Manufacturers embrace the power of AI for efficiency and excellence

In the past 12 months Artificial Intelligence (AI) seems to be everywhere we turn. Including in our home lives even our tumble dryers are remembering cycles that you used most frequently, asking if you would like to use them first.

In the manufacturing industry, this is no different! AI can be used in various ways. People are worried about the effects of AI and whether it will replace human jobs. We have been reassured countless times that this is not the case but AI is here to support current practices and enhance our jobs further, saving us valuable time to do other important tasks.

What is AI? 

AI is Artificial intelligence, algorithms are a set of instructions or rules designed to solve specific problems using Artificial Intelligence techniques. On the other hand, a workflow represents a sequence of steps or processes that need to be executed to achieve the desired outcome. Workflows can be manual where a human performs the step or automated where software tools manage the steps. 

How Can AI be used in manufacturing

Manufacturers stand to gain various advantages through the incorporation of AI technologies. Below are some ways that AI can be used within the manufacturing industry, which business leaders should consider for immediate implementation and future exploration.

Cobots

Working alongside human workers are collaborative robots also known as Cobots. These act as an extra pair of hands. In contrast to autonomous robots dedicated to completing repetitive tasks, Cobots possess the ability to learn various functions. They exhibit agility and spatial awareness, allowing them to identify and navigate around obstacles. Making them suitable for working alongside and collaborating with human counterparts.

Manufacturers typically deploy Cobots for tasks such as heavy lifting and assembly on factory lines. Some do simple tasks such as loading Forklift trucks, creating free time within your labour force to be utilised or Cobots can work through the night.

In the automotive industry, Cobots assist with lifting substantial car parts, holding them in position while human workers secure them.

Lights out factory 

A relatively uncommon yet promising AI application in manufacturing is the concept of a lights-out factory. Utilising AI, robots and advanced technologies, a lights-out factory relies entirely on a robotic workforce which operates with minimal human involvement. The potential cost savings for manufacturers in adopting lights-out factories are substantial, as robotic workers have different needs compared to humans. For instance, a factory staffed entirely by robots eliminates the necessity for lighting and various environmental controls like air conditioning or heating, allowing manufacturers to optimise costs by adjusting these services. Robots also have the ability to operate 24/7 without succumbing to fatigue or illness. Robotic workers also have the potential to enhance production output, potentially reducing errors compared to humans.

Enhancing performance with Digital Twins

In today’s world of technology, the utilisation of digital twins is proving instrumental in elevating operational efficiency. Companies are harnessing the power of these virtual models to gain profound insights into the complexities of their machinery.

A digital twin is essentially a virtual replica of a physical object, that seamlessly integrates with the object's smart sensors to capture real-time data. Employing advanced technologies, including artificial intelligence, the digital twin enhances comprehension of the object's functionalities. Throughout the lifecycle of an object, companies can employ this technology to continuously monitor and receive vital notifications, such as alerts for inspections plus maintenance.

To illustrate, consider an aeroplane engine equipped with sensors that transmit data to its digital twin every time the aircraft takes off or lands. This process offers airlines and manufacturers invaluable insights into the engine's performance. Armed with this information, airlines can conduct simulations and proactively address potential issues, optimising operational efficiency.

Streamlining operations: The role of RPA software in manufacturing

Manufacturing companies strategically deploy Cobots on the production frontlines, while the efficiency of Robotic Process Automation (RPA) Software shines in the back office. RPA proves invaluable in automating high-volume or repetitive tasks, seamlessly managing data transfers, queries, calculations and record maintenance.

RPA software plays a pivotal role in automating tasks like order processing, eliminating the need for manual data entry and reducing the time spent rectifying input errors. This capability not only enhances accuracy but also frees up valuable human resources.

Furthermore, RPA excels in addressing server issues and downtime. In the face of complications. RPA can autonomously reboot and reconfigure servers. Contributing to lower IT operational costs and ensuring continuous workflow.

As manufacturers increasingly integrate AI components into their processes to enhance efficiency and cut costs, the combination of Cobots on the production floor alongside RPA in the back office represents a comprehensive strategy for optimising manufacturing operations.

Integrating ERP with AI

Integrating ERP (Enterprise Resource Planning) systems with AI processes stands as a logical next step in the evolution of manufacturing efficiency. ERP systems act as the back of an organisation, managing various aspects such as finance, human resources and supply chain management. When coupled with AI, these systems can unlock new levels of automation, data-driven decision-making and streamlined operations.

AI can significantly enhance ERP capabilities by providing advanced analytics, predictive insights and automation of complex tasks. For example, AI algorithms can analyse historical data within the ERP system to predict future demand, optimise inventory levels and improve supply chain efficiency. This predictive capability not only reduces the risk of items being out of stock or an overstocking situation but also supports more accurate production planning.

Moreover, AI-powered automation can be seamlessly integrated into ERP processes, allowing for the automatic execution of routine tasks and data entry. This not only eliminates the need for manual intervention but also ensures a higher degree of accuracy and efficiency in data handling. For instance, AI can automate order processing within the ERP system, reducing the likelihood of errors and enabling personnel to focus on more strategic value-added activities.

Additionally, ERP and AI can enhance the capability of manufacturing processes. AI algorithms can analyse real-time data from various sources, providing insights that can be immediately incorporated into ERP decision-making. This agile approach allows manufacturers to respond rapidly to changing market conditions, optimise resource allocation and maintain a competitive edge in the industry.

In conclusion, the integration of ERP with AI processes offers manufacturing companies a powerful toolset to boost efficiency, reduce costs and stay ahead in the changing world of smart manufacturing. As AI continues to make its presence known in various industries, its synergy with ERP systems presents an exciting opportunity for those seeking to embrace the future of manufacturing excellence.

Want to discover more about how ERP can work in your manufacturing business? Drop us a quick message on our contact us form, and we will be in touch.
Download our features brochure below