**Artificial Intelligence in Manufacturing: Four Use Cases You Need to Know in 2023**
Artificial Intelligence (AI) has become increasingly essential in the day-to-day operations of manufacturers worldwide. This technology, through autonomous robots and machine learning-powered predictive analytics, allows companies to streamline processes, increase productivity, and reduce environmental damage. Rather than replacing human workers, organizations prioritize augmenting human abilities to ensure safer and more efficient work environments. In this article, we will explore four intriguing use cases for AI in manufacturing in 2023.
**Cobots: Collaborative robots revolutionizing factories**
Cobots, or collaborative robots, represent a new development in the automation of manual tasks. These robots are designed to work alongside humans safely while enhancing their abilities. Unlike traditional industrial robots, cobots are cost-effective as they do not require dedicated areas to operate. They can be seamlessly integrated into regular plant floors without the need for protective cages or segregation from humans. Cobots can handle various manufacturing operations such as component picking, screwing, sanding, polishing, and even operating conventional machinery like injection molding and stamping presses. Additionally, they can perform quality control inspections using computer vision-enabled cameras.
Automotive manufacturers like BMW and Ford benefit significantly from using cobots in tasks like gluing, welding, and quality control inspections. Consumer goods manufacturers such as Procter & Gamble also streamline their processes by employing cobots in assembling and packaging, maintaining high standards of hygiene.
**AI in Additive Manufacturing: Optimizing 3D printing**
Additive manufacturing, commonly known as 3D printing, involves building products and objects layer by layer. AI contributes to additive manufacturing by optimizing material dispensing and application methods. It also plays a vital role in designing complex products. Real-time error detection and correction in 3D printing technology are facilitated by AI. For instance, Blacksmith, a tool developed by additive manufacturing equipment manufacturer Markforged, utilizes AI to compare product designs with finished products. It automates the fine-tuning of the manufacturing process, ensuring alignment. Footwear giants Adidas and Reebok are benefiting from such technology by creating comfortable and performance-enhancing running shoes with complex lattice structures.
**Generative Design: Accelerating product development**
Generative design, akin to generative AI found in technologies like ChatGPT or Dall-E, focuses on product design. Designers input parameters such as materials, desired size and weight, manufacturing methods, and cost, and generative design algorithms generate blueprints and instructions. This method accelerates product development processes and fosters innovation in design. Generative design is particularly effective in conceptualizing possibilities with new additive manufacturing processes, such as 3D printing, due to the intricate shapes and structures it can create. It is widely used in developing new components that are cheaper, lighter, and sturdier than existing ones, enhancing the quality of various products ranging from cars and aircraft to prefabricated houses and structures.
**Predictive Maintenance: Preventing breakdowns through data analysis**
Manufacturers employ AI to analyze data from sensors and machinery on the factory floor to predict failures and breakdowns. By doing so, they can ensure the availability of necessary resources and spare parts for quick repairs. Accurate predictions regarding downtime in specific processes or operations allow for effective scheduling and logistical planning. Machine learning algorithms process data from vibrations, thermal imaging, operating efficiency, and analysis of oils and liquids in machinery, providing valuable insights into the health of manufacturing equipment. AI startup Augury provides technology to companies like Pepsi and Colgate, enabling the detection of manufacturing machinery problems before they lead to breakdowns.
**The Lights-Out Factory: The rise of autonomous manufacturing**
A lights-out factory refers to a smart factory that operates autonomously without any human presence on-site. Although mostly theoretical, some examples already exist, such as the factory operated by FANUC, a Japanese robotics manufacturer, which has operated without humans since 2001 for periods of up to 30 days. Philips, an electronics manufacturer, also operates a factory in the Netherlands where only nine human staff members are required on-site at any given time. This trend is expected to be adopted by more companies as technology becomes increasingly efficient and affordable. A robots-only workforce allows factories to potentially operate 24/7 without human intervention, leading to increased output and efficiency. However, questions regarding the impact on society due to the removal of humans from the manufacturing workforce need to be addressed.
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