Manufacturing has a long history in the U. That will likely continue to be the case, but post recession American manufacturing is otherwise characterized by slow growth and lots of change. So what can we expect from our recovering patient? The Good: Compared to previous years, manufacturing in America has been getting undeniably stronger. According to the American Manufacturing Partnership Steering Committee , manufacturing has added over , jobs in the last five years, experiencing steady growth after more than a decade of decline. In fact, U.
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- CMTC Manufacturing Blog
- Future Factory: How Technology Is Transforming Manufacturing
- The Future of Manufacturing: The Good, the Bad, and the Not Too Ugly
- Smart manufacturing
- Process manufacturing
- 5 Powerful Benefits of IoT for the Manufacturing Industry
- 10 Steps To An Effective Manufacturing Operations Management Strategy
CMTC Manufacturing BlogVIDEO ON THE TOPIC: Amazing Production Line of Manufacturing Process
After a busy and productive week, you get an urgent call from a client on Friday afternoon. They have a rush job and need it completed by Monday morning. The manufacturing facility operates over the weekend, but you need to add an additional shift to meet the deadline, which is quickly done with a few phone calls. With all details finalized, the project moves forward at a rapid rate.
Then something terrible happens. A machine part breaks and works grinds to a screeching halt. The job is seriously delayed and the client is unhappy. The Internet of Things is promising to make these types of scenarios obsolete. In the situation above, that part would never have broken because a few weeks prior, sensors would have alerted staff that it needed replacement.
It would have been quickly ordered and replaced during off-peak hours, and downtime completely avoided. The result? The rush job would have continued on schedule and the client would have been thrilled, maybe even awarding the company additional work in the near future. Results like these are the reason that manufacturing companies are taking a serious look at IoT. In fact, IoT has enabled manufacturers to experience a But what exactly is IoT, and how does it work in the context of manufacturing?
Smart manufacturing is about harnessing the power of data and using analytics to run your facility better. Internet of Things technology can communicate what needs to be done at the exact moment of relevance. Manufacturing equipment can be fitted with sensors to collect data and better understand how machines are operating.
In the past, the process involved a few basic steps, including:. Using IoT sensors that are strategically placed on the machines empowers companies with more information on equipment health than was previously possible.
A large amount of data is collected, but equally important are the insights made available by that data. Now, managers can truly understand when equipment needs maintenance and replacement before urgent situations arise. Here are five important benefits of IoT for the manufacturing industry to consider. Energy is one of the largest expenses for manufacturing firms.
Bills arrive a couple of weeks before the end of the billing cycle and highlight all of the energy used for the entire factory. But the problem is, these bills detail total energy consumption, and there is no way to break down the bill to better understand where specific inefficiencies reside.
Yet nearly 77 percent of companies reported obtaining energy consumption data from their monthly utility bills or energy monitoring tools, which both have limited points of data. IoT closes that gap, as it helps to collect and understand data right down to device level. Do you have a device that is underperforming?
If so, the technology will pinpoint that device so you can figure out how to boost efficiency. In fact, every piece of machinery on the floor can be tracked and managers can gain granular visibility into energy consumption. Actionable insights are delivered about waste, how to attain more efficiency from equipment, and even potential failures and regulatory compliance issues. This real-time data can deliver interesting insights, such as off-hour consumption, recommendations for optimizing production schedules and other opportunities for savings.
It can even benchmark similar pieces of equipment to determine which machines are performing better and proactively solve problems with underperforming ones. Similarly, managers can evaluate different locations and pinpoint hidden operational inefficiencies and waste. IoT empowers managers to determine where they are losing energy, and fix those problem spots.
One of the largest benefits of IoT in the manufacturing industry is the ability to proactively complete maintenance. You are no longer planning maintenance schedules based on historical information, but instead receiving real-time data to understand maintenance needs at an exact moment.
Sensors provide the relevant data so you can know the needs of the machine, rather than guessing. This technology drastically cuts waste from the manufacturing equation. For example, IoT sensors may monitor the temperature of a key piece of manufacturing equipment.
If the temperature starts to increase, staff can be alerted to the situation and a predictive solution can be put into action to prevent any potential issues. Many companies, such as the French rail company SNCF, are already using this technology to predict maintenance needs proactively.
These contextual insights keep equipment up and running and minimize the risk of costly downtime. Improving the quality of products is a primary goal for manufacturers, according to an IDC report. A higher-quality product leads to many other benefits, such as reduced waste, lower costs, increased customer satisfaction and higher sales.
