Smart manufacturing is a broad concept that involves a combination of various technologies’ implementation in a manufacturing ecosystem. It employs computer-integrated manufacturing, digital information, technologies, and solutions. These technologies and solutions are called enablers which optimize the manufacturing process and increase the overall profits. Some of the enablers being used currently are- artificial intelligence, robotics, cybersecurity, Industrial internet of things (IIoT) and blockchain. The main goal of smart manufacturing is efficient production and recyclability, fast changes in production levels based on demand and optimization of the supply chain.
The industrial revolution began nearly 260 years ago and has since then witnessed a lot of change. The first industrial revolution involved the usage of steam power and power loom and the second one saw the introduction of the assembly line. The third industrial revolution began much later during the 1970s in which automation and data-enhanced automation came into being. But the greatest revolution of them all, the fourth industrial revolution, that began nearly 20 years ago saw technology change the nature of manufacturing completely. Automation has become a significant advantage in today’s manufacturing because of the penetration of computers and technology. It is continuously setting the standards for the industry and has become an important determining factor of whether or not a company will remain competitive within the industry. Smart manufacturing has allowed companies to produce products at outstanding speed and great quality.
Smart manufacturing has several benefits. It improves efficiency, increases productivity and saves cost. An automated machine reduces production time and speeds up the process as it needs no thinking. When an automated machine performs a task the accuracy and repeatability as compared to an employee is much greater. Also, fewer employees are needed to get the job done which reduces numerous costs. Investment in automated equipment leads to large production volumes which in turn increases profitability. While there are so many advantages of smart manufacturing there are some disadvantages as well that shouldn’t be overlooked. Not only does it increase unemployment, but it is a large initial investment depending upon the type and degree of automation. Also, there are many unpredictable costs including maintenance costs, costs of automating a process and training employees to operate automated machines. This may cause an increase in production costs and reduce profits if not monitored and taken care of properly. A perfect process means a perfect product. A process improvement methodology like Lean Six Sigma uses techniques and methodologies to increase efficiency and profits are required to be implemented to reduce these defects so that the company stands a long chance in the competitive world out there. Lean Six Sigma is a culture of learning and continuous improvement. Introducing IT and smart manufacturing to Lean Six Sigma will merge process and culture into a single approach which will stimulate inventiveness. By analyzing the data and thinking of solutions using the DMAIC approach, even the slightest of errors that would have otherwise been overlooked can be spotted and worked upon.
The main aim of smart manufacturing is to use a technology-driven approach to monitor the production process and optimize manufacturing. It enables the use of data analytics to improve the manufacturing process. Just like smart manufacturing, the aim of Lean Six Sigma too is to use certain tools and techniques for data analysis to cut down production costs and increase profits by dramatically improving every process in an industry; financial, operational or production. Its use represents a mindset shift and is driven by the people whose main is to satisfy customers’ demands and improve their outcomes.
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