Technology has always been at the forefront of advances in manufacturing, from the Industrial Revolution onward. When we define manufacturing technology as it applies to today’s industrial business, we are inherently discussing a moment in time and the particular technological advances that are currently playing a role in driving manufacturing forward (as well as those that have driven the industry to its current state).
As a general definition, manufacturing technology describes the application of tools and processes — developed through scientific, industrial and engineering advances — to improve the efficiency, quality and productivity of operations. What is manufacturing technology in today’s industrial landscape? Right now, it is driven by industrial sensors, equipment connectivity, automation, and data-based analysis and decision-making. We will look at these facets and more in greater depth in the following section.
What does manufacturing technology include?
Manufacturing technologies in today’s industrial landscape includes numerous advances that would be considered science fiction even 15 or 20 years ago. Advances in communication speeds, data analysis and automation are creating the most powerful production technology yet seen in the manufacturing field.
Here, we will look at some of the many examples of manufacturing technology that are leading to unprecedented breakthroughs in productivity, safety and innovation:
- Computerized maintenance management system (CMMS): CMMS technology is designed to make maintenance operations more effective and efficient by centralizing and streamlining data and processes. The core of a CMMS includes digital tracking and analysis of equipment performance — based on real-time data and used for maintenance scheduling — as well as management of maintenance and spare parts inventory and resources, allowing for maximum accuracy, speed and efficacy in carrying out maintenance processes as scheduled and required. At the same time, integration with IIoT sensors make it possible to have real-time automated maintenance alerts that help manufacturers move beyond static schedules.
- R360® Machine Health Monitoring: Machine health monitoring reduces unplanned maintenance and extends the useful life of equipment by using sensors to detect potential operational issues early — right as the underpinnings of a problem begin. This technology, powered by machine learning, provides enhanced early detection of component wear and critical failures. It also allows for real-time monitoring and insight into equipment performance and status and yields major benefits in uptime, equipment longevity and productivity.
- Robotics and automation: While automation has been part of manufacturing technology for decades — and robotics have been around for nearly as long — today’s technology has created exponential advances in the use of these technologies. Automation is more effective and efficient than ever through the use of data-driven programming from machine sensors. Robotics are also more useful and collaborative thanks to smart sensors and AI technology that make it safe for robots to work essentially side by side in support of the human workers who continue to execute the most intricate and high-value operations in the facility. Known as “cobots,” these machines work alongside humans while performing repetitive, strenuous or precision-based tasks.
- Digital twin: Digital twin technology makes use of high-speed connectivity such as 5G to create a real-time “double” of a piece of equipment, mimicking its operation, status and potential maintenance issues as they occur. The digital twin can be accessed and interacted with off-site by maintenance personnel, troubleshooting engineers and even equipment operators, drawing upon true real-time interactivity to work with the piece of equipment as if they were in-person. Only with today’s high-speed connectivity can the benefits of this technology be realized, and many manufacturers are pairing this technology with augmented reality overlays to achieve remote troubleshooting and virtual equipment training.
- AI and machine learning: Long a buzzword in manufacturing technology, AI has come into its own thanks to increased adoption of industrial sensors, more in-depth and widespread analysis of data, and greater insight and innovation into using this data for AI and machine learning purposes. With the benefit of high-speed connectivity and vast amounts of real-time data — and analytical processing power — AI and machine learning can drive everything from maintenance scheduling and decision-making to production tweaks that can push productivity to its maximum. Some of the most common examples of AI technology used in the manufacturing industry today include optimizing supply chains, dynamic production scheduling and recognizing failure patterns.
- Augmented reality: Augmented reality technology allows for increased innovation and operational efficiency by allowing engineers, equipment operators, maintenance personnel and other key workers to draw out hypothetical scenarios in a hands-on and actionable way. AR can aid in product design, maintenance planning, problem-solving and other key areas — all in ways that reports, or computer modeling cannot replicate. In many cases, AR-guided maintenance workflows cut down on training time and error rates for complex tasks.
- Industrial Internet of Things (IIoT): IIoT enables machines to communicate with each other in real time. This means manufacturing systems can provide immediate data and insights to operators, which results in better maintenance scheduling and a host of other benefits. This is enhanced by advancements such as edge computing, which processes data closer to the devices for faster decision-making. Follow the link to learn more about IIoT trends impacting the manufacturing sector.
- 3D printing: Also known as additive manufacturing, 3D printing can be used to create prototypes quickly, but it is also being used increasingly for tooling, jigs and low-volume production parts. Among the many benefits of additive manufacturing are reduced waste, custom parts manufacturing and more.
- Manufacturing execution systems: A manufacturing execution system (MES) is a software platform that can track, monitor, document and control the production of goods from raw materials all the way to the finished products. It serves as a bridge between an enterprise’s planning and control systems and the actual manufacturing operations. With the integration of AI, these platforms now can dynamically optimize production flows and minimize bottlenecks.
- Cloud computing: Saving data in the cloud on decentralized servers allows for secure storage, faster analytics and improved collaboration between manufacturing units. Thanks to cloud-native solutions, manufacturers are reducing their IT costs while also enabling secure multi-location collaboration across facilities.
- Machine vision systems: MV systems use computer vision, hardware and software to help industrial equipment see what it is doing and make decisions based on the inputs. Manufacturing vision systems are a key element of factory automation and can help improve product quality along with speeding up production and optimizing operations. With the help of AI, machine vision is capable of detecting quality defects at a granular level with minimal human oversight.
