Article | November 20, 2021
Advanced manufacturing enables the concept of industry 4.0 and represents a significant milestone in the manufacturing industry. Additive manufacturing is a critical component of the industry 4.0 concept, propelling the industry to new heights of innovation.
In various fields that are not immediately related to industry 4.0 or manufacturing, additive manufacturing has alternatively been referred to as 3D printing. The numerous advantages of additive manufacturing, such as reduced cost and time, are boosting its popularity and use in manufacturing and other industries.
“Digital technology is so empowering on so many fronts, but for it to be empowering, it must be for everyone.”
– Michael Walton, Director, Industry Executive (Manufacturing) at Microsoft.
The global market of additive manufacturing is anticipated to increase at a 14.42 percent compound annual growth rate from USD 9.52 billion in 2020 to USD 27.91 billion in 2025. According to this market research, the future of 3D printing or additive manufacturing is quite bright in the coming years, and we will see widespread application across industries.
First, let us understand the idea of additive manufacturing and its benefits to various industries.
Concept of Additive Manufacturing
Additive manufacturing is building a real thing from a three-dimensional computer model, often by successively layering a material. This technique utilizes computer-aided design (CAD) software or 3D object scanners to command devices to deposit material in exact geometric shapes layer by layer. As the name implies, additive manufacturing involves the addition of material to produce an object.
Additive Manufacturing Benefits
Produces Fewer Scraps and Trash
When we compare additive manufacturing to traditional manufacturing techniques such as milling or turning, additive manufacturing adds only the amount of material required to build a product. As a result, it generates less waste and conserves scarce resources.
Reduces the Time and Cost of Prototyping
Making a product prototype is now faster, easier, and cheaper. Other production processes, like milling, have high setup and material costs. Prototyping is less expensive and takes less time, so you can quickly produce, test, and modify. It also shows practically instant verification of progress done.
It Encourages the Digitalization of Businesses
Continuous and effective communication between devices, machines, and robots is required for additive manufacturing. However, this is only achievable with effective digitization of production processes. As a result, businesses invest more in digital and IoT, a prerequisite for Industry 4.0.
It Simplifies the Assembling Process by Condensing it into a Single Component
Additive manufacturing in Industry 4.0 also simplifies the production process, especially product assembly. A traditional component requires numerous manufacturing procedures. This increases material and labor expenses as well as production time. However, additive manufacturing allows you to print the group in one piece.
The Top Three Industries That Make the Most Use of Additive Manufacturing
Additive manufacturing is presently used in a variety of industries. However, specific sectors make the best use of it. Thus, we will examine the industries embracing additive manufacturing technology and emerging with new life easing solutions.
In the healthcare industry, dentistry is the critical application of additive manufacturing. Technology helps it create bridges, crowns, braces, and dentures, always in high demand.
Additive manufacturing has also been used to create tissues and organs, surgical tools, patient-specific surgical models, and personalized prosthetics. For example, many medical equipment companies employ 3D printing to build patient-specific organ replicas that surgeons can practice before completing complex surgeries.
Additive manufacturing is utilized to fabricate metal brackets that serve as structural components within airplanes. Prototypes are increasingly being printed in three dimensions, allowing designers to fine-tune the shape and fit of finished parts. In addition, interior airplane components such as cockpit dashboards and door handles are manufactured using 3D printing services.
3D printing can manufacture molds and thermoforming tools, grips, jigs, and fixtures for the automotive industry. Automakers utilize additive printing to customize parts for specific vehicles or drivers (e.g., seats for racing cars).
An appealing colored dashboard, efficient fuel systems, and complicated braking mechanisms are all possible with 3D printing in the automotive industry. Therefore, it is best suited for pre-production, manufacture, and modification of automotive parts.
How Does NASA use additive manufacturing in its space projects?
The space environment has always been unpredictable, and scientists must be adequately prepared before embarking on any space mission. They must consider the durability and weight of all the objects they propose to transport into space. To land any object on a planet that does not have a flat surface or similar weather conditions to earth, scientists must design each object with these considerations in mind.
“You always want it to be as light as possible, but you also want it to be strong enough.”
-Chris Chapman, NASA Test Engineer
It is not conceivable to make items capable of dealing with all the changes on other planets and achieving these project objectives using conventional materials and production processes. However, scientists do require a technique that will enable them to manufacture lighter and stronger objects for their space missions.
3D printing has played a significant part in meeting this demand and has provided space projects to manufacture objects that would withstand any unexpected events during space missions. For example, NASA employed 3D-printed metal components in their Mars project.
