Smart manufacturing

Smart manufacturing[1] is a broad category of manufacturing that employs computer-integrated

manufacturing, high levels of adaptability and rapid design changes, digital information technology, and
more flexible technical workforce training.[2] Other goals sometimes include fast changes in production
levels based on demand,[3][1] optimization of the supply chain,[3] efficient production and recyclability.[4]
In this concept, as smart factory has interoperable systems, multi-scale dynamic modelling and
simulation, intelligent automation, strong cyber security, and networked sensors.

The broad definition of smart manufacturing covers many different technologies. Some of the key
technologies in the smart manufacturing movement include big data processing capabilities, industrial
connectivity devices and services, and advanced robotics.[5]

Big data
processing
Smart manufacturing
leverages big data analytics
to optimize complex
production processes and
enhance supply chain
management. [7] Big data
analytics refers to a method
for gathering and
understanding large data sets
in terms of what are known
as the three V's, velocity,
variety and volume. Velocity
informs the frequency of
Graphic of a sample manufacturing control system showing the
data acquisition, which can interconnectivity of data analysis, computing and automation.[6] Graphic of a
be concurrent with the sample manufacturing control system showing the interconnectivity of data
application of previous data. analysis, computing and automation
Variety describes the
different types of data that
may be handled. Volume represents the amount of data.[8] Big data analytics allows an enterprise to use
smart manufacturing to predict demand and the need for design changes rather than reacting to orders
placed.[2]
Some products have
embedded sensors, which
produce large amounts of
data that can be used to
understand consumer
behavior and improve future
versions of the
product. [9][10][11]

Advanced
robotics
Advanced industrial robots,
also known as smart
Advanced robotics used in automotive production
machines, operate
autonomously and can
communicate directly with manufacturing systems. In some advanced manufacturing contexts, they can
work with humans for co-assembly tasks.[12] By evaluating sensory input and distinguishing between
different product configurations, these machines are able to solve problems and make decisions
independent of people. These robots are able to complete work beyond what they were initially
programmed to do and have artificial intelligence that allows them to learn from experience.[5] These
machines have the flexibility to be reconfigured and re-purposed. This gives them the ability to respond
rapidly to design changes and innovation, which is a competitive advantage over more traditional
manufacturing processes.[13] An area of concern surrounding advanced robotics is the safety and well-
being of the human workers who interact with robotic systems. Traditionally, measures have been taken
to segregate robots from the human workforce, but advances in robotic cognitive ability have opened up
opportunities, such as cobots, for robots to work collaboratively with people.[14]

Cloud computing allows large amounts of data storage or computational power to be rapidly applied to
manufacturing, and allow a large amount of data on machine performance and output quality to be
collected. This can improve machine configuration, predictive maintenance, and fault analysis. Better
predictions can facilitate better strategies for ordering raw materials or scheduling production runs.

3D printing
As of 2019, 3D printing is mainly used in rapid prototyping, design iteration, and small-scale production.
Improvements in speed, quality, and materials could make it useful in mass production[15][16] and mass
customization.[16]

However, 3D printing developed so much in recent years that it is no longer used just as technology for
prototyping. 3D printing sector is moving beyond prototyping especially it is becoming increasingly
widespread in supply chains. The industries where digital manufacturing with 3D printing is the most
seen are automotive, industrial and medical. In the auto industry, 3D printing is used not only for
prototyping but also for the full production of final parts and products. 3D printing has also been used by
suppliers and digital manufacturers coming together to help fight COVID-19.[17]
3D printing allows to prototype more successfully, thus companies are saving time and money as
significant volumes of parts can be produced in a short period. There is great potential for 3D printing to
revolutionise supply chains, hence more companies are using it. The main challenge that 3D printing
faces is the change of people's mindset. Moreover, some workers will need to re-learn a set of new skills
to manage 3D printing technology.[17]

Eliminating workplace inefficiencies and hazards

Smart manufacturing can also be attributed to surveying workplace inefficiencies and assisting in worker
safety. Efficiency optimization is a huge focus for adopters of "smart" systems, which is done through
data research and intelligent learning automation. For instance operators can be given personal access
cards with inbuilt Wi-Fi and Bluetooth, which can connect to the machines and a Cloud platform to
determine which operator is working on which machine in real time.[18] An intelligent, interconnected
'smart' system can be established to set a performance target, determine if the target is obtainable, and
identify inefficiencies through failed or delayed performance targets.[19] In general, automation may
alleviate inefficiencies due to human error. And in general, evolving AI eliminates the inefficiencies of its
predecessors.

