What will manufacturing of the future look like? Production lines running day and night with no one physically monitoring them. Processes so precise they literally run with the lights off and with 100% reliability. Fully integrated sites with live process data that notifies you of a two-second delay in production.
It may sound like something from a science fiction movie, but thinking about your factory with a future state in mind – even if you never get there – can be the key to operational success.
So how do manufacturers tackle this new world? We can look to the automotive industry as a success story. General Motors' “Factory of the Future” project in the 1980s employed new (at the time) automation methods and employed just 42 people. At the time, the factory was considered one of the most advanced in the world. While their “fully automated” operational goal was never fully achieved, many of the technologies and processes were transferred to other GM plants and are still in use today.
58% Manufacturing Leader Many companies said they have autonomous factory efforts underway, but many lack the simple ability to track data and retain staff. Some say the solution is technology. It can be tempting to deploy expensive AI programs, sensors, virtual reality and automation.
But technology itself is not the solution, it's a catalyst. What's the most important part of achieving your digital transformation goals? It's starting with the right foundation: understanding the root cause of your asset failures. To get there, you need to balance people, process, tools and technology. This is what we call Smart Operations, and it starts with understanding what needs to change in your organization and why you're changing it.
Know your destination
We see clients spend millions of dollars deploying IT systems or measurement equipment without first clarifying why it is needed or will be used. Without a fundamental work plan or workflow, technology initiatives are likely to fail.
If you find yourself in this situation, ask yourself: What is your organization trying to achieve? Do you want to achieve a more automated state of operations? If so, your goal may be to reduce reliance on people and get the most out of your assets. How robust is your existing asset dataset? How far do you need to go on your digitalization journey? Are your assets critical enough to your operations to justify collecting data?
There are many tools that can be used during this process: streamlining applications, evaluating data capabilities and measurement, mapping migration from one software to another, to name a few. Applying these tools and ensuring workflows are followed is just as important (if not more so) than the tools themselves.
It's no exaggeration to say that technology is a key consideration when moving from reactive to proactive operations, but success requires a balance of people, process and technology.
Capturing knowledge from humans and machines
If there's one thing the labor shortage has taught us, it's the importance of optimizing processes and improving workflow management. We've all heard the story of the plant manager who's been there for decades and can hear by ear when a bearing or gear is failing and pinpoint the exact location. But now that person has retired, they've taken their expertise with them.
Technology can help transfer this knowledge to the next generation of workers through electronic work instructions and augmented reality, while simultaneously reducing the number of workers needed to keep the job running. Digital sensors are used to monitor the condition of machines and transmit information wirelessly, so issues can be logged and maintenance decisions made.
Adopting these technologies also means that employees have the opportunity to learn new skills and hone old ones, potentially leading to reskilling or upskilling employees. While technology may replace some of the unemployed, it may also help you retain the employees you want to keep.
My machine is installed, what do I do next?
Once the groundwork is done, you know which path you are on, your goals are defined, and the work of getting your employees on board is complete. Now we have technology in place to help us do our jobs better, faster, cheaper and safer.
Now may be the right time to begin a risk-based asset management plan to optimize your physical assets – a critical step in building a solid foundation for any digital transformation.
in In the initial stage of risk assessment, a value stream map is created to identify waste and better understand how asset reliability impacts the value stream. During this stage, data from the machines is also collected. Equipment analysis helps organizations better understand the significance of failures to workflows and business processes. This can include environmental impact, safety, production, quality, etc.
We recently guided and supported a global pharmaceutical company in its digital transformation efforts. We began by analyzing the operational status of their equipment and processes, and using our AI and machine learning platform to predict equipment failures. We developed a comprehensive set of over 130 software/system user requirements. AI/ML modeling capabilities, system data exchange interfaces, system scalability, etc.
The project has now progressed to the next phase – the implementation of a new Asset Performance Management (APM) platform at the client’s biotech manufacturing site. Establishing the necessary engineering support roles and business processes will enable the client to effectively use this technology within their operations.
Digital transformation is underway
For any organization, improving reliability and maintenance practices is just the beginning of the journey to smart operations. Financial stability and increased employee retention are some of the benefits. Invest in your employees and equip them with the right skills and knowledge to succeed. As Steve Jobs once said, “People with passion can change the world.”
Digital transformation has no finish line; it is an ongoing process that requires constant innovation, improvement and adaptation. Of course, technology plays a key role, but with the determination to put the right foundations in place first, a “lights-out” operation may not be such a distant goal.