NASA's specialized engineers are utilizing additive manufacturing to create rocket engines and possible Moon and Mars outposts. NASA used the 11 3D printed metal components on its Mars mission as well. It employed 3D printed components for the first time in the Curiosity rover, which landed on Mars in 2012. It was a successful project, and NASA has since begun employing 3D printed parts in its space missions to make machines lighter while remaining robust and functional.
Additive manufacturing technology is making a real difference in the manufacturing process, and it is becoming the trending technology in the manufacturing industry. The benefits of additive manufacturing make the manufacturing process more advanced, easy, and customer-oriented. Additive manufacturing is the major transformation in the manufacturing industry and will take it to new heights of precision.
Why is additive manufacturing critical?
Additive manufacturing reduces the time and cost of prototyping and reduces the scraps amount during the manufacturing process of any object. In addition, it simplifies multiple processes from various industries.
Are additive manufacturing and 3D printing the same?
Yes, additive manufacturing and 3D printing are the same processes with different names as per the choice of the different industries. For example, in some industries such as space missions, It is also referred to as Fused Deposition Modelling (FDM).
Which is the most applied sector for additive manufacturing?
Healthcare is the industry that utilizes additive manufacturing technology the most. It also helps medical practitioners practice surgery on any critical body part with its 3D printed model from human tissues.
"name": "Why is additive manufacturing critical?",
"text": "Additive manufacturing reduces the time and cost of prototyping and reduces the scraps amount during the manufacturing process of any object. In addition, it simplifies multiple processes from various industries."
"name": "Are additive manufacturing and 3D printing the same?",
"text": "Yes, additive manufacturing and 3D printing are the same processes with different names as per the choice of the different industries. For example, in some industries such as space missions, It is also referred to as Fused Deposition Modelling (FDM)."
"name": "Which is the most applied sector for additive manufacturing?",
"text": "Healthcare is the industry that utilizes additive manufacturing technology the most. It also helps medical practitioners practice surgery on any critical body part with its 3D printed model from human tissues."
Article | November 1, 2021
Manufacturing processes will undergo significant transformation in 2022 as a result of advanced manufacturing technology. The changing manufacturing industry is full of digitization to improve processes, products, productivity, and business revenue.
Manufacturers must realize the advantages of advanced manufacturing and learn to enhance their production processes to increase their manufacturing plant's productivity. Once you understand the heart of your business and where to integrate technology, you're halfway to success.
The manufacturing industry's top professionals have also recognized the technology shift and are supporting upskilling in the manufacturing business. Mr. Matt Mong has said in his interview with Media7,
“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 Market Innovation and Project Business Evangelist at Adeaca
Importance of Advanced Manufacturing
Adopting innovative manufacturing technologies has several advantages that grow its acceptance and relevance among manufacturers across industries. The following are the most significant advantages of advanced manufacturing.
Amplifying the product and process quality
Improvement in productivity
Encourages new ways to innovation
Decreases production time
Considering the factors above that contribute to the production process becoming more efficient, productive, and revenue-generating, advanced manufacturing will continue to dominate the manufacturing business in 2022.
Top Five Technologies That Are Advancing Manufacturing in 2022
To better understand the current trends in manufacturing technology, let us comprehend the technologies that are advancing the manufacturing industry. Additionally, discover how these technologies help manufacturers to advance their manufacturing processes.
Cloud computing in manufacturing is used for marketing, product development, inventory management, and productivity management. It stores software and commercial data via internet connections. Cloud computing is becoming a prevalent technology because it enables manufacturers to improve communication and manage the entire production cycle effectively.
According to MarketsandMarkets' study, the global cloud computing market will also increase to 832.1 billion dollars by 2025, growing at a 17.5 percent annual rate in the following years.
Benefits of Cloud Computing
Fewer technical issues when compared to traditional software use
Cost savings because no in-house servers are required
Cloud computing enables easy scalability for your developing firm
Cloud computing provides centralized control and access from any device
How did McDonald's use AWS cloud computing services to transform their customer service?
Additive manufacturing enables the fabrication of lighter, more sophisticated designs that would be impossible or prohibitively expensive to fabricate using conventional dies, molds, milling, and machining techniques. Rapid prototyping is another area where additive manufacturing thrives.
As a result, it is gaining a grip in the manufacturing business. According to Statista's market research, the additive manufacturing industry is worth approximately 12.6 billion US dollars in 2020 and is predicted to increase at a compound annual growth rate of 17% until 2023.