Achieving this goal, however, is not always easy. This is where IoT can help. One major culprit behind product-quality issues is faulty equipment, whether it has not been set correctly, calibrated properly or maintained.
The company has a reputation for doing high-quality work, but one misstep may lead to months of problems. Without warning, the temperature of the painting station shifts outside the norms. As a result, the paint does not adhere to the metal correctly, but at first glance, everything looks fine. A recall is issued and large amounts of resources are spent correcting the problem.
These types of quality issues have far-reaching effects, resulting in product recalls, lost trust and damage to the brand. Those customers affected may jump to conclusions and assume the faulty paint was the result of cutting corners or using a less superior paint product. Using IoT can help avoid these types of costly problems. With this technology in play, the paint station would have had IoT sensors embedded into the equipment.
At the moment the sensors detected the temperature change, staff members would receive an alert. Employees could then stop production and solve the challenge immediately. As a result, the recall, angry customers, and damaged client relationships would all be avoided. This technology is also useful in the product design and testing phases. For example, the production of aircraft, trains and other transportation equipment can be designed with sensors that help to measure important components that determine the safety, performance, and durability of the product.
Simple mistakes can be avoided with the use of IoT, which has the ability to minimize quality-control issues and recapture those lost dollars. Timely, accurate and high-quality production is at the core of profits. Without reliable production, companies risk serious loss.
Plus, when a machine stops working in the middle of a run, the product on the machine can be a total loss, in addition to traditional downtime expenses. IoT provides safeguards against these types of losses. Sensors immediately detect problems in the baking machine at the moment that performance declines. Staff are alerted in real time and the problem can be resolved to minimize any associated downtime costs.
In addition, there is also the lost cost of opportunity. IoT helps recapture these costs and minimizes downtime. Managers are never in the dark about equipment performance and problems when using IoT technology. They may have assumed everything was going smoothly in the past — until something broke. But the Internet of Things unlocks critical data about performance and allows those insights to flow freely to those who need them most. Now managers can transform a reactive approach, focused on replacing parts on set schedules using historical data, into a proactive approach, in which stress is reduced, waste is decreased and visibility is elevated.
As a result, they can make faster and more informed decisions at the precise moment of relevance. The manufacturing industry is competitive, and companies are constantly seeking an edge to stay competitive and get ahead.
They want to become more efficient, operate with greater profitability and serve customers better. IoT technology provides a powerful set of tools that can deliver these advantages. It takes data that has always been there but was never accessible before and puts it into the hands of those who need it most. Product quality is solid because the equipment is operating optimally, and clients are happier — so the company is positioned with greater strength and resiliency.
It is these benefits that make IoT a critical tool for manufacturing companies that want to grow and thrive in the future. Fathym is a low-code IoT framework that empowers developers of all skill levels to rapidly and collaboratively build data applications that optimize businesses and fuel the Internet of Things. Fathym lowers the barrier for entry in developing data and IoT solutions, minimizing risk by shortening development cycles and reducing reliance on limited expert resources.
In giving a larger population of users the power to quickly, easily and economically bring ideas to life, Fathym seeds diverse innovation in the connected world. Fathym harnesses the proliferation of IoT devices and sensor data to accelerate enterprise digital transformation. Fathym simplifies cloud service provisioning and the rapid development of scalable, distributed applications.
Our road weather solution combines the power of road and atmospheric weather observations with a state of the art, on-demand pavement forecast that delivers sub-kilometer road condition and ground truth data for the transportation, smart city and agricultural industries.
Posted by Sales. According to IDC and SAP , in , 60 percent of global manufacturers will use analytics data tracked using connected devices to analyze processes and identify optimization possibilities. Find more statistics at Statista. Manufacturers and industrialists in every sector have a significant opportunity at hand where they can not only monitor but also automate many of complex process involved in manufacturing.
Future Factory: How Technology Is Transforming Manufacturing
As well as maintaining safety and compliance across the plant, managers are leaned on to:. This expectation impacts on any continuous improvement, KPIs, quality, maintenance and production processes, as well as supply chain and staffing decisions across the business. To succeed today, managers need to find new and better ways of doing things with the resources they have. This means innovation is required to meet daily production demands and improve operations into the future. Easier said than done with a busy workload and high-pressure environment. Create regular thinking time.
