Manufacturers know they must adapt to changing conditions to stay competitive. Many look to artificial intelligence (AI) and the Internet of Things (IoT) to meet that goal in a continually demanding landscape. Below, we'll look at some specific ways to use AI and IoT in manufacturing to maintain productivity and stay innovative. Tapping Into IoT Data to Pinpoint SlowdownsModern manufacturing facilities contain a wealth of valuable information. IoT sensors help tech-savvy leaders access it and obtain actionable data about what’s going well and where improvements must happen. For example, IoT data could show which assembly lines are most productive and at what times of the day. In cases of manufacturers having multisite presences, IoT data could show them which facilities have the highest outputs. People can then narrow down the potential causes of discrepancies, working toward better consistency. Perhaps newer team members need more training or outdated equipment is to blame for inefficiencies. IoT sensors can often get to the bottom of things, provided the people using them take the time to analyze the data. Consider the case of an Indian subsidiary of an automotive manufacturer based in the United Kingdom. It makes full vehicles and components. However, the company dealt with a slowdown due to its legacy systems being 20 years old. Leaders invested in an industrial IoT solution to find and fix process bottlenecks. One step was to upload time-based data from each manufacturing step into a dashboard that provided further analysis. People could also use the dashboard to monitor and optimize all shop floor equipment. It even has a color-coded design to show whether key metrics are within ideal parameters. Since this IoT tool is cloud-based, authorized users can easily access data from anywhere. There’s also a built-in digital twin feature. Utilizing it allows the manufacturer to test various approaches before applying them. They can then feel more confident about making operational changes without encountering unpleasant surprises. Overall, the technology enabled a 15% improvement in a paint shop line. Representatives also said the real-time data from the IoT sensors helps them prevent downtime. Using AI and IoT in Manufacturing to Learn What Customers WantBrowsing retail shelves reveals an incredible assortment of possibilities. However, it’s not always easy to determine which of those items will become rapid sellers or flops. Developing new products is so resource intensive that people cannot afford to leave everything to chance. That’s why some manufacturers are using artificial intelligence and the IoT to take much of the mystery out of figuring out what people are most likely to buy. For example, a major e-commerce brand unveiled a new smart speaker feature in 2022. It allows brands to answer the questions potential customers ask most frequently and direct them to dedicated e-commerce storefronts. When a smart speaker user asks something like, “How do I get pet hair off my carpet?” they might get a suggestion for a specific vacuum cleaner. The seller can also link to where they can buy it. Sellers can also log into a portal showing customers' most common questions. If a company manufactures and sells its products, those queries could reveal people’s pain points and how businesses could solve them with new or existing items. In another case, a food brand with more than 150 years of history has turned to AI to accelerate its innovation efforts. Coming up with tantalizing flavors can be a great way to keep people interested in buying, but it’s also complicated. The company tracks billions of data points to find product inspiration. This approach also accelerates the overall time frame for bringing those items to market. If a potential new flavor seems particularly likely to succeed in one region, a manufacturer might focus on it first. These are just some of the many ways to rely on AI and IoT in manufacturing. Using both simultaneously can give excellent results. Keeping Equipment and Production Running SmoothlyManufacturing leaders often deploy AI and the Internet of Things to avoid production stoppages or prolonged periods of decreased output. Those events can be prohibitively costly and erode customer confidence. Fortunately, it’s increasingly possible to find products that give manufacturers better visibility so they can steer clear of problems. For example, one smart valve positioner gives continuous diagnostics in three categories and sounds alarms when performance problems arise. When people get immediate alerts about potential issues, they can address them quickly, making equipment shutdowns less likely. Many people also combine AI and the IoT in manufacturing by capitalizing on predictive analytics. In such cases, IoT sensors continuously collect data and AI algorithms analyze it to check for abnormalities. Besides warning people of operational problems, such setups can help companies limit emissions. They give carbon footprint snapshots of overall resource usage. Consider a case where a manufacturer notices a particular machine suddenly uses up to 30% more energy than its counterparts in the same factory. A closer examination might reveal the main difference is the piece of equipment using more power is nearly a decade older than the others. Upgrading it could curb excessive emissions while reducing the chances of breakdowns. Some companies use AI and IoT in manufacturing by relying on robots to perform preventive maintenance using measuring devices. One business was losing $75,000 per month from compressed air leaks. Leaders believed having a robot roam around while carrying an instrument to measure them could help the organization tackle the problem. Using robots for maintenance and inspections is also beneficial when a machine is within an area too small for humans to access safely or includes other hazards. How Will You Use AI and IoT in Manufacturing?The examples above are just some of the many exciting ways people can deploy AI and IoT in manufacturing. Let them inspire you about how to use these technologies, too—possibly at the same time.
Before diving into the process, think about some specific challenges for your company to overcome, as well as potential ways to make progress using technology. If you need more help, consider partnering with a technology provider that can suggest the most beneficial ways to get the desired results while staying within budget. Source: The International Society of Automation (ISA)
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These four innovations are already shaking things up in the worlds of sheet metal and ductwork fabrication
Sheet metal fabrication undergoes continuous improvements. Those changes affect related areas and professionals, such as aiding HVAC experts with ductwork fabrication. Here are some recent examples of eye-opening progress in the field.