- Advanced industrial analytics: New analytics platforms can centralize machine, production and maintenance data to better identify patterns, predict failures, optimize performance and uncover hidden inefficiencies.
- Cybersecurity for smart manufacturing: With the increase in connectivity across systems, it has never been more important to protect IIoT platforms, production data and digital twins from cyber threats. Cybersecurity is key to preserving operational resilience in the face of these dangers.
Benefits of technology in manufacturing
Manufacturing technology offers numerous benefits in areas across the organization, driving ROI on the technology investments that power these innovations.
These benefits include:
- Predictive maintenance: Industrial sensors and connected equipment are the pillars that enable predictive maintenance, a proactive maintenance approach that identifies potential equipment problems long before they lead to machinery breakdown, allowing operators and managers to identify issues and make plans for repairs at times of minimal impact. Proactive maintenance is one of the most effective tools enabled by manufacturing technology, making use of real-time data collection and historical analysis in areas such as vibration detection, ultrasonic monitoring and more, to provide unprecedented insights into equipment operations.
- Safety options in today’s working landscape: The shadow of the COVID-19 pandemic continues to loom over workplaces, but manufacturing technology helps to solve any lingering issues by enabling options for off-site and remote work while maintaining real-time access to data, analytics and hands-on experience through the use of digital twin and AR technology.
- Operational flexibility: With technology enabling off-site work, facilities are better equipped to handle any potential challenges, whatever the cause may be. Increased communication, connectivity and data access empowers organizations and their people to have more control over operations.
- Increased innovation: Technology such as AR and digital twins allows for engineers and product designers to work with lifelike replicas of machinery, components and products. These tools have spurred frontiers in manufacturing innovation that may not have been achieved through traditional methods such as CAD software. Innovation is always at the forefront of breakthroughs in efficiency, quality and competitive advantage.
- Cost reduction: Advanced manufacturing technologies such as AI and automation can reduce labor and operational costs to a significant degree. In some sectors, predictive maintenance strategies enabled by machine health monitoring are helping reduce unscheduled downtime by 20% to 40% and lower the total cost of ownership by 10% (Toyoglu et al., 2023).
- Quality improvement: With real-time monitoring and precision manufacturing technologies, manufacturers can enhance the overall quality of their products and achieve greater consistency.
- Sustainability: With advancements in technology, manufacturers have been able to reduce energy consumption and wasted resources. One of the best examples of this is smart energy management systems that optimize electricity and water usage. This makes it possible for them to achieve their sustainable manufacturing goals, including supporting ESG initiatives and lowering operational expenses.
- Faster time to market: Technologies such as 3D printing and digital twins accelerate product development and market entry. For example, cloud collaboration and digital design iterations through twins and AR are dramatically compressing product development cycles in many sectors.
Who benefits from manufacturing technology?
Manufacturing technology is a broad topic that can apply to — and benefit — any industrial or manufacturing company. While this article detailed some of the most advanced benefits of manufacturing technology, any facility can begin to see these benefits through steps as simple as aftermarket retrofitting of industrial sensors to legacy equipment. In fact, many small and mid-sized manufacturers are starting to access these technologies affordably, helping them level the playing field.
Some of the industries where advanced manufacturing technology is focused include:
- Aerospace — Manufacturing technology enhances precision machining, predictive maintenance and quality control in the production of highly regulated aerospace components.
- Automotive — Automation, robotics and machine vision systems drive efficient assembly lines, support electric vehicle innovation, and ensure consistent quality in automotive manufacturing.
- Building Products — IoT-enabled production lines optimize the output and quality of building materials such as doors, windows, insulation and roofing products, while reducing waste.
- Consumer Packaged Goods — Smart manufacturing technologies improve production speed, reduce downtime, and ensure consistent quality for food, beverage and household goods manufacturers.
- Heavy Equipment — Predictive maintenance, machine health monitoring and advanced analytics extend asset life and improve uptime for the production of construction and agricultural machinery.
- Metal Products —Additive manufacturing, advanced automation and real-time monitoring enhance efficiency and precision in metal fabrication, forging, and casting operations.
- Paper & Pulp — Machine learning algorithms and sensor technologies optimize production variables such as moisture content, pulp consistency and energy usage for greater efficiency.
- Pharmaceutical & Medical Devices — Manufacturing technology ensures compliance with strict regulatory standards, supports cleanroom automation and enables precision production of sensitive products.
- Power Distribution — IoT devices, real-time monitoring and predictive analytics increase reliability and optimize production processes for transformers, switchgear and related infrastructure.
- Tire and Rubber — Advanced process controls, robotics and vision systems help maintain consistency, improve curing processes and detect defects early in tire and rubber manufacturing.
Helping manufacturers around the world
ATS is a global leader in services for manufacturers, including cutting-edge manufacturing technology to drive maintenance efficiency improvements, performance advances and more.
With over four decades of experience, we remain at the forefront of technology-driven maintenance — including machine health monitoring, sensors, CMMS, reliability engineering and more — to ensure our customers are equipped with the latest advances to increase productivity, improve safety, enhance efficiency, extend equipment life, increase uptime and boost the bottom line. To learn more, contact us today.
References
Toyoglu, H., Lin, A., Knapp, J., Van Wyck, J., Rose, S., & Pentecoste, A. (2023, September 21). Predictive maintenance in manufacturing. Boston Consulting Group. https://www.bcg.com/publications/2023/predicitive-maintenance-in-manufacturing
