How Can Small Manufacturers Benefit From Smart Manufacturing?
Published on : Monday 11-05-2020
Manufacturers that invest in smart technologies today are setting themselves up for success tomorrow, says Megan R Nichols.
It's not just big corporations that can afford and benefit from modern technology. Small and regional manufacturers have just as many advantages at their disposal when they invest in smarter infrastructure. The National Institute of Standards and Technology (NIST) describes smart manufacturing as fully-integrated and collaborative platforms that respond in real-time to meet changing demands and conditions in the factory [and] in the supply network. The following are all examples of how this concept applies to small manufacturers and why they have a lot to gain from tapping into modern technology:
1. Achieve greater consistency in small batches
By now, you're aware that the most significant benefit of smart manufacturing is the ability to gather process data. Collecting data on tolerances and machine performance – plus other metrics related to throughput and product quality – is extremely helpful in any context. But for small manufacturers dealing with small batches of parts or products, data might be even more important. Short runs of products, or even one-off goods, have an inherent degree of variability that larger- scale assembly lines don't usually have to deal with. IIoT-enabled assembly equipment, robotics and intelligent analytics all play a role in orchestrating every part of the value chain. Whether through real-time machine monitoring or machine vision analysis for completed products, smart factories have the tools they need to uphold consistent quality standards and eliminate variability from key processes – even on a small business scale.
2. Maximise equipment budgets and life cycles
Any manufacturer will tell you they're only as efficient as their least-effective machine. Between sorting, handling, assembly and inspection equipment, small manufacturers have many assets to purchase and maintain – and usually on a limited budget. Smart manufacturing makes it far easier to get the most out of even modest equipment budgets by maximising their useful lifetimes and RoI. Using sensors and logic boards embedded in machines – whether they're bought that way or retrofitted into legacy equipment – manufacturers can use substantial amounts of data in the following ways:
• Computer models calculate health scores" for equipment in real-time and predict the life spans of critical assets, which helps with short- and long-term budget planning.
• Convenient dashboards provide access in real-time, so engineers and decision-makers have up- to-the-minute information about infrastructure health.
• Sensors detect anomalies that signify impending machine failure, determine the causes of sub- par performance and help facility management intervene before failure.
• Smart manufacturing equipment offers guidance on its own maintenance intervals, eliminating guesswork and wear-and-tear from lapses in maintenance. Getting the most extensive life possible out of a piece of equipment goes a long way in helping small manufacturers stretch their budget, avoid downtime and get ahead of maintenance issues that can result in machine failure and premature – and costly – upgrades.
3. Do more with fewer personnel
Manufacturing labour is in a strange place right now. On the one hand, research shows manufacturers may face difficulties filling some 2.4 million positions between 2018 and 2028. On the other, equally compelling research says the number of open positions may begin to diminish starting in 2022. However the coming years shake out for manufacturers, smaller and regional companies will need to turn to technology to do two things: supplement the shrinking number of interested and qualified job applicants, and use automation and machine learning to stay competitive. Machine learning and robotic systems, working together, could help small manufacturers navigate the labour market's uncertain future effectively. Automated guided vehicles (AGVs) and robotic arms are some of the most useful and versatile labour-enhancing tools available today. Pneumatic arms, especially, are deceptively simple technologies that require little maintenance. They improve upon human precision and endurance with repeatability down to the hundredth of a millimetre and remain fully functional in various temperatures and conditions. Robotic inspection stations are another crucial piece of the puzzle concerning replacing workers in a troubled labour market – or, more likely, supplementing human efforts in manufacturing plants. Many factories in the United States and across the world have come to depend on the higher accuracy of machine vision inspections compared to tasking humans with the same repeated and fatiguing duties daily.
In a lot of these cases, bringing machine learning into the mix raises productivity and improves quality control without shedding workers. It can even help the workers who previously performed these tasks upskill themselves into higher-paying jobs in the same facility. No matter how small manufacturers put robotics and machine vision/learning to use, it's clear these technologies provide an answer for companies looking to accomplish more without overextending themselves with labour spending.
4. Enjoy smaller energy bills, less waste and faster prototyping
We can expect 3D printing to play a larger role in smart manufacturing in the coming years. Some of its current applications might seem like novelties, but it's hard to deny the technology's growing impact in various industries. Here are just some of the benefits of additive manufacturing as they apply to small manufacturers:
• Smaller energy bills: Research shows 3D printing could save businesses between 41% and 74% on energy expenses compared to injection moulding and other common manufacturing processes.
• Less material waste: Small manufacturers operate with slimmer margins than larger companies, meaning avoiding waste should be a top priority. Traditional manufacturing wastes up to 21% of raw materials, while 3D printing results in only 10% material waste.
• Faster prototyping: Small companies can innovate just as well as larger ones, but only if they have the resources to explore new designs and get them to market quickly. Traditional rapid prototyping can cost twice as much as rapid prototyping using 3D printers.
3D printers aren't the only technology making it easy to save money and eliminate wasted resources. Automated lighting and HVAC systems, plus green energy from solar or wind, all make for a smaller environmental footprint, goodwill from customers and cost savings over time. Some estimates say commercial building owners could trim 75% off their energy expenses by going solar. Plus, by becoming a node in a larger smart electricity grid, companies flatten demand curves and keep their equipment and lights on during what otherwise might be a blackout or brownout.
Punching above their weight
Smart technology helps small manufacturers punch above their weight. Manufacturers that invest in smart technologies today are setting themselves up for success tomorrow. A couple years ago, 58% of manufacturing company representatives already showed a strong interest in smart technologies. Yet, only 12% were actively planning to invest in them. With the cost of key technologies falling year over year, this could be the perfect moment for smaller manufacturers, even those with lean budgets, to get ahead of the trends and the competition.
Megan R Nichols is a technical writer specialising in manufacturing and engineering topics. She has four years’ experience covering these industries writing for sites like Thomas, IoT Times, and American Machinist. For more of Megan’s work, subscribe to her blog: http://www.schooledbyscience.com/
