Smart technology is all around us today, including smartphones, smart thermostats, smart stereo speakers and smart parking meters.From our appliances to our shared infrastructure, the systems and materials we interact with daily are only getting smarter.
But “smart” isn’t just a buzz word; it’s a legitimately big deal. Labeling something smart, in the broadest definition, means a product or system adapts to its user to make the experience of its use easier. A smart parking lot can broadcast how much capacity it has available and guide a motorist to an open space. A smart thermometer can cool your house by turning on the air conditioning on a hot night, 30 minutes before you arrive.
These examples are made possible by the burgeoning Internet of things , which is the extension of internet connectivity to everyday devices, and the advent of fifth-generation cellular network technology (better known as 5G) that makes data transfer almost instantaneous.
That hyperconnectivity and blazing speed are now leading to the rise of the smart factory.
Smart Manufacturing
Smart manufacturing is not science fiction; there are plenty of steps along the production process manufacturers can streamline, and it only follows that the manufacturing sector is an obvious place for such technology to take hold. Nor is smart manufacturing simply automation by another name; not that that kind of improved productivity is a true threat to manufacturing employment anyway. Instead, it’s potentially the next big thing.
Think about it— by weaving together the chains of production instead of simply linking them, manufacturers will be able to create more responsive and specific products. What’s more, they’ll be able to do so reliably.
For example, consider the ability to integrate decisions made on a shop floor into product design in real time or being able to reroute inventory directly to customers to match changes in demand. This kind of flexibility will prove extraordinarily helpful to businesses, and it will make the manufacturing process exponentially more efficient.
In a nutshell, that explosion of interaction (IoT) and efficiency (5G) is a smart factory. It is in our near future, and American manufacturers are preparing for it, but this also includes preparing for the inherent risks.
Smart Risks
Some risks are obvious. For example, how do we make a wholly integrated IoT secure?
Cybersecurity has become a daily part of our increasingly online lives, and it’s no different for manufacturers. Businesses must constantly protect themselves against attempts at intellectual property theft, sabotage and even data corruption because of the exposure that our shared online space brings.
Other risks double as challenges, like how best to ensure this technology advent we’re witnessing can still be used by small- and mid-size manufacturing companies that don’t have internal R&D, or access to large amounts of capital. Their participation is important to maintain. Apple was famously founded in a garage, after all. So how should we guarantee this potential industrial revolution has a low barrier to entry requirement for a strong culture of ground-up innovation?
The answer to both of these problems is the same. You lay the ground rules for the rollout and implementation of this technology, and you set the parameters for its use. Some market forecasts predict $1 trillion in added value generated from smart manufacturing processes by 2025. If that’s the case, our government should establish the norms of behavior, so smart manufacturers can focus on meeting that economic potential.
The United States should create a manufacturing policy so American manufacturers can thrive in its framework. And luckily, we’ve got a framework upon which to build. The Manufacturing USA program, a nationwide network of centers each focused on an emerging trend in production, has better connected domestic manufacturers with the fruits of government-funded R&D, and it should be drastically expanded.
However, there are equally useful legal moves that the government could make, for example championing rules on data governance in future trade deals and treating them as non-tariff barriers should other nations abuse them to create an artificial advantage. We should leverage the size of the American marketplace so that America’s smart manufacturing policy benefits American smart manufacturers.
Lastly, the U.S. should create such a policy because policy abhors a vacuum, and other manufacturing powerhouses (such as China or Germany at the lead of the European Union) have no intention of waiting for us to establish rules first. They realize a competitive edge is at stake, and we should take the hint and retain some of that edge for our own.
Smart factories are coming, and they’re quietly, incredibly important. We should be preparing the way for them by thinking about the guardrails in which we want them to operate.
Industry 4.0 is an omnipresent issue in every sector of industry. The Industry 4.0. vision has already emerged as a distinct reality in the injection molding sector. The focus is on consistent digitization – leading to enhanced product quality and increased cost-efficiency. Injection molders equipped with morden systems for process monitoring and control are ideally placed to meet the requirements for digital networking.
According to the definition given by Germany’s Mechanical Engineering Industry Association (VDMA), Industry 4.0 is a three-pillar model: Smart Machines – the first pillar – refers to machines that can optimize themselves with the help of intelligent tools. Smart Production means networked production – even across multiple sites. Finally, Smart Services are intelligent services or business models that only become possible once machines or their components are networked.
Some companies already offers injection molders Industry 4.0 solutions for the first two pillars of this model. They open up wide-ranging possibilities for networking to improve product quality and optimize processes in injection molding production. In terms of Smart Machines, morden process monitoring and control system is available; and as regards Smart Production, there is the related database component. Together, these two products provide an excellent foundation for users to meet increasing quality requirements by continuously monitoring, controlling and optimizing the injection molding process.