1. Continued Interest in Sheet Metal Fabrication Robots
Until recently, robots for sheet metal fabrication were relatively niche products. Now, they’re coming into the mainstream. One of the most compelling examples is how federal entities — including NASA and the U.S. Air Force — are among the investors supporting California startup Machina Labs.
That company specializes in robots for sheet metal fabrication. Its machines are too slow for mass production, but many clients rely on the technology to test their ideas during the early stages. Some other customers place orders for metal components in quantities from dozens to hundreds to ensure they have enough spare parts available. The Machina robots excel in fulfilling such needs. Some people in the industry who’ve seen the robots at work say they can do the jobs as well as seasoned metalworkers, preventing those professionals from suffering complications like back pain. There will likely be more examples of robots supplementing sheet metal professionals but not replacing them as the years and technology progress. 2. Digital Processes for Sheet Metal Work and Ductwork Fabrication
Metalworking shops were not traditionally known for using digitized processes to improve workflows. However, that’s starting to change. More shop owners and managers are exploring digital solutions, and they’ll be increasingly likely to notice competitive advantages.
One of the most significant advantages of digitalization is that it can break down the data silos that would otherwise slow or stop productivity. For example, someone might clock in to start a shift, access digital files in a cloud-based platform and immediately see what co-workers did on a client’s order earlier. Workers can spend more time focusing on making high-quality sheet metal parts, knowing they always have access to the most up-to-date information. Data-driven operations are also valuable when a client makes a last-minute change request. A digital system often reflects the difference immediately, while a person updating things manually may take hours to communicate the change to shop employees. Digital processes can also prove valuable in the field. A client may need an on-site estimate about ductwork fabrication for a home under construction. The contractor could use a digital tool to provide that quote and any other particulars that could help the customer reach an informed decision and feel confident about working with a specific professional. 3. Simulations to Improve Training and Planning
Learning sheet metal fabrication requires mastering numerous techniques. For example, air-powered metal-cutting tools significantly ease molding and shaping needs. People receiving metalworking training get the necessary knowledge in various ways. They might read textbooks, go through online modules, and attend in-person lectures and hands-on training sessions. Those are all valid learning options.
However, some students now use virtual reality simulations and similar technologies to learn the necessary skills. Augmented reality (AR) is another popular choice because it adds virtual details to real environments. For example, someone new to sheet metal fabrication might see a checklist floating in midair for them to follow. That approach keeps their hands free to work. AR can also support error prevention. In one case, an AR overlay detected someone’s mistake before they incorrectly placed a sheet metal panel. Failing to catch that error would have ruined a million-dollar product. Simulations play an increasingly important role in ductwork fabrication plans. People can easily access and learn simulation software that helps them see how certain options would work before committing to them during a project. Workers who can see the possibilities with software first have the knowledge needed to please clients and ensure the work finishes on schedule. 4. 3D Printing for Additional Fabrication Options
Anyone who has stayed abreast of 3D printing developments knows many are game-changing. Manufacturers can quickly prototype new designs and even create spare parts on-site instead of relying on external suppliers.
3D printing also creates new opportunities for sheet metal fabrication. One example comes from 3D printer maker Desktop Metal. Its recently released FIGUR G15 machine provides on-demand shaping for standard sheet metal by pulling details from a design file and exerting up to 2,000 pounds of force to achieve the desired outcome. The current model can make sheet metal pieces measuring up to 1.5 meters by 1.2 meters. People save substantial production time by not needing to use stamps, dies or other tools. Elsewhere, Australian architecture firm BVM hopes to change ductwork fabrication with 3D printing. The company uses recycled plastic for its ductwork rather than aluminum or steel. Moreover, this solution requires ductwork to be exposed rather than hidden behind drywall. Company representatives have also studied how to create 3D-printed designs that promote even air distribution throughout a room rather than leaving some people too warm and others cold. Tests of the concept showed it achieved that goal and used 10% less energy than conventional options. Watch for and Embrace Trends
These four innovations are already shaking things up in the worlds of sheet metal and ductwork fabrication. People who are not yet familiar with them should learn about them soon. That’s a great way to keep up with peers and the fast-changing pace of the industry.
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At Machan, we have over 40 years of experience in designing and manufacturing high-quality sheet metal products that meet your specifications and expectations. We have rich experience in offering OEM/ODM solutions for various industries and applications. Whether you need tool storage, van module systems, healthcare equipment, charging carts, smart locker systems, or any other sheet metal solutions, we can deliver them to you with speed and precision.
Not just a sheet metal fabricator, we are also a data-driven intelligent factory that constantly optimizes our workflow and upgrades our manufacturing facilities. We use the latest sheet metal fabrication techniques and equipment to handle a wide range of processes - from cutting, stamping, bending, welding, coating, assembly, and more. We can supply any quantity of sheet metal products - from low-volume, high-mix prototypes to high-volume production runs. We also have a dedicated design and development team that works closely with you to bring your creative ideas to life. We establish a streamlined workflow that ensures efficiency and effectiveness in every stage of the project. We are experts in creating stunning products for tool storage applications that will impress your customers and users. Machan International is more than just a sheet metal fabricator. We are your trusted partner in delivering customized solutions that exceed your expectations. Contact us today and let us show you what we can do for you.
Source : ACHR NEWS Network
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