Introduction to digital manufacturing
Digital manufacturing is about integrating the latest computing technologies available to manufacturers to really improve the metrics that matter.
Creating this single digital thread across the factory floor, from the design office to the warehouse, creates the opportunity to do more and do better than ever before.
1. What is Digital Manufacturing?
In the digital transformation of manufacturing, companies start implementing new digital technologies to improve all aspects of the manufacturing process. This can be a comprehensive approach or piecemeal implementation where software applications and digitization are the main drivers.
Many manufacturers have gone digital, using programmable logic controllers (PLCs) and computer numerical controls (CNCs). They enable automatic operation of machines and devices with a higher level of control than relay logic systems. Then came CAD, CAM, ERP, computerized maintenance management systems (CMMS), and more. Today, lean manufacturing, Six Sigma, and quality control methodologies are layered on this patchwork quilt of disparate technologies.
As many industry leaders will admit, this is a bit tricky.
Digital manufacturing is all about integrating these tools and working seamlessly together. Product data becomes a digital thread through the entire manufacturing industry, from design and development to sales and service. Product definition relates to simulation and testing, manufacturing layout planning and mechanical design, ERP, quality and after-sales service.
2. Benefits of Digital Manufacturing Technology
Different computer systems, or worse, no computer systems, mean more time spent reviewing, analyzing, and entering data. This is why so many operations and processes are still managed primarily in spreadsheets, with minimal analysis and planning capabilities. It’s slow, wasteful, and an opportunity for bugs to sneak in.
The integration of digital manufacturing technology reduces this waste and delivers immediate, quantifiable savings. In the aforementioned report, Deloitte found Smart his manufacturing initiatives:
- Enabled 10% increase in production
- Increased utilization by 11%
- Increased labor productivity by 12%
3. Digitization in Manufacturing and Processes
A closer look at what digitization means and can achieve across manufacturing reveals possible applications and potential pitfalls.
The pitfalls of not realizing the expected benefits are usually caused by using the wrong tools. It starts with not identifying your digital transformation goals. Only by keeping your purpose in mind can you determine what is necessary and useful and what is unnecessary.
It is important to understand the features and functions of the tool under consideration, plan and precisely control their implementation.
- Simulation
- Smart Manufacturing
- Digitalization of the Factory
4. Digital Manufacturing Transformation Begins
Most manufacturers have already implemented some part of their digital transformation. All they have to do is put it all together. No doubt this involves many difficult decisions about legacy systems and spending. But there is also the danger that the seeming scale of the challenge can lead to a kind of laziness. To fix this, we recommend the following steps:
focus. Instead of trying to digitize your entire operation, choose one area where digitization will have a significant and highly visible impact.
Identify your current location. See which tools you use and which ones you don’t currently use. Additive manufacturing and robotics are examples.
Define a goal. Looking to lower costs, speed time to market, increase flexibility, and more?
See product data. Is this suitable for use as a common source of truth across manufacturing?
If you are new to simulation, look for products that support your digital transformation. If it’s a technology you already use, see if it can be extended and integrated with other tools you use now or in the future.
Impact of Digital Transformation in Manufacturing
The impact of digital transformation in manufacturing is far-reaching and includes increased safety, quality, throughput, efficiency, profitability and sustainability while reducing costs to remain competitive in the market. The impact is enormous and this transformation is necessary to meet evolving customer needs and fierce competition.
Key benefits of digitizing your manufacturing company include:
Providing digital solutions that improve safety reduces workplace injuries and accidents and increases customer satisfaction.
Improving process efficiency has a positive impact on employee productivity and bottom line. Strong returns enable us to continue to innovate and drive sustainability in our markets while increasing value for our business, shareholders and customers.
Digital transformation has also created real-time manufacturing data. These digital processes give you instant data that matches your analysis, enabling your organization to make faster, real-time decisions. This involves not only reactive responses, but also predictive analytics to improve future processes and products. This standardizes preventive maintenance and outage approaches that directly impact every aspect of your business.
Digital transformation in manufacturing comes with empowerment. It is the empowerment to speak up and do something to improve a process, hold yourself and others accountable for improving the process, and have a mindset of continuous improvement within your organization.
Empowerment comes in many ways, but it’s most effective when it aligns with the organization’s vision for the future and communicates effectively with employees.
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