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We constantly hear buzzwords like artificial intelligence (AI), industrial internet of things (IoT), Industry 4.0, machine learning (ML), and smart manufacturing, but they do not all have the same meaning or serve the same purpose.
Smart manufacturing uses the right technology to address business and operational challenges that help improve productivity, quality, safety, and workforce efficiency. By focusing technology investments on specific business needs, manufacturers can identify opportunities for productivity improvements and other operational benefits.
Manufacturers can build a smart manufacturing strategy by understanding their current operations, evaluating their readiness, and developing a practical technology roadmap.
Readiness and Planning
Before investing in smart manufacturing technology, manufacturers should start with the problem they want to solve — such as improving quality, increasing safety, or reducing lead time — not the technology they want to purchase.
Once they have identified a problem, they should develop a clear understanding of the current process. Process mapping and value stream mapping can help identify bottlenecks, inefficiencies, information and material flows, and opportunities for improvement.
Manufacturers should also evaluate whether their operation can support a technology investment, considering available data, engineering and maintenance capabilities, existing equipment and systems, and the resources and time required to implement and support new technology.
Workforce Preparation
Technology can eliminate dangerous, repetitive, or time-consuming tasks, but it does not replace people. Manufacturers should consider whether their employees have the skills and time necessary to support technology implementation, including employee training, maintenance capabilities, and ongoing support.
Technology can also support workforce development. For example, digital work instructions can simplify complex instructions, onboard new employees, and provide process checks.
Manufacturers should involve employees who work directly with a process in the planning. Frontline employees have a different perspective on the challenges and limitations of a process than engineers or management. Their input can help identify opportunities, improve implementation, and support technology adoption.
Technology Roadmap
Since manufacturers rarely have unlimited capital or resources to implement every technology at once, a practical roadmap aligned with the business and operational strategy can establish priorities and timelines based on:
- Available resources
- Business priorities
- Expected return on investment
- Implementation complexity
- Potential impact on key performance indicators
- Technology readiness
The technology roadmap should remain a living document that manufacturers revisit regularly and whenever significant changes occur, such as changes in business strategy, competitive pressures, customer or production volume, equipment investments, or new technology capabilities.
As technology continues to evolve, a previously impractical solution may become viable. Regularly reviewing the roadmap allows manufacturers to reconsider priorities and incorporate new opportunities.
Artificial Intelligence
AI continues to create new possibilities, but it may not represent the right solution for every problem.
Manufacturers should identify the problem and then evaluate whether AI or another technology provides the most practical solution. Depending on the problem, a manufacturer may find a more affordable or simpler option, such as automation, data collection, machine vision, or system integration.
Common Mistakes
Manufacturers often make these common mistakes:
- Starting with the technology instead of the problem. Wanting to “add a robot” or “use AI” should not determine whether the investment will provide value. Manufacturers should define the problem and establish what success looks like.
- Automating a misunderstood or unstable process. Technology cannot compensate for a broken or inconsistent process. Manufacturers should understand the current process, identify potential bottlenecks, and determine how the technology will impact the operation.
- Bringing vendors into the process too early. Vendors can provide valuable expertise, but manufacturers should understand their own processes and requirements before evaluating potential systems.
- Trying to solve every problem at once with technology. Introducing unnecessary complexity can make implementation more difficult and discourage future technology investments. Manufacturers should start with a focused project that can provide a measurable quick win to help build confidence and support for future technology investments.
Customized Support
If you have questions or need assistance with technology, our experts can help you evaluate your current operation, identify opportunities, and develop a practical roadmap for implementing smart manufacturing technology.
Technology Solutions Expert Guidance
Planning and Strategy:
- Technology assessments
- Technology roadmapping and planning
- Technology scouting
- Facility design and plant layout
- Engineering and product design
Implementation and Support:
- Automation and robotics
- Digital manufacturing and data analytics
- Equipment maintenance and reliability
- Technical skill development
- Customized technology solutions
