Article | May 13, 2021
When the manufacturing industry began to embrace digital technology a decade ago, it adopted a new identity — smart manufacturing or Industry 4.0. Applying cloud, automation, analytics, machine learning and big data to production operations created a connected ecosystem for manufacturing and supply chain management, and became a high-growth market. At the start of 2020, the sector was on track to grow into a market worth more than $300 billion in the coming five years.
Then the pandemic hit. By spring, millions of workers had lost their jobs. Some plants closed temporarily or slowed production so workers could spread out to maintain a safe distance from one another. Investment in smart manufacturing fell too, by 16 percent between March and April alone. Some researchers predicted that such a pull-back would dampen investment through 2025.
But the conversations we’ve had with C-suite manufacturing executives and service providers suggest investment in smart manufacturing will intensify. By 2025, it could be worth more than $400 billion. It’s no wonder.
Article | November 20, 2021
Modern manufacturing methods are pioneering and adopting manufacturing industry advancements. To remain competitive in the present era and provide the most excellent industry solutions to your organization and target customer group in 2022, you must employ new manufacturing technologies in your manufacturing processes.
Additionally, embracing current technologies is the ideal approach to tackle the industry's current challenges such as workplace safety, digitalization of operations, and a lack of skilled workers.
This article will discuss some of the leading manufacturing technologies that transform traditional manufacturing facilities into smart manufacturing factories. So, let us begin.
Manufacturing Technology & Innovations for 2022
To better understand industry 4.0, let's look at some of the manufacturing technologies that will dominate the manufacturing industry in 2022.
Numerous industries, including aerospace, healthcare, electronics, and architecture, utilize 3D printing in manufacturing. It is the most widely used technology across industries and will remain so in 2022 and in the years to come.
We may also anticipate more advancements in this technology to help overcome current barriers to 3D printing adoption, including equipment costs, material constraints, lengthier manufacturing times, a lack of knowledge, and legal issues.
Additionally, it would assist manufacturers in overcoming current manufacturing challenges such as increasing product demand, increasing automation, and locating and retaining the workforce in manufacturing plants. It is vital to incorporate 3D technology into production processes to achieve greater precision and accuracy in manufacturing.
The Internet of Things is a critical component of the industry 4.0 revolution. It has altered the environment of data collection and analysis across sectors. For example, the Internet of Things is assisting manufacturers in better understanding manufacturing and supply chain operations, forecasting product demand, and boosting customer experiences.
Implementing IoT in your manufacturing plant will also help you avoid production delays and increase the performance of your production lines. Additionally, it will decrease equipment downtime and improve process efficiency. It also enhances worker safety and enables more effective labor management.
To begin implementing IoT in your manufacturing plant, you must first examine your manufacturing processes and research how other organizations have implemented IoT in their manufacturing processes or products. This method will assist you in determining the optimal location to begin integrating the IoT in your manufacturing plants and transforming them into smart ones.
“Once you start to look at yourself in the right way and realize that projects are at the core of your business, it is easy to see how you should use technology to support your business.”
– Matt Mong, VP of Market Innovation and Project Business Evangelist at Adeaca.
GD & T
The model created in the CAD program for any product is not exactly replicated with the exact dimensions during the production procedures. Thus, manufacturers or engineers utilize GD&T (Geometric Dimension &Tolerancing) to manage and communicate the permissible variation within a product assembly to manufacturing partners and inspectors.
GD&T is a programming language that enables developers and inspectors to optimize functionality without incurring additional costs. The primary advantage of GD&T is that it expresses the design intent rather than the final geometry. However, as with a vector or formula, it is a representation of the actual item.
AR & VR
The two primary transformation aspects in the industry 4.0notion are augmented reality (AR) and virtual reality (VR). AR technology in manufacturing enables firms to operate more efficiently by reducing production time. Additionally, it discovers and resolves manufacturing process difficulties.
Virtual reality technology benefits the industrial business in a variety of ways. It enables product designers to mimic their prototypes or models using powerful virtual reality software. This enables them to correct faults at the first stage of production and minimize production time and cost. Additionally, the technology provides additional benefits, such as increased workplace productivity and safety.