Benefits of Additive Manufacturing
Reduces material waste
Simplifies manufacturing processes
Additive manufacturing enables on-demand production
Increases supply chain flexibility
The finished product can be made close to the end customer
Robots are used in manufacturing to automate repetitive tasks, resulting in a more efficient assembly line. Humans and robots work together on a variety of things as well during the production of various products. Many jobs are hazardous or necessitate many supplies, which could be harmful to the human workers themselves. So, in such instances, robots play a significant role in executing manufacturing operations.
Robotics' increasing application in production is transforming it into a necessary component of industrial processes in the future. According to Mordorintelligence's study, the robots industry was worth USD 27.73 billion in 2020 and is predicted to reach USD 74.1 billion by 2026, growing at a CAGR of 17.45 percent between 2021 and 2026.
Benefits of Robotics
Increased productivity when compared to traditional manufacturing
Consistent speed and quality during goods production
Increased workplace safety for all employees at the manufacturing plant
Aids in more efficient use of floor space
Internet of Things
The Internet of Things allows devices to interconnect with one another and exchange data. The IoT connects assets to processes, systems, and people in manufacturing. This enables improved process integration, increased efficiency, and the advancement of manufacturing to the next transformation phase, Industry 4.0.
According to Mordorintelligence's market research, the global IoT market is estimated to reach USD 1,386.06 billion in 2026, up from USD 761.4 billion in 2020, a CAGR of 10.53 percent over the forecast period of 2021 to 2026.
Benefits of Internet of Things
It contributes to increased energy efficiency by identifying and optimizing underperforming devices
It monitors all processes and parameters to determine when to replace specific components
It improves product quality by analyzing and correcting issues at any stage of the manufacturing process
It reduces downtime by detecting and alerting production line personnel to problems
It enables more informed decision-making by unlocking
Virtual reality enables plant managers to mimic manufacturing processes and assembly line layouts to discover potentially harmful scenarios. Additionally, virtual reality can immerse an employee in a future workstation and then capture their movement to assess task feasibility and proficiency. As a result, the usage of virtual reality in manufacturing is increasing daily and is widely seen as the industry's future.
According to market research firm markets and markets, the worldwide virtual reality industry is estimated to rise by USD 20.9 billion by 2025, expanding at a 27.9 percent compound annual growth rate from 2020 to 2025.
Benefits of Virtual Reality
Enables a more thorough examination of the product's design
Enables the gathering of feedback on future items before they are launched in the real world
In recent years, advanced manufacturing technology has helped the manufacturing industry become more efficient, precise, and goal-oriented. As a result, manufacturers are eager to upgrade their current manufacturing facilities to state-of-the-art facilities. As a result, manufacturing companies would become more competitive and an integral industry component if they implement cutting-edge technologies.
How do you define advanced manufacturing?
Product and process improvement through inventive use of new technology is called advanced manufacturing.
Which sectors are utilizing cutting-edge technology?
Aerospace, Medical, Electronics, Transportation, Energy, and Consumer Product Production Companies are the top businesses or sectors that use cutting-edge technologies with sophisticated manufacturing.
What is the difference between conventional manufacturing and advanced manufacturing?
Traditional manufacturing adds value to attain the goal. Traditional manufacturing adds value to attain the goal. But, on the other hand, advanced manufacturing covers production methods in specific industries like aerospace, medical, pharmaceutical, etc.
Article | December 8, 2021
The manufacturing production schedule is a critical aspect that enables the manufacturing business to complete each production activity precisely and on time. Allocating different raw materials, resources, or processes to distinct project phases is called a production schedule. Its goal is to make your manufacturing process as efficient and cost-effective as possible in terms of resources and labor — all while delivering products on schedule.
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
So, how is the overall production schedule managed?
According to businesswire, the global APS (Advanced Production Planning and Scheduling) software market was valued at $1,491.22 million in 2020 and is anticipated to raise $2,941.27 million by 2028 expanding at an 8.86 percent CAGR from 2020 to 2028.
Some software and tools are available to assist manufacturing organizations in properly scheduling production planning, including MaxScheduler, TACTIC, MRPeasy, and Gantt charts. Though there are numerous software programs available on the market for production scheduling, the most crucial aspect is determining which elements to consider when planning production.
This blog will look at the five most important factors to consider while planning the production schedule.
Five Elements to Consider When Scheduling Production
As we saw in the introduction, production scheduling is used in the manufacturing process to assign plant and machinery resources, schedule human resources, plan production processes, and purchase materials.
So, what are the primary components or stages of this production scheduling process? Let's take a quick look at each of them.
Planning to Make the Best Use of the Company's Resources
The role of planning in production scheduling is to use the company's resources to maintain a regular production flow. As a result, downtime is decreased, and bottlenecks are minimized, allowing production to be optimized. For production scheduling, two forms of planning can be used:
Dynamic Planning: Dynamic planning is carried out under the idea that process stages will alter. So, materials must be ready, but production cannot begin until demand is decided.
