Artificial Intelligence AI in Manufacturing

This proactive approach to maintenance is a game-changer in maximizing production uptime. Meanwhile, predictive maintenance typically reduces machine downtime by 30-50% and increases machine life by 20-40%, according to a McKinsey article. With manufacturing’s increasing reliance on machinery and need to boost uptime and productivity, companies require much more than good luck and happy thoughts to keep production humming.

This part explores the pivotal role of AI in manufacturing, highlighting its critical importance for the industry’s growth and evolution. V7 arms you with the tools needed to integrate computer vision into your existing applications, and the good news is that you don’t even need to be an expert. Worse still, it means that tasks which could in theory be automated were being carried out by staff who could serve a more productive purpose elsewhere.

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The sensor data can flag parts that the analytic model suggests are likely to be defective without requiring the part to be CT-scanned. Only those parts would be scanned instead of routinely scanning all parts as they come off the line. For instance, our client, a global manufacturer of heavy construction and mining equipment, faced challenges with a decentralized supply chain, resulting in increased transportation costs and manual data resolution. To address this, we developed a data-driven logistics and supply chain management system using AI-powered Robotic Process Automation (RPA) and analytics. The RPA bots automated manual processes, resolving errors and enhancing supply chain visibility by 60%, ultimately improving operational efficiency by 30%.

Predictive maintenance and prognostics minimize downtime and maximize the life of equipment. And quality and throughput are increased with computer vision-enabled inspection, productivity inspection, and bottleneck analysis. AI allows us to maintain supply chains without the involvement of any physical labor.

Summary: How does AI benefit manufacturing?

Currently, AI adoption in business operations and management is primarily observed in finance, with anticipated growth in energy and human resource management. For manufacturing companies, energy consumption represents a substantial portion of production costs. Varied factors such as equipment, techniques, processes, product mix, and energy management influence energy usage. Employing AI for efficient diagnosis enables businesses to enhance energy savings. Successful implementations of AI here have led to significant reductions in overall energy consumption in factories, including the steel manufacturing sector.

• Data from vibrations, thermal imaging, operating efficiency, and analysis of oils and liquids in machinery can all be processed via machine learning algorithms for vital insights into the health of manufacturing machinery.
• Another key area of focus for AI in manufacturing is predictive maintenance.
• Oftentimes, you’ll need to implement AI technology from multiple categories mentioned above to maximize efficiency.
• Additive processes are primary targets because their products are more expensive and smaller in volume.

The AI and ML use cases in manufacturing discussed throughout the blog have highlighted how artificial intelligence and machine learning are revolutionizing various aspects of manufacturing. From supply chain management to predictive maintenance, the integration of AI and ML in manufacturing processes has brought significant improvements in efficiency, accuracy, and cost-effectiveness. AI has several applications in every manufacturing phase, from raw material procurement and production to product distribution. By applying AI to manufacturing data, manufacturing enterprises can better predict and prevent machine failure.

How Artificial Intelligence Is Used in Manufacturing

Applications like these reduce human error and elevate adherence to quality standards. The integration of Artificial Intelligence has unfolded a new chapter in the manufacturing saga. From AI-driven quality control to predictive maintenance and revolutionizing supply chains, the role of AI is not just enhancing efficiency; it’s reshaping the foundation of manufacturing. Data-driven insights, cognitive assistance, and proactive decision-making have converged to elevate industry practices to unparalleled levels of sophistication and innovation. In the intricate world of manufacturing, disruptions in production processes can have far-reaching consequences.

AI smart cameras are gaining widespread acceptance for high-speed machine vision applications. Nowadays, AI-based leak detection is being widely deployed in the process industries. For instance, AI-based cameras detect a leak of chemicals or gas in real time and help technicians diagnose leaks quickly and accurately. This technology has significant potential and has demand across industries where hazardous gases or chemicals are processed and produced. Additionally, AI-based quality assurance systems use machine vision and deep learning algorithms to inspect products and identify defects that may be missed by human inspectors.

The trajectory of Artificial Intelligence (AI) in manufacturing is laden with both promise and obstacles. While the potential benefits are compelling, the journey toward AI maturity presents a roadmap that manufacturers must navigate thoughtfully to harness its full potential. The journey towards ethical AI begins with meticulous data collection and preprocessing. This involves scrutinizing data sources, identifying potential biases, and taking steps to rectify them. It’s imperative to recognize that diverse and representative datasets are the cornerstone of unbiased AI. As Artificial Intelligence (AI) establishes a profound presence within manufacturing, ethical considerations come to the forefront.

The upkeep of a desired degree of quality in a service or product is known as quality assurance. Utilizing machine vision technology, AI systems can spot deviations from the norm because the majority of flaws are readily apparent. It improves defect detection by using complex image processing techniques to classify flaws across a wide range of industrial objects automatically. While AI solutions may take time to implement, their benefits are significant. With the right approach and mindset, manufacturers can leverage AI solutions to improve efficiency, drive growth, and remain competitive in the market.

Artificial Intelligence and Machine Learning

Cameras and sensors capture images and data, which are then analyzed to identify defects that human inspectors might miss. This boosts brand reputation and customer happiness by increasing product quality, cutting waste, and lowering the likelihood that customers will receive defective products. AI in manufacturing enables predictive maintenance by analyzing sensor data from machinery and equipment. This allows manufacturers to anticipate when equipment might fail and perform maintenance tasks before a breakdown occurs. This reduces downtime and maintenance costs and enhances overall operational efficiency.

The majority of these systems cannot still learn or integrate new information, resulting in countless false-positives, which then have to be manually checked by an on-site employee. Factories without any human labor are called dark factories since light may not be necessary for robots to function. This is a relatively new concept with only a few experimental 100% dark factories currently operating. Manufacturers can use digital twins before a product’s physical counterpart is manufactured. This application enables businesses to collect data from the virtual twin and improve the original product based on data. The extreme price volatility of raw materials has always been a challenge for manufacturers.

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• In order to attain better output levels with less resource consumption, machine learning algorithms can determine the best production parameters, such as speed, temperature, and material utilization.
• Digital twin simulations can drive precise factory planning, safety improvements, agility, and flexible factory design.
• Automation is often the product of multiple AI applications, and manufacturers use AI for automation in a number of different ways.