Smart manufacturing (SM)—the use of advanced, highly integrated technologies in manufacturing processes—is revolutionizing how companies operate. Evolving technologies and an increasingly globalized and digitalized marketplace have driven manufacturers to adopt smart manufacturing technologies to maintain competitiveness and profitability.

An innovative application of the Industrial Internet of Things (IIoT), SM systems rely on the use of high-tech sensors to collect vital performance and health data from an organization’s critical assets.

Smart manufacturing, as part of the digital transformation of Industry 4.0, deploys a combination of emerging technologies and diagnostic tools (e.g., artificial intelligence (AI) applications, the Internet of Things (IoT), robotics and augmented reality, among others) to optimize enterprise resource planning (ERP), making companies more agile and adaptable.  

Key technologies of smart manufacturing

Smart manufacturing (SM) is a sophisticated process, dependent on a network of new technologies working collaboratively to streamline the entire production ecosystem.

Key SM tools include the following:

Industrial Internet of Things (IIoT)

The IIoT is a network of interconnected machinery, tools and sensors that communicate with each other and the cloud to collect and share data. IIoT-connected assets help industrial manufacturing facilities manage and maintain equipment by utilizing cloud computing and facilitating communication between enabled machinery. These features use data from multiple machines simultaneously, automate processes and provide manufacturers more sophisticated analyses.

In smart factories, IIoT devices are used to enhance machine vision, track inventory levels and analyze data to optimize the mass production process. 

The IIoT not only allows internet-connected smart assets to communicate and share diagnostic data, enabling instantaneous system and asset comparisons, but it also helps manufacturers make more informed decisions about the entire mass production operation.

Robotics

Robotic process automation(RPA) has been a key driver of smart manufacturing, with robots taking on repetitive and/or dangerous tasks like assembly, welding and material handling. Robotics technology can perform repetitive tasks faster and with a much higher degree of accuracy and precision than human workers, improving product quality and reducing defects. 

Robotics are also extremely versatile and can be programmed to perform a wide range of tasks, making them ideal for manufacturing processes that require high flexibility and adaptability. At a Phillips plant in the Netherlands, for example, robots are making the brand’s electric razors. And a Japanese Fanuc plant uses industrial robots to manufacture industrial robots, reducing personnel requirements to only four supervisors per shift.

Perhaps most significantly, manufacturers interested in an SM approach can integrate robotics with IIoT sensors and data analytics to create a more flexible and responsive production environment.

Benefits of smart manufacturing 

Smart manufacturing solutions, like IBM Maximo Application Suite, offer a number of benefits compared to more traditional manufacturing approaches, including the following:

• Increased efficiency: Smart manufacturing can improve organizational efficiency by optimizing production processes and facilitating data convergence initiatives. By leveraging new information technologies, manufacturers can minimize production errors, reduce waste, lower costs and improve overall equipment effectiveness.
• Improved product quality: Smart manufacturing helps companies produce higher-quality products by improving process control and product testing. Using IIoT sensors and data analytics, manufacturers can monitor and control production throughputs in real time, identifying and correcting issues before they impact product quality.
• Increased flexibility: Smart manufacturing improves production flexibility by enabling manufacturers to adapt quickly to changing market demands and maximizing the benefits of demand forecasting. By deploying robotics and AI tools, manufacturers can quickly reconfigure production lines throughout the lifecycle to accommodate changes in product design or production volume, effectively optimizing the value chain.