Static Planning: Static planning is done keeping in mind that all process steps will be completed on schedule and without adjustments.
Routing to Determine the Order of Actions
A “bill of materials” is used in discrete manufacturing to specify what things are needed and in what quantities.
Routing determines the path and sequence of required phases of the process. It may involve in-house operations, but it may also comprise sub-contracted components that must be returned to the production flow for final assembly.
Scheduling to Make Use of Predetermined Planning Levels
To manufacture products from components or raw materials, scheduling makes use of the previously set planning level. As a result, it is time-dependent and must meet the demand outlined at the planning level.
Each department, product, and procedure can have their own unique set of timetables. Sub-schedules for sub-assemblies or mixes and blends may be defined by department-specific master production schedules, utilized at the highest level to define product timeframes.
Dispatching to Decide on Immediate Actions
Dispatching assigns the following jobs to be done from a subset of the production queue. Dispatching is utilized to make quick decisions. This is in contrast to planning, which involves the planning of future actions. Dispatching is utilized in both pull and push production systems.
Execution to Ensure that all Processes are Carried out Correctly
Production scheduling must rely on proper execution to ensure that all processes are completed appropriately and in the sequence planned.
It requires everyone to know what they are expected to do and when they are expected to do it. Execution requires knowledgeable management decisions, well-trained employees, correct data in the manufacturing plan and schedule, and consistent sales statistics and forecast numbers. All must be present for the organization to carry out its production plan and fulfill orders.
How MRPeasy – A Production Scheduling Software Assist Manufacturing Companies in Scheduling Their Production?
MRPeasy is a cloud-based material requirements planning (MRP) application explicitly designed for small manufacturing units. Its primary functions are purchase order management, forecasting, and inventory management.
This software simplifies the process of scheduling production. It enables you to evaluate all of your anticipated manufacturing orders (MO). The bill of materials (BOM), purchasing, and stocking are all maintained in one location, allowing you to quickly book inventory and increase purchase orders (PO) for acquired parts.
MRPeasy enables you to:
Obtain all of the detailed information on all of your MOs
Consider MOs as a single block or as distinct operations.
Drag-and-drop operations and operations to reschedule
Calendar or Gantt chart views are available for monitoring scheduled orders.
Additionally, you can manage MOs smoothly. With the production planning component, you may create, amend, and update MOs. This app compiles an exhaustive list of all your MOs. You can track their progress based on the status of an order or a part's availability. Additionally, you can search for, filter, and export your MOs.
How to schedule production for your organization requires extensive research, planning, and analysis of overall product demand as well as a grasp of the time required to meet the demand. Production scheduling techniques such as job-based planning, batch method, flow method, and others help develop a productive manufacturing production schedule. Include the elements mentioned above in your manufacturing scheduling to get the best possible benefits, such as better production efficiency, lower production costs, and on-time product delivery for your manufacturing in 2022.
How production planning differ from production scheduler?
Production planning and scheduling are often mixed. But there is a difference. Planning decides what and how much work must be done, whereas scheduling specifies who and when the work will be done.
What is real-time manufacturing scheduling?
Real-Time Scheduling is a production planning, scheduling, and tracking tool that enables manufacturing organizations to improve customer satisfaction and achieve optimal operational performance cost-effectively.
How can scheduling be improved?
Communication with staff is a great way to improve scheduling. This is true for all businesses, software or otherwise. However, management should not burden employees with ambiguous or unclear communication, and vice versa.
"name": "How production planning differ from production scheduler?",
"text": "Production planning and scheduling are often mixed. But there is a difference. Planning decides what and how much work must be done, whereas scheduling specifies who and when the work will be done."
"name": "What is real-time manufacturing scheduling?",
"text": "Real-Time Scheduling is a production planning, scheduling, and tracking tool that enables manufacturing organizations to improve customer satisfaction and achieve optimal operational performance cost-effectively."
"name": "How can scheduling be improved?",
"text": "Communication with staff is a great way to improve scheduling. This is true for all businesses, software or otherwise. However, management should not burden employees with ambiguous or unclear communication, and vice versa."
Article | October 20, 2021
Machine vision is becoming increasingly prevalent in manufacturing daily across industries. The machine vision manufacturing practice provides image-based automated inspection and analysis for various applications, including automatic inspection, process control, and robot guiding, often found in the manufacturing business.
This breakthrough in manufacturing technology enables producers to be more innovative and productive to meet customer expectations and deliver the best products on the market.