The Future of Manufacturing: The Good, the Bad, and the Not Too Ugly
Manufacturing is a great place to work. Manufacturing employs 8. Manufacturing spans some of the most interesting high-tech industries, such as aerospace, food technology, machine monitoring, and pharmaceuticals. Things have come a long way.
Overcoming the challenges of making company-wide manufacturing operations more customer driven needs to start with a clear definition of what success looks like. Defining the strategic goal of having all production centers contributing to a series of company-wide lean manufacturing, supply chain, quality, and production, service and customer satisfaction goals galvanize diverse production locations together. Instead of having to rely on many different, disconnected systems to manage diverse production locations to a common set of goals, manufacturers are adopting company-wide Manufacturing Execution Management MES systems. Planning and scheduling, quality management, inventory optimization, tooling management, preventative and predictive maintenance, and Manufacturing Intelligence are the core functional areas included in an MES today. Across all selling and service channels customers expect real-time responses to their questions in addition to product quality that is world class. How well a manufacturer meets or exceeds these expectations will have as big impact on their future growth opportunities. The core components of this strategy are available in an MES. Increasing customer trust, making on-time order shipments, earning a reputation for high-quality products, achieving traceability, and optimizing production scheduling are all achievable with manufacturing operations management strategies.
Process manufacturing is a branch of manufacturing that is associated with formulas and manufacturing recipes,  and can be contrasted with discrete manufacturing , which is concerned with discrete units, bills of materials and the assembly of components. Process manufacturing is common  in the food, beverage, chemical, pharmaceutical, nutraceutical, consumer packaged goods, cannabis, and biotechnology industries. In process manufacturing, the relevant factors are ingredients, not parts; formulas, not bills of materials; and bulk materials rather than individual units.
By: Steve Wright on November 8th, Manufacturing Blog Posts. As the old adage goes, time is money. The more production you can squeeze out in a period of time, the more money you make, right? Three areas contain critical information to help you identify needed changes. Before you make any changes, understand how everything works now. Processes that have been in place for a long time may be riddled with workarounds as new equipment was added or production methods changed. When identifying new technology and equipment, keep in mind the total cost of ownership and how the bottom line will be affected. A high initial expense is worth it if the total cost of ownership is lower than the technology or process you are replacing and if it solves a problem such as a clearing a production bottleneck or reducing scrap. The fastest way to slow things down is by ignoring regular maintenance. Downtime for maintenance costs much less than downtime due to broken and worn equipment.
Posted by Steven Brand. A fancy title and office with a window will not make you a strong leader. Being a great leader is no easy task as you must inspire, motivate and be effective while becoming a well-respected member of your company. Whether or not you are comfortable with it, you will be in the spotlight with high expectations for your effectiveness. Those who work for you are looking for direction and guidance while your direct reports expect to see results.
Posted by Tammy Borden. After years of sluggish growth and in several cases decline , many areas of the country are experiencing a thriving manufacturing sector. Today, 6 out of 10 open skilled production positions are unfilled. While automation and robotics may help fill the labor gap, skilled workers will still be needed to apply problem-solving capabilities, perform analysis and manage production. One reason manufacturers are finding it difficult to fill positions, both skilled and unskilled, is the lack of trade school opportunities for young men and women. To solve for this problem, many manufacturers are developing robust training programs to teach candidates everything from die making and welding to robotics programming and sheet rolling. The more effective way to connect, especially with millennials, is through social media.
5 Powerful Benefits of IoT for the Manufacturing Industry
Manufacturing is no longer simply about making physical products. Changes in consumer demand, the nature of products, the economics of production, and the economics of the supply chain have led to a fundamental shift in the way companies do business. Customers demand personalization and customization as the line between consumer and creator continues to blur. As technology continues to advance exponentially, barriers to entry, commercialization, and learning are eroding.
10 Steps To An Effective Manufacturing Operations Management Strategy
After a busy and productive week, you get an urgent call from a client on Friday afternoon. They have a rush job and need it completed by Monday morning. The manufacturing facility operates over the weekend, but you need to add an additional shift to meet the deadline, which is quickly done with a few phone calls.
These jobs are found in a factory, plant, or mill. They can also exist in a home, as long as products, not services, are created. For example, bakeries, candy stores, and custom tailors are considered manufacturing because they create products out of components.
Некоторое время он сидел словно парализованный, затем в панике выбежал в коридор. - Мидж. Скорее. ГЛАВА 44 Фил Чатрукьян, киля от злости, вернулся в лабораторию систем безопасности.