We often use buzzwords in the manufacturing business such as Industry 4.0 and digital twin as if there were clear definitions of what these terms encompass. I am often in meetings with customers who state they are trying to “automate production” or are looking for an “Industry 4.0 showcase installation.” However, as you drive deep into the specifics of the implementation plan, I frequently walk away with the feeling they have not mapped out their own manufacturing process. And in many cases, they do not fully understand how to leverage new metrology technology and the impactful data immediately available for analysis and decision-making.
Manufacturers are now embracing the move to the digitization of their production processes. Many initial project goals are very narrowly focused around removing manpower, manual errors, and running 24/7 to improve total output. These are all worthy goals for sure. Yet, this approach leaves many facets in their overall process often overlooked. There are critical questions that must be asked. How can the upfront programming and integration effort be reduced? How can downstream quality data be leveraged to react more quickly and efficiently in the manufacturing process? What method can be used to make production turnover between products easier and more efficient? How can part design changes or manufacturing process changes be easier to implement? How can overall equipment effectiveness (OEE) data be used to improve production workflow or predict hardware downtime?