity in a variety of ways. Production data is an effective means of determining the factory's efficiency and identifying areas where it might be more productive.
“Without big data analytics, companies are blind and deaf, wandering out onto the web like deer on a freeway.”
– Geoffrey Moore, an American Management Consultant and Author
Creating a product-specific data collection may assist you in determining and visualizing what needs to be improved and what is doing well. In this article, we'll look at why manufacturing data collection is vital for your organization and how it may help you improve your operations.
Why is Manufacturing Data Collection so Critical?
Visibility is the key benefit that every manufacturer gets from manufacturing data collection. By collecting real-time data, or what we refer to as "shop floor data," manufacturers better understand how to assess, comprehend, and improve their plant operations. Manufacturers can make informed decisions based on detailed shop floor data. This is why having precise, real-time production data is critical.
“According to Allied Market Research, the worldwide manufacturing analytics market was worth $5,950 million in 2018 and is expected to reach $28,443.7 million by 2026, rising at a 16.5% compound annual growth rate between 2019 and 2026.”
For modern manufacturers, the advantages of data collection in manufacturing are numerous. The manufacturing industry benefits from production data and data-driven strategy in the following ways.
Substantial reduction in downtime by identifying and addressing the root causes of downtime.
It increases manufacturing efficiency and productivity by minimizing production bottlenecks.
A more robust maintenance routine that is based on real-time alerts and machine circumstances.
Improvements in demand forecasting, supplier scoring, waste reduction, and warehouse optimization reduce supply chain costs.
Higher-quality goods that are more in line with customers' wishes and demands depending on how they are utilized in the current world.
So, after looking at some of the significant benefits of real-time manufacturing analytics, let’s see what type of data is collected from production data tracking.
What Sorts of Data May Be Collected for Production Tracking?
Downtime: Operators can record or track downtime for jams, cleaning, minor slowdowns, and stoppages, among other causes, with production tracking software. In the latter scenario, downtime accuracy is optimized by removing rounding, human error, and forgotten downtime occurrences. The software also lets you categorize different types of stops.
Changeovers: Changeovers can also be manually recorded. However, changeovers tracked by monitoring software provide valuable data points for analysis, considerably reducing the time required for new configurations.
Maintenance Failures: Similar to downtime classification, the program assists in tracking the types of maintenance breakdowns and service orders and their possible causes. This may result in cost savings and enable businesses to implement predictive or prescriptive maintenance strategies based on reliable real-time data.
Items of Good Quality: This is a fundamental component of production management. Companies can't fulfill requests for delivery on schedule unless they know what's created first quality. Real-time data collection guarantees that these numbers are accurate and orders are filled efficiently.
Scrap: For manufacturers, waste is a significant challenge. However, conventional techniques are prone to overlooking scrap parts or documenting them wrong. The production tracking system can record the number and type of errors, allowing for analysis and improvement. Additionally, it can capture rework, rework time, and associated activities.
WIP Inventory: Accurate inventory management is critical in production, yet a significant quantity of material may become "invisible" once it is distributed to the floor. Collecting data on the movement and state of work in progress is critical for determining overall efficiency.
Production Schedule: Accurate data collection is essential to managing manufacturing orders and assessing operational progress. Customers' requests may not be fulfilled within the specified lead time if out of stock. Shop floor data gathering provides accurate production histories and helps managers fulfill delivery deadlines.
Which Real-time Data Collection Techniques Do Manufacturers Employ?
Manufacturers frequently employ a wide range of data collection techniques due to the abundance of data sources. Manual data collection and automated data collection are two of the most common data collection methods. Here are a few examples from both methods:
IoT: To provide the appropriate information to the right people at the right time with the correct shop floor insight, IoT (Internet of Things) sensor integration is employed.
PLC: The integration of PLC (Programmable Logic Controller) is used to measure and regulate manufacturing operations.
HMI: It can provide human context to data by integrating line HMI (Human Machine Interface) systems (such as individual shop terminals like touch screens located on factory floor equipment).
SCADA: Overarching management of activities with SCADA (Supervisory Control and Data Acquisition) systems.
CNC and Other Machines: Integrating CNC and other machines (both new and older types) to keep tabs on production efficiency and machine well-being is a must these days.
One of the most challenging aspects of shop floor management is determining what to measure and what to overlook. The National Institute of Standards and Technology recently conducted a study on assisting manufacturing operations in determining which data to collect from the shop floor.Additionally, you may utilize the manufacturing data set described above to obtain information from your manufacturing facility and use it strategically to improve operations, productivity, efficiency, and total business revenue in the long term.
What is manufacturing analytics?
Manufacturing analytics uses operations and event data and technology in the manufacturing business to assure quality, improve performance and yield, lower costs, and optimize supply chains.
How is data collected in manufacturing?
Data collection from a manufacturing process can be done through manual methods, paperwork, or a production/process management software system.