Enterprise Resource Planning (ERP) refers to a comprehensive end-to-end software solution that is used across sectors. It assists the manufacturing business in successfully maintaining production processes and other operational data by avoiding numerous roadblocks along the way. ERP technology enables enterprises to improve process efficiency and product quality by tackling industry-specific difficulties such as insufficient data, operation integration, inventory control, supply chain management, and on-time delivery.
Discover How John Deere Manufactured Their Tractors Using Cutting-edge Technologies
John Deere is a significant firm that embraces innovation and the Internet of Things. The company integrates Internet of Things sensors, wireless communication, and intelligent land management systems. It further integrates IoT tools into its manufacturing process, bridging the gap between technologies. Additionally, the company is a pioneer in GPS technology. Its most modern technology, which it incorporates into tractors, is accurate to within two centimeters. Additionally, the organization has implemented telemetry technology for predictive maintenance.
Manufacturing innovations are assisting manufacturers in modernizing their traditional manufacturing processes. Modern manufacturing is equipped with modern technologies that aim to improve the processes and goods, increasing the manufacturers' commercial revenues. So, to remain competitive in this age of technological innovation, manufacturers must update their manufacturing processes to remain relevant in today's manufacturing world.
What is manufacturing innovation?
Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors.
Which technologies are considered to be a component of advanced manufacturing?
3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing.
How are cutting-edge technologies assisting the manufacturing sector?
The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more.
"name": "What is manufacturing innovation?",
"text": "Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors."
"name": "Which technologies are considered to be a component of advanced manufacturing?",
"text": "3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing."
"name": "How are cutting-edge technologies assisting the manufacturing sector?",
"text": "The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more."
Article | December 21, 2021
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 analyticshas become essential for manufacturers.
Manufacturing analyticsis 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 analyticscan assist in maintaining production quality, boost performance with high-profit returns, decrease costs, and optimize supply networks.
This article will outline manufacturing analyticsand present a list of possible application cases. It will also highlight the benefits of manufacturing analyticsfor 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 analyticsuses predictive manufacturing, big data, Industrial IoT, network virtualization, and machine learningto produce better scalable production solutions.
Manufacturing analyticscollects 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 analyticscollects 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 analyticsthat drive any company’s production and overall manufacturing business growth. The benefits of manufacturing analyticsfall 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
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 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.
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 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 analyticsallows 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.
Businesses should adapt to changing times. Using analytics in manufacturinghas altered the business industry and spared it from possible hazards while boosting production lines. Industry 4.0's route has been carved. Manufacturing analyticsis 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.
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.
Article | November 20, 2021
The manufacturing business has always prioritized providing the excellent and most user-friendly products worldwide to its target consumer groups. However, digitalization and customer interaction approaches have altered the manufacturing industry's traditional business model.
Now, manufacturers must prioritize improving the customer experience for their target consumer group and keeping up with new trends daily to flourish and remain competitive in the upgrading market. Because, in the end, the buyer is the one who drives your business and generates money. Manufacturers are committing significant efforts to improve the customer experience in the following years.
To assist manufacturers in their sincere efforts to improve the customer experience in the manufacturing industry, we have compiled some key facts that must be understood and executed by the industry's or business-specific needs.
Before going into manufacturing customer experience statistics, it's essential to understand why customer experience is so critical in the manufacturing industry.
The Importance of Customer Experience in Manufacturing
Customer service and experience are critical components of any business, which is true in the manufacturing sector. Customer experience can be described as any activity taken by a business to positively influence a customer's impression and opinion of the business, its products, or services.
“You’ve got to start with the Customer Experience and work back toward the technology, not the other way around”
– Steve Jobs.
Customer experience benefits your business in a variety of ways, including the following,
It increases customer retention
It increases the customer lifetime value
It creates brand loyalty
It influences brand reputability
It can deliver businesses with a competitive edge.
Manufacturing Customer Experience Statistics
Make your manufacturing business more customer-centric and reap the benefits that many customer-centric companies, such as Apple, Nissan, and Chick-fil-A, are experiencing.
To better understand what the customer and industry have explored regarding the customer experience in 2022, below are some statistics from well-known businesses.