As robots take on more of the physical tasks of manufacturing, workers no longer need to be present and
are exposed to fewer hazards.[20]

Impact of Industry 4.0

Industry 4.0 is a project in the high-tech strategy of the German government that promotes the
computerization of traditional industries such as manufacturing. The goal is the intelligent factory (Smart
Factory) that is characterized by adaptability, resource efficiency, and ergonomics, as well as the
integration of customers and business partners in business and value processes. Its technological
foundation consists of cyber-physical systems and the Internet of Things.[21]

This kind of "intelligent manufacturing" makes a great use of:

Wireless connections, both during product assembly and long-distance interactions with
them;
Last generation sensors, distributed along the supply chain and the same products (Internet
of things);
Elaboration of a great amount of data to control all phases of construction, distribution and
usage of a good.
European Roadmap "Factories of the Future" (http://ec.europa.eu/research/industrial_technologies/factori
es-of-the-future_en.html) and German one "Industrie 4.0″ (https://web.archive.org/web/2013101418320
2/http://www.acatech.de/fileadmin/user_upload/Baumstruktur_nach_Website/Acatech/root/de/Material_f
uer_Sonderseiten/Industrie_4.0/Final_report__Industrie_4.0_accessible.pdf) illustrate several of the
action lines to undertake and the related benefits. Some examples are:

Advanced manufacturing processes and rapid prototyping will make possible for each
customer to order one-of-a-kind product without significant cost increase.
 Collaborative Virtual Factory (VF) platforms will drastically reduce cost and time associated
to new product design and engineering of the production process, by exploiting complete
simulation and virtual testing throughout the Product Lifecycle.
Advanced Human-Machine interaction (HMI) and augmented reality (AR) devices will help
increasing safety in production plants and reducing physical demand to workers (whose age
has an increasing trend).
Machine learning will be fundamental to optimize the production processes, both for
reducing lead times and reducing the energy consumption.
Cyber-physical systems and machine-to-machine (M2M) communication will allow to gather
and share real-time data from the shop floor in order to reduce downtime and idle time by
conducting extremely effective predictive maintenance.

Statistics
The Ministry of Economy, Trade and Industry in South Korea announced on 10 March 2016 that it had
aided the construction of smart factories in 1,240 small and medium enterprises, which it said resulted in
an average 27.6% decrease in defective products, 7.1% faster production of prototypes, and 29.2% lower
cost.[22]

See also
Open manufacturing
Fourth Industrial Revolution

References
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nufacturingglobal.com/technology/evolution-3d-printing-manufacturing). Manufacturing
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19. Jung, Kiwook (2015-03-16). "Mapping Strategic Goals and Operational Performance Metrics
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20. Louchez, Alain (January 6, 2014). "From Smart Manufacturing to Manufacturing Smart" (htt
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External links
CESMII - US National Institute on Smart Manufacturing (http://cesmii.org/)
Factories of the Future (http://ec.europa.eu/research/industrial_technologies/factories-of-the
-future_en.html)
Agnieszka Radziwon (https://web.archive.org/web/20211221103330/https://academic.micro
soft.com/author/2598638453), Arne Bilberg, Marcel Bogers, Erik Skov Madsen. The Smart
Factory: Exploring Adaptive and Flexible Manufacturing Solutions (https://www.daaam.info/D
ownloads/Pdfs/proceedings/proceedings_2013/157.pdf) – Proceedings (https://daaam.info/2
4th-proceedings-2013/) of the 24th DAAAM International Symposium on Intelligent
Manufacturing and Automation, 23–26 October 2013, Zadar, Croatia. – Elsevier, Procedia
Engineering, ISSN 1877-7058, 69 (2014), 1184–1190
Agnieszka Radziwon, Marcel Bogers, Arne Bilberg. The Smart Factory: Exploring an Open
Innovation Solution for Manufacturing Ecosystems (https://ssrn.com/abstract=2503064)
Date Written: May 28, 2014. Available at SSRN, 11 Pages. Posted: 1 Oct 2014
GE launches 'microfactory' to co-create the future of manufacturing (https://www.techrepubli
c.com/article/ge-launches-microfactory-to-co-create-the-future-of-manufacturing/#ftag=RSS
56d97e7)

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