Topline growth through digitalization: Industry 4.0 insights for executives

JONNY WILLIAMSON| July 08, 2019
TOPLINE GROWTH THROUGH DIGITALIZATION: INDUSTRY 4.0 INSIGHTS FOR EXECUTIVES
There has been an increased emphasis on digitalisation within manufacturing. While some may see this as a means of reducing cost, Simon-Kucher believe the bigger profit opportunities will come from focusing on the topline revenue side of the profit equation.

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Agri Beef

Agri Beef Co. has been dedicated to providing the highest quality meat products with a commitment to superior service, value and innovation for over 45 years. We are a family company that works with family owned and operated farms and ranches throughout the Northwest. From ranch to table we are involved in every step of the beef lifecycle, including cattle ranching and feeding AB Livestock, cattle nutrition PerforMix Nutrition Systems and beef processing Washington Beef, while preserving natural resources through recycling by-products, composting, water reclamation and bioenergy initiatives .

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Real-Time Data Collection in Manufacturing: Benefits and Techniques

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. Final Words 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. FAQ 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.

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Top 5 Manufacturing Applications of Machine Vision

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. Predictive Upkeep 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. Defect Elimination 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. Barcode Scanning 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. Final Words 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. FAQ 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. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is the difference between computer vision and machine vision?", "acceptedAnswer": { "@type": "Answer", "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." } },{ "@type": "Question", "name": "Where does machine vision come into play?", "acceptedAnswer": { "@type": "Answer", "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. 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Filmmaking is Manufacturing

Article | July 27, 2021

Filmmaking is manufacturing. To date, no one has made the direct correlation between the two. As many entertainment professionals know, the budget gap between indie productions and big studio blockbusters continues to grow. The day of mid-budget, independent (indie) movies is disappearing as fast as the middle class in the American economy. According to newbiefilmschool, the average budget is barely at $2 million for these pictures and producers have been forced to adapt by discovering creative ways to decrease costs, while maintaining a high production values for a sophisticated audience with high expectations. Though there are many ways to cut costs, any business professional will agree to go with the options that bring down the budget the most. Just as dog is man’s best friend, here are three reasons why manufacturers have become the same for a filmmaker by saving money and time for every type of production. Film equipment manufacturers No long may a film lack quality in picture, sound, and bad acting. Once acceptable, these older movies were produced with the technology and film equipment constraints and from limited funding. Film equipment manufacturers from cameras, sound equipment, and computers cost less to achieve high production values. Film equipment companies face increasing competition, which has driven down the purchase price. Better equipment with significant technology improvements has reframed the indie film industry with high-level sound and image capture quality. The transition of cameras from film to digital was a notable shift for manufacturers. Many industry-insiders believe that digital is free, and film is expensive, but there is more the manufacturing construct. Digital cameras, when compared to film cameras in the same market price bracket, are much more expensive than analog counterparts. It is true that film costs money and is single-use. Digital memory cards are relatively expensive and can be reused. Film also needs to be developed and there is a cost associated with that production cost. There are other ways in which digital modalities save filmmakers. Automation Across all industries, efficiency always wins. Innovative manufacturers have developed machines to make numerous jobs easier for everyone. Machines have been assisting filmmakers since the invention of the camera. AI (artificial intelligence) is poised to change film even more and continues to augment human creativity. Storytellers work with computers during every process of creating a motion picture which has sped up the time it takes to complete each-step in film making. Automating pre-production processes, such as creating a budget and writing a script, is analogous to an ERP (enterprise resource planning) software for a traditional manufacturing operation. The Movie Magic budgeting software by Entertainment Partners has made creating a budget more efficient and accurate. Screenwriter programs vary from the downloadable Final Draft, and the purely cloud based, Celtx, are the reasons automated scriptwriting is the norm. These programs also automatically format writing to industry standards, facilitating the creative process. Automation in post-production is equally advanced through editing software for video, sound, effects, and colors all the way to distribution and promotional content. Editing footage from digital rather than film saves time and money. Industry favorites include Adobe Premiere Pro and Apple’s exclusive Final Cut Pro and are used on almost all well-known movies and TV shows. The impacts of COVID-19 on entertainment manufacturers Without question, the pandemic has affected every industry by creating an unanticipated production standstill. Entertainment manufacturers have sacrificed countless productions, lost billions of dollars, and major talent agencies have furloughed hundreds of employees. This negative impact is not just difficult for indie filmmakers, big studios are suffering just as much with production delays and cancellations still happening as this article goes to press. Any way back to the set is better than no set at all. A new necessity for productions to safely reopen includes epidemiologists and other public health specialists; they provide detailed strategies dealing with large crews who work in cramped spaces, makeup artists who get face-to-face with actors who kiss, hug, and fight on set. These COVID-19 consultants rely on the manufacturing industry for PPE supplies and carry out regular PCR tests. Face coverings and hand sanitizing stations have also become the norm, just like most other manufacturing operations.