Businesses that prioritize customer experience see an 80% increase in revenue.
A positive customer experience increases customer interest in the product and acts as a form of word-of-mouth marketing. This way, the business benefits from increased sales and organic promotion by genuine consumers, critical for any manufacturing organization.
# Stat 2
73% of customers say that customer experience influences their purchasing decision.
Customers are not solely concerned with the product's quality or pricing. Instead, they are interested in the complete experience they get while purchasing a product. Therefore, if customers have a negative experience during the purchasing trip, it is pretty likely that they will leave the purchase process in the middle and hunt for other viable solutions on the market. Whereas, if the purchasing journey and post-purchase service are satisfactory, they will gladly purchase the goods and suggest new clients to your business.
# Stat 3
By 2023, AI and machine learning will manage around 40% of all consumer contacts.
(Source: Super Office)
Manufacturing production and revenue are increasing as a result of technological advances and applications. However, the customer experience is not far behind in implementing cutting-edge technology like AI, VR, and AR. For instance, chat bots are the best example of how artificial intelligence, natural language processing, and machine learning are being used to increase consumer engagement.
Virtual interaction is becoming more prevalent in the manufacturing industry daily, and both manufacturers and customers like this digital interaction.
“Our interactions with our customers have become much more virtual, which frankly seems to work well for the customer and us.”
-Scott Heide, Chief Executive Officer at Engineering Intent Corporation
Technology application in manufacturing will be maximized, and businesses intend to automate the customer experience by 2023.
# Stat 4
According to 70% of customers, an ideal customer experience should be quick, convenient, and cooperative, as well as friendly.
Customer service is a skill, and it's always a good idea to put yourself in your clients' shoes. According to an Adobe study, 70% of customers want a quick and convenient service that saves them time. In addition, they anticipate full collaboration throughout the purchasing process, including post-purchase servicing.
# Stat 5
72% of customers with a good consumer experience will tell six or more people about it.
(Source: Nice Reply)
In the first statistic, we discussed word-of-mouth marketing. You will always receive referrals for the excellent products or services you provide to your target consumer group. Customers that have a positive experience will always bring you two additional potential customers, and this number will grow exponentially with each pleasant experience delivered by your organization.
How did MacDonald's plan to increase revenue simply by improving the customer experience?
When McDonald's revenues started to decline, they focused on the customer experience rather than marketing strategies.
They began by listening to their clients and giving them a more streamlined experience. Customers told McDonald's to simplify the menu, increase order accuracy, and use higher-quality ingredients.
McDonald's also improved store interiors and introduced digital self-order kiosks and table service, reducing customer wait times. BTIG predicted a 4.1% increase in revenues as these modifications were made. As a result, McDonald's may outperform competitors by improving total customer service.
Customer experience is crucial in manufacturing, and manufacturers must leverage digital customer experience trends to improve their reputation. These a fore mentioned customer experience statistics can assist you in shaping a compelling client experience for 2022 and propelling your organization to new heights of success.
Why should a manufacturing company invest in customer experience?
Client experience improves customer retention, builds brand reputation, and gives companies a competitive edge. So manufacturers must invest in the consumer experience.
What is the difference between customer service and customer experience?
Customer service is one aspect of the customer journey, whereas consumer experience is the sum of all customer encounters with the brand.
What does a customer experience include?
Customer experience is the overall perception of your business or brand. It is the consequence of a customer's engagement with your website, customer service, and the product they purchase. So, it is the aggregate of all elements from browsing to buying to the product experience.
"name": "Why should a manufacturing company invest in customer experience?",
"text": "Client experience improves customer retention, builds brand reputation, and gives companies a competitive edge. So manufacturers must invest in the consumer experience."
"name": "What is the difference between customer service and customer experience?",
"text": "Customer service is one aspect of the customer journey, whereas consumer experience is the sum of all customer encounters with the brand."
"name": "What does a customer experience include?",
"text": "Customer experience is the overall perception of your business or brand. It is the consequence of a customer's engagement with your website, customer service, and the product they purchase. So, it is the aggregate of all elements from browsing to buying to the product experience."