Every industry across the world has experienced some sort of digital transformation in the last decade. The industrial world is no exception. Digitization has taken over factories. The future is here, and it isn’t going anywhere.
Change can feel intimidating, but we don’t have to fear all this new technology. The sci-fi writers of yesteryear predicted that robots and computers would destroy the workforce and eventually, humanity. While those made for good stories, reality looks a bit less dramatic.
Embracing the smart factory mainly just means higher degrees of automation, smoother workflows, more efficient supply chain management, and simplified business processes. No robots are going to start a coup. In fact, robotics play just one small part of the smart factory.
We want to help you get a handle on this new technology ecosystem, so we put together this brief post to give you a better idea of the smart factory.
What is a Smart Factory?
A smart factory (also called a digital factory) is a manufacturing facility that utilizes advanced technology like robotics, smart sensors, artificial intelligence, big data analytics, and cloud computing to share information about each stage of the production process across the organization in real time.
Access to all this information enables organizations to more easily pinpoint and solve problems within their processes, resulting in higher levels of efficiency, productivity, and effectiveness.
One key element of the smart factory is that each individual piece of technology works with the others to create a type of digital ecosystem. The levels of automation may vary; some ecosystems are larger than others. But a connected network is the goal.
An in-depth smart factory might look a little like this: Customers send in an order, which triggers an automated, AI-based workflow. Robots pick out the appropriate parts to assemble and place them onto self-driving vehicles that transport the pieces to the appropriate workstation. The digital aspect of these services also gives visibility to inventory numbers, making it easier for the organization to keep the right pieces in stock.
Once the pieces enter their workstation, they’re ready to be assembled through digitized manufacturing. Smart sensors at each station send information like the strength of the equipment or the total manufacturing time to a digital analytics platform that provides insight into the process for the manufacturing team.
What does Digitization in Manufacturing look like?
Enabling digitized manufacturing automation can save organizations a ton of time, money, and resources while improving their production process.
Digitized manufacturing usually consists of automated 3-D printing or digital twins. 3-D printing, also called additive manufacturing, is a process that utilizes computer-aided design (CAD) programs to build stronger, more reliable parts in a more efficient and cost-effective manner. 3D printing is revolutionizing product development, allowing for rapid prototyping and the creation of complex geometries that were previously impossible. The process starts at nothing and then adds parts layer by layer instead of milling away at a block to get to an end product.
WATCH: Learn more about the hypergrowth of additive manufacturing from industry leader Desktop Metal.
Digital twins have also brought about positive changes in the manufacturing industry. They are digital representations of physical objects that allow engineers to analyze and make changes to the design. The most sophisticated digital twins even simulate real-world situations, giving organizations the ability to see how the changes would affect day-to-day operations.
Here are more cornerstone features of a smart factory:
Revolutionized Production Lines with IIoT
The advent of Industry 4.0 has heralded a new era in manufacturing, marked by the integration of smart technologies into production systems such as connectivity across the Industrial Internet of Things (IIoT), and advanced analytics drive unprecedented levels of operational efficiency and profitability.
Real-Time Insights and Reduced Downtime
Connectivity is the backbone of smart manufacturing, linking machines, systems, and processes to create a seamless production environment. The use of IoT devices on the shop floor allows for continuous monitoring of production lines, providing critical data that can be analyzed to predict maintenance needs and prevent equipment failures. This predictive maintenance capability is a hallmark of smart factory technologies, minimizing unexpected downtime and optimizing asset utilization.
Augmented Reality
In the factory of the future, augmented reality (AR) plays a pivotal role in bridging the gap between human intervention and automated systems. AR technologies provide workers with real-time information and guidance, enhancing their ability to make informed decisions and self-correct processes.
Machine Learning
Machine learning and IIoT are critical drivers of smart manufacturing. Machine learning algorithms analyze vast amounts of data generated by IIoT devices, uncovering patterns and insights that inform decision-making and improve production line performance.
5 Benefits of the Smart Factory
These advancements in technology can bring a variety of benefits to any manufacturing system, especially in areas of efficiency, sustainability, safety, productivity, and cost reduction.
Operate More Efficiently
As with most modern technology, the smart factory helps manufacturing happen smoothly. Everything that used to require intentional monitoring and documentation now happens automatically. Such optimization allows organizations to streamline their workflows and simplify production processes. Decision-making becomes easier as the smart technology also records and analyzes datasets that leaders can use to become more informed on what works and what doesn’t.
Ensure Sustainability
The equipment within a smart factory will automatically notify manufacturing team leaders when it’s time for maintenance, ensuring that you never miss a need. Increasing the reliability of these machines will make malfunctions far less likely and will allow teams to reduce their spending on repairs.
Digital factories also help create a more sustainable workforce because these machines will never call out of work or quit. Organizations know what they will get every day. Plus, the recorded and analyzed data allows leaders to predict and plan for future production processes.