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Top Electronics Manufacturing Trends to Watch in 2022

Article | October 13, 2021

The electronics manufacturing business is adopting new technologies to create smart electronics manufacturing products for its consumer base. Next-generation technologies are shaping the future of the manufacturing industry by enabling it to create technologically advanced and user-friendly products. Matt Mong, one of the manufacturing industry's leading professionals, stated in an interview with Media7, “Be Different. Don’t position your product in an existing category. Instead, create your category and make the competition irrelevant and obsolete.” – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca. The year 2022 will be a year of advancement and development for the electronics manufacturing industry. So, manufacturers are eager to embrace new technologies and produce more innovative, more user-friendly goods that become part of consumers' daily lives and meet their needs. To make the manufacturing process manageable and deliver advanced products, we will look at the top five trends flourishing in the electronics manufacturing industry. Top Five Electronics Manufacturing Industry Trends Future manufacturing technologies are transforming the electronics manufacturing industry's processes and products. Let's look at the top electronics manufacturing industry trends for 2022, which will propel the sector to new heights of technological advancement. Utilizing the Benefits of the Internet of Things The Internet of Things is being used in both the manufacturing process and the products themselves. It enables electronic manufacturing products and processes to become more intelligent and performance-driven to fulfill business and customer needs. In electronics manufacturing, the Internet of Things (IoT) enables businesses to solve common production challenges such as product quality issues, changing demands, and a complex global supply chain. As a result, it increases productivity and efficiency while reducing human effort. Industrial units may gather and analyze real-time data and processes using IoT-based sensor systems. Additionally, it assists organizations in managing data and transforms traditional manufacturing into an intelligent manufacturing unit. Using an ERP System to Maintain the Company's Competitive Edge ERP (Enterprise Resource Planning) is a centralized management system for all operational and business activities. The software automates all manufacturing processes and enables the electronics manufacturing sector to achieve higher precision throughout the manufacturing process and product delivery. ERP has the potential to boost productivity, improve efficiency, decrease expenses, and increase profitability. ERP enables electronics manufacturers to forecast, plan, modify, and respond to changing market demands. By using an ERP system in your manufacturing unit, you may expand your business and increase revenue. Making Use of Big Data The electronics manufacturing industry benefits from the use of big data to make critical business decisions. It aids in the integration of previously isolated systems to provide a comprehensive view of industrial processes. It also automates data gathering and processing, allowing for more excellent knowledge of each system individually and collectively. Big data also assists manufacturers in discovering new information and identifying trends, allowing them to optimize operations, improve supply chain efficiency, and find variables that impact manufacturing quality, volume, or consistency. In addition, big data assists the electronics manufacturing industry in keeping up with the rapidly changing digital world. Using AR and VR to Create Consumer-friendly Goods AR and VR are future manufacturing technologies that are changing electronics manufacturing products and driving growth. Robotics is a crucial usage of virtual reality in electronics production. Manufacturers may use powerful virtual reality software to design goods. This implementation of virtual reality software reduces production errors and saves time and money. AR in electronics manufacturing allows product developers to generate interactive 3D views of new products before production. AR and VR are part of Industry 4.0, the digital revolution of conventional electronics production units. Adoption of 3D Printing on a Wide Scale One of the essential advantages of today's electronics 3D printing is that companies can quickly prototype PCBs and other electrical devices in-house. In addition, 3D printing has simplified the electronics