How AI Transforms Manufacturing 6 Use Cases & Solutions

Since talent of this caliber is in high demand and therefore scarce, companies might consider upskilling current employees, such as data-savvy engineers, or hiring experts from outside. Traditionally, these manufacturers have financed improvements as capital expenditures. AI offers a less costly alternative by enabling companies to use their existing software to analyze the vast amount of data they routinely collect and, at the same time, customize their results.

Instead, organizations can start by building a simulation or “digital twin” of the manufacturing line and order book. The agent’s performance is scored based what is AI in manufacturing on the cost, throughput, and on-time delivery of products. Next, the agent “plays the scheduling game” millions of times with different types of scenarios.

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The dangers will increase at an exponential rate as the number of IoT devices proliferates. The costs of managing a warehouse can be lowered, productivity can be increased, and fewer people will be needed to do the job if quality control and inventory are automated. Internet-of-Things (IoT) devices are high-tech gadgets with sensors that produce massive amounts of real-time operating data. This concept is known as the “Industrial Internet of Things” (IIoT) in the manufacturing sector. The factory’s combination of AI and IIoT can significantly improve precision and output. A digital twin can be used to track and examine the production cycle to spot potential quality problems or areas where the product’s performance falls short of expectations.

ai solutions in manufacturing

AI is now at the heart of the manufacturing industry, and it’s growing every year. Manufacturers of industrial automation and information solutions, Rockwell Automation, serves around 80 countries worldwide and provides solutions for smart manufacturing. With its smart devices, machines and systems, Rockwell Automation optimises production and quality as well as safety. The company’s smart devices provide insights from the plant floor, the smart machines optimise productivity while the smart systems improve quality on top of providing insights to make enterprises more profitable. Manufacturers are frequently facing different challenges such as unexpected machinery failure or defective product delivery.

AI-enabled product system design

To learn more about analytics in manufacturing, feel free to read our in-depth article about the top 10 manufacturing analytics use cases. Previously CEO at Aipoly – First smartphone engine for convolutional neural networks. Companies are already leveraging it to speed up their processes, improve safety, assist manual workers so that their skills can be used better elsewhere, and ultimately improve their bottom line. How awesome would it be if you could detect a machine failure … before it happens? The eCommerce giant has also been working with AI-driven Kiva robots, which work on the factory floor, moving and stacking bins. These robots can also carry, transport and store merchandise that’s as heavy as 3,000 lbs.

This is because OCR is able to identify data directly from scanned/printed images, thereby reducing data entry time. Computer vision also assists operators with Standard Operating Procedures when the operators have to switch products numerous times in one day. Moreover, it provides the workers with instructions to help them complete each step correctly. This allows it to make more accurate predictions on the future quality of a material or product, thus allowing your company to reach an error-free production.

Quality Controls

Machine learning solutions can promote inventory planning activities as they are good at dealing with demand forecasting and supply planning. AI-powered demand forecasting tools provide more accurate results than traditional demand forecasting methods (ARIMA, exponential smoothing, etc) engineers use in manufacturing facilities. These tools enable businesses to manage inventory levels better so that cash-in-stock and out-of-stock scenarios are less likely to happen. Defect detection, predictive maintenance, liquid level analysis, asset inspection are all being shaped by AI solutions based on computer vision and machine learning.

  • We are the trusted authority at the cutting-edge of developments in artificial intelligence, machine learning and automation; guiding the business leaders, influencers and disruptors that are shaping the industry.
  • When AI enters into the equation, it can analyze how recycled material interacts with raw materials, giving the manufacturer an atomic-level view that is critical to ensuring everything works together.
  • Frequent changes can lead to unforeseen space and material conflicts, which can then create efficiency or safety issues.
  • Managers are also informed each time there’s a malfunction or other type of problem that needs to be rectified ASAP.
  • Monitoring production in real-time and using low-cost data display and AI analysis tools is a way for manufacturers to immediately bump their productivity.
  • See how the partnership creates a digital thread for visibility across systems engineering, services lifecycle and asset management.

Thanks to AI-powered predictive maintenance, manufacturers can improve efficiency while reducing the cost of machine failure. This popularity is driven by the fact that manufacturing data is a good fit for AI/machine learning. Manufacturing is full of analytical data which is easier for machines to analyze.

Take a Deeper Dive Into AI for the Industrial Sector

This scenario suggests an opportunity to effectively package an end-to-end work process to sell to a manufacturer. One of the main problems the industry faces is a need for more historical data upon which to build effective AI models. The current lack of processes for collecting and storing data from individual machines not only makes it impossible to transition to AI in the future but harms the short-term interests of manufacturers as well.

ai solutions in manufacturing

Examples of possible upsides include increased productivity, decreased expenses, enhanced quality, and decreased downtime. Big factories are just some of the ones that can benefit from this technology. Many smaller businesses need to realise how easy it is to get their hands on high-value, low-cost AI solutions.

Computer Vision for Industrial Inspection

The company provides parallel processing capabilities to researchers and scientists that allow them to efficiently run high-performance applications. Semiconductor company, Advanced Micro Devices (AMD), specialises in manufacturing semiconductor devices used in computer processing. The company offers microprocessors, embedded microprocessors, chipsets, graphics, and video and multimedia products.

AI can enhance overall operational efficiency by streamlining processes and eliminating wasteful practices. It achieves this by learning from historical data and making recommendations for optimal operational practices. For example, AI can suggest more efficient routes for in-factory logistics or recommend better machine utilisation strategies that result in lower energy consumption. With its AI solutions, Hewlett Packard Enterprise (HPE) enables its customers to unlock the value of data with flexible AI solutions that provide scalability, performance and cost controls. HPE AI is data-driven, production-orientated, and cloud-enabled so that it is available anytime, anywhere, and at scale.

Extracting Insights from Data

In doing so, they gain a better understanding of today’s evolving technologies and the value they deliver. These AI applications could change the business case that determines whether a factory focuses on one captive process or takes on multiple products or projects. In the example of aerospace, an industry that’s experiencing a downturn, it may be that its manufacturing operations could adapt by making medical parts, as well. Generative design can create an optimal design and specifications in software, then distribute that design to multiple facilities with compatible tooling. This means smaller, geographically dispersed facilities can manufacture a larger range of parts.

A digital twin is an exact virtual replica of the physical part, the machine tool, or the part being made. It’s an exact digital representation of the part and how it will behave if, for example, a defect occurs. (All parts have defects; that’s why they fail.) AI is necessary for the application of a digital twin in manufacturing process design and maintenance. In industries like this, the belief is that replacing humans with machines is difficult or nearly impossible because their expertise is at a delicate intersection of chemistry and physics. They often use personal experience to develop a “recipe” for steel that strikes a balance between quality and cost.

Data can also be used to augment customer experiences and reduce customer acquisition time. NVIDIA’s automotive solutions offer the performance and scalability needed to design, visualize, and simulate the future of driving. Designers and engineers can create virtual showrooms and car configurators, develop in-vehicle AI assistants, and validate autonomous driving technology—all with NVIDIA AI, Omniverse™, and accelerated computing platforms.

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