Optimised production processes thanks to smart manufacturing

Smart manufacturing is about automating production processes as completely as possible. Machines involved in production are networked with each other via the internet, enabling data to be exchanged in real time. Production lines can therefore be monitored and controlled with minimal human intervention. Basically, artificial intelligence is taking over the task of ensuring optimal networking between the machines in a production chain. Existing technologies are integrated and interlinked in such a way that they are used as efficiently as possible in production. This digitalisation also offers the opportunity to collect data that allows certain predictions to be made in the analysis. For example, optimisation potential for production or possible maintenance requirements can be identified at an early stage and production can be adapted accordingly.

Smart manufacturing is an overarching term that does not refer exclusively to production in a factory, but also includes, for example, market demand, medium-term corporate planning and the logistics upstream and downstream of production.

As already mentioned, the term smart manufacturing refers to the entire manufacturing process, from planning and production through to logistics. Smart production, on the other hand, focuses on the production processes within a factory. The aim here is to manufacture the specified product types and quantities as efficiently and cost-effectively as possible. Smart production offers a number of advantages:

• Thanks to optimal data analysis, production processes can be optimised and downtimes reduced. Production times are optimally utilised and raw material requirements can be determined more precisely and processed more accurately.
• The use of intelligent systems enables a quick response to any disruptions and other unforeseen changes in the production process. This improved agility also leads to a reduction in costs and a more flexible response to market conditions.
• An important part of a smart factory is the use of so-called Predictive maintenance systems. Thanks to special, interactive sensor technology, faults on the machines or in the production process can be recognised and rectified more quickly. Possible workarounds are also identified more quickly.
• The quality control can also be automated in smart manufacturing. Products can be checked for defects by the machines themselves and removed from circulation in good time if necessary. This eliminates the need for manual quality checks.
• So-called digital twins. These are digital representations of production systems that can be used to simulate possible optimisations or adjustments in the production process. The advantage of this is that innovations can be thoroughly tested before they are physically implemented at great financial expense.

Smart factories are increasingly being used in industrial manufacturing. But what is a smart factory? Companies such as Mercedes-Benz and Boehringer have been using the possibilities of digitalisation for several years to meet the challenges of the modern market and the general digital transformation.

• The Mercedes-Benz Group has equipped its "Factory 56" with Wi-Fi and 5G networks, which makes big data analyses possible.
• The Volkswagen Group has a factory in Neckarsulm for which innovative design software has been developed. This enables employees to produce 3D printing aids themselves, even without prior knowledge.
• At its Haiger site, Rittal produces 8,000 compact enclosures every day using a highly automated production control system. Production and dispatch are also digitally interlinked, and the company's own logistics are integrated accordingly.
• At the pharmaceutical company Boehringer , medicines such as tablets are being produced automatically for the first time in Ingelheim. Larger production facilities will then be planned and built on the basis of the knowledge gained in this smart factory. This will allow larger scaled production facilities to be planned more reliably.

For all its advantages, the digital transformation Entrepreneurs are always faced with challenges. You can expect the same if you want to optimise your production and take advantage of the benefits of smart manufacturing. But: No change process is easy. It is therefore important that you are aware of the potential hurdles in advance so that you can recognise and plan for them at an early stage.

• The complexity and high costs of a digital transformation process should not be underestimated. Make sure that you work with specialised project managers and that your company's liquidity is not jeopardised by such a major project.
• Data protection concerns also crop up time and again when it comes to collecting and analysing big data. It is therefore essential to ensure that data processing complies with the GDPR and seek legal advice if necessary.
• Smart manufacturing is radically changing the requirements profile for your employees. Open communication and extensive training programmes are therefore absolutely essential and should be factored into resource planning.

If you master these challenges, nothing stands in the way of smart production and state-of-the-art production lines for your company.