manufacturing process, and it is currently being utilized to manufacture multilayer printed circuit boards. It uses material jetting technology to spray conductive and insulating inks onto the printing surface. Let's look at an example of an analogy that worked for Jinzhenyuan - The Electronic Technology Co. Ltd., managed by Mr. Huang Runyuan, Jinzhenyuan's General Manager, and based on the concept of Industry 4.0. (Reference: Forbes) Jinzhenyuan - The Electronic Technology Co. Ltd. Takes a Significant Step Forward with Industry 4.0 Jinzhenyuan - The Electronic Technology Co. Ltd., formed in 2012, sells its products globally. In addition, it manufactures cellphones, computers, cars, and a variety of other consumer electronics. Due to changing market needs, the firm planned to upgrade its production facility to industry 4.0 by the end of 2017 to participate in smart manufacturing. The company increased production efficiency, shortened production cycles, and cut costs due to the digital revolution. Today, Jinzhenyuan is regarded as a model of digital transformation in the community in which it works. Let’s observe the statistics for Jinzhenyuan following the deployment of Industry 4.0. 32% improvement in total production efficiency 33% cost reduction 41% decrease in R&D to production cycles 51% reduction in substandard parts rate – from 3,000 to 1,500 per million Final Words The electronics manufacturing sector is on the verge of a digital revolution that will improve the production process efficiency and cost-effectiveness. Many of the world's biggest firms, like Apple, Microsoft, Hitachi, and Saline lectronics, are developing future agile factories to keep up with the world's digital transformation. Future manufacturing technology will help your manufacturing company make the manufacturing process more efficient and boost the business revenue. FAQs What are the future electronics technologies? Smart grid solutions, wearable technology devices, prefabricated goods, the Internet of Things, and robots are some of the future electronics innovations that will propel the business forward. Is the supply chain benefiting from new technology trends? Yes, supply chain management benefits from smart technology as well. Trucks equipped with cutting-edge technologies can get real-time data on the weather and road conditions ahead of time. It contributes to the supply chain process's reduction of possible risks. Which manufacturers are implementing the industry 4.0 concept in their factories? Whirlpool, Siemens, Hirotec, Tesla, Bosch, and Ocado, among others, have turned their traditional factories into digitally smart ones that incorporate all of the cutting-edge technology necessary to improve and optimize the production process. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the future electronics technologies?", "acceptedAnswer": { "@type": "Answer", "text": "Smart grid solutions, wearable technology devices, prefabricated goods, the Internet of Things, and robots are some of the future electronics innovations that will propel the business forward." } },{ "@type": "Question", "name": "Is the supply chain benefiting from new technology trends?", "acceptedAnswer": { "@type": "Answer", "text": "Yes, supply chain management benefits from smart technology as well. Trucks equipped with cutting-edge technologies can get real-time data on the weather and road conditions ahead of time. It contributes to the supply chain process's reduction of possible risks." } },{ "@type": "Question", "name": "Which manufacturers are implementing the industry 4.0 concept in their factories?", "acceptedAnswer": { "@type": "Answer", "text": "Whirlpool, Siemens, Hirotec, Tesla, Bosch, and Ocado, among others, have turned their traditional factories into digitally smart ones that incorporate all of the cutting-edge technology necessary to improve and optimize the production process." } }] }

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Spotlight

Agri Beef

Agri Beef Co. has been dedicated to providing the highest quality meat products with a commitment to superior service, value and innovation for over 45 years. We are a family company that works with family owned and operated farms and ranches throughout the Northwest. From ranch to table we are involved in every step of the beef lifecycle, including cattle ranching and feeding AB Livestock, cattle nutrition PerforMix Nutrition Systems and beef processing Washington Beef, while preserving natural resources through recycling by-products, composting, water reclamation and bioenergy initiatives .

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