The challenges for the manufacturing segment facing the Industry 4.0 universe are numerous and complex: while they need to internally achieve maximum efficiency to increase profitability in highly competitive times, they must also meet the needs of an increasingly responsible consumer who demands sustainable operations and with supply chains that need the greatest possible predictability.

It is no longer enough to have a good product: it must also be aligned with the needs and purposes of customers.

Artificial intelligence (AI), which offers numerous benefits in manufacturing companies, has established itself as an ideal option to move towards smart manufacturing models.

Preventive maintenance: without interruptions

One of the applications most used by manufacturing companies today is the preventive maintenance of assets: machine learning and AI algorithms are capable of detecting a potential failure in a machine in advance, in a production line or even in any particular piece of equipment, to then generate the corresponding alerts and even provide the necessary information for its fix: component that needs inspection, with what tool or method it can be solved and how much time is available to proceed and that there are no consequences.

The result? Continuous operations, a notable decrease in unscheduled downtime of equipment and, as a consequence of the above, greater productivity and fewer losses due to product shortages. In addition, the useful life cycle of the equipment is extended thanks to best maintenance practices.

Flawless Customized Products

AI can be applied in the creation of products through what is known as “generative design”: the algorithm is fed by detailed reports by designers and engineers, including parameters, constraints, types of materials, manufacturing times and methods, and budgets. From the analysis of all possible configurations, the software returns the most optimal manufacturing option.

Without going that far, manufacturing can gain quality thanks to AI in scenarios that are much easier to implement. The incorporation of collaborative robots in production lines, for example, helps to minimize faults rates, which translates into fewer returns and lower reputational risk.

Another great advantage that AI brings to production is the possibility of creating products under the make-to-order model, that is, adjusted to the specific needs of a client at a given time. Although this proposal is limited to specific industries (such as metalworking or construction), it could be extended in the future to cover other segments.

The previous requirements are to maintain well-aligned processes and an intelligent tool that allows determining the viability of each request based on the capacity of the factory to be able to develop the requested product and whether its realization will be cost efficient.

Certainty in uncertain times

In highly uncertain times like the ones we live in, where changes occur at great speed, the existence of solutions such as Intelligent Forecasting (IF) becomes essential: it allows predicting business results, planning demand, eliminating excess inventory and generating savings. annual money as a result of an automated and intelligent operation. Among its benefits, it reduces forecast errors by up to 25% and safety stock by up to 10%.

It also has a “green” side: a correct planning based on demand behavior that prevents subsequent discards and reduces pollution levels.

End-to-end sustainability

Sustainability finds other development paths in intelligent manufacturing: for example, with AI, optimal distribution routes can be traced -from the moment the product leaves the factory until it reaches the point of sale or the final customer- to reduce the emission of carbon dioxide.

It is also possible to make plans with maximum precision to calculate the exact amounts of raw materials needed and consequently avoid waste during the production process.

The consumer has changed. The competitors are changing. Performing the same things is no longer an option. For manufacturing companies facing the industry 4.0 model, the time has come to bet on intelligent manufacturing.