In the 1930s, Allen Morgenstern coined the phrase “Work smarter, not harder.” This was attributed to the idea of achieving more with less effort in the “work simplification” program. Today, AI is similarly accomplishing this.
Artificial intelligence is transforming the manufacturing industry by improving efficiency, modifying manufacturing processes, streamlining supply chains, automating quality checks, and monitoring maintenance needs. Let’s examine how AI is essential in modern manufacturing and Industry 4.0.
The “Why” Behind Using AI in Manufacturing
The 2024 National Association of Manufacturers (NAM) report, Working Smarter: How Manufacturers Are Using Artificial Intelligence, states that “The potential applications for AI in manufacturing are expansive and can help industry leaders improve efficiency, product development, predictive maintenance and improve performance.”
Industry leaders responded in multiple ways when asked for their reasoning for using AI in manufacturing facilities. The majority reported that they use AI to “Reduce costs and improve operational efficiency,” while a close second response was, “Improve operational visibility and responsiveness.” Other responses included compensating for labor shortages, improving the quality of products, improving the manufacturing process and keeping a competitive edge in the market.
Whenever possible, manufacturers develop their own AI tools to complete these tasks. Still others purchase AI products from technology companies. Regardless of whether manufacturers develop AI technology or deploy AI technology—or both—they find that AI helps ease the burden of repetitive tasks, allowing manufacturing workers to devote their energy and time to more complicated and forward-thinking activities and projects. (NAM 2024 Report)
Improving Efficiency
Using artificial intelligence has significant benefits for efficiency. Machinery run by AI rarely needs a break unless it is for routine maintenance. It can operate as commanded until the job is complete and will not be distracted by other tasks.
One area where AI positively impacts efficiency is using cobots, also known as collaborative robots, that work alongside humans. This new use of AI enhances productivity and safety while handling repetitive or physically demanding tasks.
AI makes manufacturing more efficient by optimizing production schedules and analyzing data, including order volumes, machine availability, and workforce capacity.
Predicting Maintenance
No manufacturer wants to experience unplanned downtime due to a machine that needs repairs. AI can help predict when technology will require maintenance and help you plan it at the least disruptive time to your workflow.
Assistance with Product Development & Design
Beyond improving efficiency and maintenance schedules, AI can help improve the design and development of products. Using AI, products can be quickly adapted to a customer’s unique needs and on customer feedback. Tailoring products to individual customers was once thought impossible in the mass production of manufacturing. Now, with the help of adjustments to designs on the computer and within the manufacturing technology, changes can be made without a massive upheaval to the entire process.
Analyze Performance
Using digital twin technology, AI can analyze a manufacturing facility’s performance and recommend improvements.
Digital twin technology creates a virtual replica of a real-world object, system, or process. This identical digital counterpart simulates, monitors, and analyzes the physical twin’s behavior, performance, and condition throughout its lifecycle.
Want to learn more about AI in manufacturing? Look at our classes and seminars, available for free through the Northeast Manufacturing Consortium.