Simplify Safety
While nothing can completely eradicate all potential risk, the smart factory has become a much safer alternative to traditional manufacturing facilities. Digital tools do exactly what they’re programmed to do, and they do it the same way every time. This greatly reduces the costly mistakes that arise from human error. AI-based technology even learns to adapt when something is in its way or near it, meaning it will stop what it’s doing before hitting and damaging the object.
A More Productive Factory Floor
The equipment within a smart factory never gets tired. It doesn’t require breaks, and it only stops when you shut it off. On top of that, the smart sensors these pieces of equipment have constantly collect and analyze data. Engineers can use these insights to see what portions of the process flow require corrections and which ones work well. As the team trims the fat of production, they will get closer and closer to a perfect and productive workflow.
Reduce Costs
Digital manufacturing provides organizations with insights into issues within the supply chain that can help leaders mitigate unnecessary risks and reduce spending on unneeded inventory items. Having inventory, delivery, and demand data all in one place also makes it easier for managers to see the whole picture and make more informed spending decisions.
4 Features of a Successful Smart Factory
Switching operations can take a toll on any organization. Many industry leaders resist the idea of a smart factory simply because of the complexity associated with rolling out such a massive change in their business strategy. However, there’s no stopping the digital wave from coming in. For the most part, it has already rolled onto the shore.
Because of this, organizations looking to succeed need to be ready to incorporate at least some elements of the smart factory, but do not fear! The beauty of going digital is that you get to pick what works best for your organization, and as long as you stick with a few key features, you should be just fine. Below are 4 essentials of any smart factory.
A Motivated Team
Like any type of organizational change, a successful smart factory relies heavily on getting people excited about the idea. Your employees will want to understand how all the new technology will benefit them, and how it will make their lives easier. Executive leadership also needs to be on the same page. Workers will notice if some people have not fully bought in, which will only create more confusion and division. Once the organization is unified, the rollout will go much more smoothly.
Interconnectivity
Digital factories work best when each piece of equipment or technology connects with one another—from design all the way to delivery. A workflow started by an order should trigger a robot to transport the appropriate pieces onto a conveyor belt that has sensors recording real-time data for software to analyze. Each step flows into the other for an entirely integrated and automated manufacturing process.
Analytics Platforms
Every organization will want to measure the success of their digital initiatives, even if the specific metrics vary between each company. With the data collected from all this new technology, gathering insights has never been easier, and software companies have created platforms that help leaders collect, track, and analyze the most important information so they can make informed choices on improvement.
Different Levels of Digitization
Many organizations either feel the need to go all-in on digitization or to resist it completely, but such a binary is unnecessary. Teams can choose how much or how little they want to incorporate, especially at the beginning. Some may choose to invest heavily in the startup costs and do a giant overhaul. Others will take one step at a time, trying it out with one specific piece to see how it goes. Either way is fine as long as everyone is fully committed to the task they choose to take on.
Digital transformation has come to the manufacturing industry. Automation, optimization, integration, and efficiency are all made possible with the new technology found in digital factories. Organizations will want to think about how they can incorporate these tools into their business strategies if they want to adapt and prepare for the future of manufacturing.
How Propel is Paving the Way for the Rise of Smart Manufacturing
Propel Software stands out among smart manufacturing software providers due to its revolutionary approach to end-to-end digitalization. By connecting product lifecycle management (PLM), quality management (QMS), and product information management (PIM) on a single platform, Propel ensures that every aspect of the product lifecycle is managed efficiently and effectively. This holistic approach, called product value management (PVM), provides manufacturers with the tools they need to maintain competitiveness in the rapidly evolving landscape of Industry 4.0.
By integrating PLM, QMS, and PIM, Propel creates a true digital thread that spans from product development to marketing and sales. This end-to-end integration ensures real-time insights into manufacturing operations, reducing downtime and enhancing overall efficiency.
Conclusion
The implications of smart factory technologies extend far beyond immediate operational gains. As manufacturers continue to adopt these innovations, they will benefit from enhanced profitability, lower costs, and improved product quality. The integration of edge computing and ERP systems with Propel's PLM platform further enhances these capabilities, providing real-time insights and enabling data-driven decision-making.
Embracing smart manufacturing is key to remaining competitive in the fourth industrial revolution. By leveraging Propel's advanced functionalities, manufacturers can position themselves at the forefront of this transformation, driving innovation and achieving sustainable growth.
The rise of the smart factory, powered by Propel's cloud-native software, represents a significant leap forward in manufacturing operations. With its seamless connectivity, advanced analytics, and end-to-end integration, Propel is not just a tool but a strategic enabler of the factory of the future. As the industry continues to evolve, embracing these technologies will be essential for maintaining competitiveness and achieving long-term success in the dynamic landscape of modern manufacturing.