A renowned industry leader Mr. Matt Mongonce conveyed in an interview with Media7,
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.
Why is Machine Vision so Critical?
The machine vision manufacturing process is entirely automated, with no human intervention on the shop floor. Thus, in a manufacturing process, machine vision adds significant safety and operational benefits. Additionally, it eliminates human contamination in production operations where cleanliness is critical.
For instance, the healthcare business cannot afford human contamination in some circumstances to ensure the safety of medicines. Second, the chemical business is prohibited from allowing individuals to come into touch with chemicals for the sake of worker safety. Thus, machine vision is vital in these instances, so it is critical to integrate machine vision systems into your production process.
Machine Vision Application Examples
To better understand how businesses are utilizing machine vision in production, we will look at five cases.
Even a few seconds of production line downtime might result in a significant financial loss in the manufacturing industry. Machine vision systems are used in industrial processes to assist manufacturers in predicting flaws or problems in the production line before the system failure. This machine vision capability enables manufacturing processes to avoid breakdowns or failures in the middle of the manufacturing process.
How is FANUC America Corporation Avoiding the Production Line Downtime with ROBOGUIDE and ZDT?
FANUC is a United States-based firm that is a market leader in robotics and ROBOMACHINE technology, with over 25 million units deployed worldwide. In addition, the company's professionals have created two products that are pretty popular in the manufacturing industry: ROBOGUIDE and ZDT (Zero Down Time).
These two standout products assist manufacturers in developing, monitoring, and managing production line automation. As a result, producers can enhance production, improve quality, and maximize profitability while remaining competitive.
Inspection of Packages
To ensure the greatest possible quality of products for their target consumer groups, manufacturers must have a method in place that enables them to inspect each corner of their product. Machine vision improves the manufacturing process and inspects each product in detail using an automated procedure.
This technology has been used in many industries, including healthcare, automation, and electronics. Manufacturers can detect faults, cracks, or any other defect in the product that is not visible to the naked eye using machine vision systems. The machine vision system detects these faults in the products and transmits the information to the computer, notifying the appropriate person during the manufacturing process.
Assembly of Products and Components
The application of machine vision to industrial processes involves component assembly to create a complete product from a collection of small components. Automation, electronics manufacturing, healthcare (medicine and medical equipment manufacturing), and others are the industries that utilize the machine vision system in their manufacturing process. Additionally, the machine vision system aids worker safety during the manufacturing process by enhancing existing safety procedures.
Manufacturers are constantly endeavoring to release products that are devoid of flaws or difficulties. However, manually verifying each product is no longer practicable for anybody involved in the manufacturing process, as production counts have risen dramatically in every manufacturing organization. This is where machine vision systems come into play, performing accurate quality inspections and assisting producers in delivering defect-free items to their target clients.
Earlier in the PCB penalization process, where numerous identical PCBs were made on a single panel, barcodes were used to separate or identify the PCBs manually by humans. This was a time-consuming and error-prone process for the electronics manufacturing industry. This task is subsequently taken over by a machine vision system, in which each circuit is segregated and uniquely identified using a robotics machine or a machine vision system. The high-tech machine vision system "Panel Scan" is one example of a machine vision system that simplifies the PCB tracing procedure.
The use of machine vision in the manufacturing business enables firms to develop more accurate and complete manufacturing processes capable of producing flawless products. Incorporating machine vision into manufacturing becomes a component of advanced manufacturing, which is projected to be the future of manufacturing in 2022. Maintain current production trends and increase your business revenue by offering the highest-quality items using a machine vision system.
What is the difference between computer vision and machine vision?
Traditionally, computer vision has been used to automate image processing, but machine vision is applied to real-world interfaces such as a factory line.
Where does machine vision come into play?
Machine vision is critical in the quality control of any product or manufacturing process. It detects flaws, cracks, or any blemishes in a physical product. Additionally, it can verify the precision and accuracy of any component or part throughout product assembly.
What are the fundamental components of a machine vision system?
A machine vision system's primary components are lighting, a lens, an image sensor, vision processing, and communications.
"name": "What is the difference between computer vision and machine vision?",
"text": "Traditionally, computer vision has been used to automate image processing, but machine vision is applied to real-world interfaces such as a factory line."
"name": "Where does machine vision come into play?",
"text": "Machine vision is critical in the quality control of any product or manufacturing process. It detects flaws, cracks, or any blemishes in a physical product. Additionally, it can verify the precision and accuracy of any component or part throughout product assembly."
"name": "What are the fundamental components of a machine vision system?",
"text": "A machine vision system's primary components are lighting, a lens, an image sensor, vision processing, and communications."