Smart manufacturing, also referred to as Industry 4.0, is the use of advanced digital technologies to enhance and streamline manufacturing. This can include integrating digital technology, smart computing, automation, and big data with physical production processes like plastic injection molding.
The Industrial Internet of Things facilitates real-time data collection from different stages of manufacturing in smart factories. With artificial intelligence (AI) and machine learning, analyzed data can uncover valuable insights, make predictions, and enable autonomous decision-making.
How Does Smart Manufacturing Work With Lean Manufacturing Principles?
Lean manufacturing emphasizes the optimal use of resources to minimize waste and improve productivity in the supply chain. Smart automation manufacturing in plastic injection molding uses control systems and machinery to mechanize the entire process. These improvements align with the fundamental objectives of lean manufacturing.
Automation can effectively handle duties like loading raw materials into machines, moving components within the machinery, and extracting finished molded parts. These automated smart manufacturing systems can regulate various aspects of the molding process, such as temperature, pressure, and timing.
This ensures that you maintain consistency and quality throughout the manufacturing process. Furthermore, AI can analyze data collected from various processes and optimize the relevant parameters in real-time.
Smart manufacturing technology can build on these five lean manufacturing principles:
1. Identify Value
You ascertain the elements that hold value for your customers regarding your product or service. In this context, value refers to something customers are willing to invest in. Advanced data analytics to offer valuable insights into customer behavior and preferences.
2. Map the Value Stream
During this step, the goal is to use the customer’s perceived value as a benchmark. You must identify all the activities that contribute to this value. Wasteful activities are ones that don’t add value to the final product.
Smart manufacturing technology like IoT sensors can gather comprehensive data on each stage of the plastic injection molding process. This valuable information can be critical in identifying areas where waste occurs. You will be able to make targeted improvements to enhance productivity and reduce costs.
3. Create Flow
Once you eliminate waste from the value stream, you must establish a seamless flow in the remaining process steps. This often requires re-engineering the production process, resulting in reduced interruptions, delays, and wait times. Real-time monitoring and predictive modeling techniques can effectively mitigate bottlenecks and minimize downtime.
4. Establish a Pull SystemThis means you only manufacture what the customer wants when the customer wants it. This helps to prevent overproduction—a common form of waste in traditional manufacturing. Smart manufacturing facilitates more accurate demand forecasting and responsive production scheduling with predictive modeling.
5. Seek Perfection
The final principle of lean thinking involves a commitment to continuous improvement. In your pursuit of process optimization, it is crucial to prioritize the enhancement of efficiency, cost reduction, and elevating customer satisfaction. Again, real-time data from smart manufacturing can help with continuous improvement.
The integration of smart manufacturing principles, including real-time monitoring, data analytics, and connectivity, to enhance production efficiency, quality control, and predictive maintenance.
Benefits of Smart Manufacturing Technology in Plastic Injection Molding
Below are some key benefits of using smart manufacturing technology in plastic injection molding.
Increased Efficiency: Smart manufacturing enables real-time monitoring and control of the manufacturing process. This advanced approach enhances efficiency, productivity, and operations.
Improved Quality: Using real-time data gathered from IoT sensors empowers manufacturers to closely monitor processes and make immediate adjustments. This will maintain product quality by preventing potential defects or deviations in the manufacturing process. It can reduce imperfections like warping, burns, and sink marks.
Cost Reduction: Predictive maintenance practices mitigate the risk of expensive equipment failures. Automation can also decrease labor expenses. Enhanced productivity and minimized wastage result in reduced operation costs. Moreover, employing cloud platforms for data analysis can decrease IT infrastructure expenses.
Flexibility and Custom Manufacturing: Implementing advanced data analytics and automated systems in manufacturing can bring about enhanced flexibility in production processes. This enables manufacturers to swiftly transition between various products, leading to increased responsiveness in meeting changes in market demand.
Supply Chain Optimization: Smart manufacturing improves supply chain planning and management by providing real-time manufacturing data. This can reduce inventories and lead times, leading to more efficient operations.
Sustainable Production: Smart manufacturing can effectively mitigate the environmental impact by reducing waste and energy consumption. You will use less raw materials during production.
Improved Worker Safety: Automating hazardous tasks and implementing predictive maintenance measures are crucial in creating a safer work environment. Automating these tasks reduces potential accidents and injuries.
Increased use of digital manufacturing tools and simulation software for optimizing mold designs, part quality, and production processes. Digital twin technology is becoming more prevalent for simulating and analyzing the entire molding process.