Since the first industrial revolution in 1760, manufacturing has progressed greatly. This progress is often divided into separate revolutions. Currently, we are in the midst of the fourth industrial revolution, also known as Industry 4.0. or 4 IR. Industry 4.0 offers diverse technological solutions to improve manufacturing processes. But, with constantly changing technology, it can be difficult to understand the tools available and how they are best utilized. We’ll break down three of the major technologies of Industry 4.0 and discuss how they can be utilized in a manufacturing setting.
Artificial Intelligence Use Cases
Artificial Intelligence (AI) encompasses the topics of machine learning and deep learning. In other words, it is a tool that takes data and then performs calculations and analyses on the data to create predictions, suggestions, and recommendations. The most popular use-case of artificial intelligence in manufacturing is predictive maintenance.
Of the AI-based predictive maintenance tools available, IBM’s Watson is one of the most popular. This tool uses artificial intelligence to analyze equipment and process data to predict when equipment will fail. Knowing when an asset is likely to break is crucial for scheduling maintenance activities and preventing downtimes. This technology can be used to predict not only when an asset will break down but also the most effective maintenance activities to ensure every piece of equipment operates efficiently.
In addition to predictive maintenance, artificial intelligence can also be used to manage inventory levels, automate processes, and perform quality control tasks. To effectively manage inventory levels, a variety of data inputs must be considered. These can include historical sales data, promotions, weather, industry trends, and customer behavior. AI can be utilized to consider all these inputs and other applicable data to perform analysis and calculations faster than humans could alone. One way AI is being used to automate processes is through the creation of lights-out factories. These lights-out factories are designed to run entirely with robots and AI, so they do not require the lighting traditional factories would, contributing to their unique name. Lastly, AI can be used to improve quality control processes. By analyzing final products for flaws that are impossible for the human eye to detect, AI can identify potential process issues before they have the chance to become catastrophic.
Virtual Reality vs. Augmented Reality
While virtual reality (VR) and augmented reality (AR) are related concepts, they are two distinct technologies. Virtual reality is a simulated 3D world separate from the physical world. Augmented reality adds artificial elements to the real world. One way of thinking of the difference between virtual and augmented reality is that virtual reality is made entirely of simulated elements, whereas augmented reality adds simulated elements to the real world.
Virtual Reality Use Cases
Since virtual reality is a simulated world separate from the physical world, it is often used to create immersive gaming experiences. However, it also has applications in manufacturing. One such application is designing and prototyping. Ford Motor Company has been utilizing virtual reality when developing vehicles. Called the Ford immersive vehicle environment lab, or FIVE, this technology allows two developers to don goggles and interact with a vehicle design before a physical prototype ever exists.
Using FIVE technology, Ford can make design, ergonomic, and aesthetic decisions quicker, cheaper, and easier than if physical prototypes were created. Additionally, while the FIVE lab is limited to two people interacting with the prototype at a time, many other stakeholders can watch the design process. This improves the collaborative process as stakeholders from around the world can provide their input on the virtual prototype.
However, virtual reality offers many more benefits than just designing and prototyping. Virtual reality can be used to run simulations to determine how different variables will affect plant operations. This simulation can be used to predict accidents, making facilities safer. Virtual reality can also be used to run simulations on such a large scale as plant layout to smaller changes like workstation layout. This enables process managers and engineers to optimize systems without the need to interrupt employees and workers by running experiments and time studies.
Augmented Reality Use Cases
Like virtual reality, augmented reality also offers several user cases in manufacturing settings. One of the most common use cases of augmented reality is training. Since augmented reality appends additional, simulated information onto the physical world, it can be used to provide real-time directions to employees. These directions can help employees complete their tasks more quickly and with fewer errors.
One such example of this application of augmented reality is Light Guide Systems. Light Guide Systems is an augmented reality tool that provides directions, verification, and QA checks to the medical manufacturing process. Since the entire manufacturing process is recorded for analysis, traceability is easily accomplished with Light Guide Systems. If a recall is ever instituted, manufacturing data can be reviewed, and the root cause of the defect uncovered to ensure it does not occur again.
Light Guide Systems and other such augmented reality programs have the added advantage of customization and real-time adjustments. The directions can be translated into any language, so any worker can receive instructions in the language they are most comfortable with. Additionally, process changes can be added to the system, easily pushing updated directions across an entire facility or company.
Advantages of Industry 4.0
Artificial intelligence, virtual reality, and augmented reality are all advantageous tools that originated with Industry 4.0. These tools have a wide array of applications and have proven useful in the manufacturing sector. No matter what manufacturing problem you are trying to solve, AI, VR, or AR almost certainly has a solution that can be tailored to your facility.
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