AI or Artificial Intelligence has major applications in the manufacturing industry. Right from developing OEE (Overall Equipment Efficiency) to FPY (First Pass Yield) production, AI is transcending levels. In manufacturing operations, AI is transforming machinery maintenance, AI-ML-powered analytics based on data predicts how often hulls of ships should be cleaned for maximum efficiency leading to huge cost savings in transportation, etc. For example, some companies use AI for evaluating component images during ongoing production lines that help to spot deviations from the standard in real-time.AI innovations are helping to expand uptime while focussing on quality, and efficient production, process, and the overall output. Let’s see the top 10 AI innovations in the manufacturing industry that are attracting manufacturing companies across the globe.

1. Robotic Plasma Cutters

The AI-driven robotic arm is assisting in the plasma cutting process and eliminates the requirement of the human labor force. Plasma cutting is a significant part of the manufacturing process and it was considered as one of the biggest technology wonders at the time of the industrial revolution. Traditionally it involves huge human labor but AI innovation is allowing to replace this with the cutting-edge robot arm simplifying cutting and assembling processes. It is considered now a remarkable AI innovation in the manufacturing segment.

2. MV Error Detection

AI-driven  MV (Machine Vision)is helping manufacturing with error detection. The technology of Machine Vision frameworks allows manufacturers to digitalize quality control processes in the front & back finish of creation lines. Machine Vision mistake location further allows to recognizing error while expanding a value-based creation of the products concerned.

3. AI-IoT Sensors

AI-IoT-based sensors are a leading AI innovation in the manufacturing sector. IoT (Internet-of-Things)sensors help to assemble information throughout the manufacturing processes at varied phases. All this information serves for continuous advancements and prescient support to manufacturers across levels. IoT sensors backed by Artificial Intelligence are an innovative name, too, in the manufacturing industry.

4. 5G Digital Connectivity

Though 5G (just like IoT) is not a complete AI-based manufacturing technology, it is helping the industry alongside AI for smart Connectivity. Companies offering 5G connectivity have not yet reached the farthest connectivity levels for buyers but proving to be a great support for assembling offices.5G  facilitates a high-speed data transmission bringing in more connectivity potential where AI-powered tools capture those data and process, analyze them helping manufacturing owners with better decision-making ability.

5. 3D Printing

 3D Printing has come out as one of the latest AI innovations in the manufacturing sector. Also referred to as an added substance fabricating,3 D printing is a notable digital device for specialists. The technology is helping manufacturers to create just specific parts or items in a singular form, as solitary pieces. This is allowing for a better arrangement and efficiency in the ecosystem. This is also considered one of the major AI-powered digital innovations in manufacturing the world over.

6. Video Surveillance Cameras

AI-powered video surveillance cameras are considered a boon towards managing security in the manufacturing industry. The very technology helps to manufacture businesses to cope with the higher costs involved for live security personnel ensuring safety and security. Workplaces, factories, logistics, and several areas that need constant vigilance and monitoring are not possible to be done manually. So, AI innovation in the form of advanced video surveillance technology, cameras, is helping organizations to carry out security features in a seamless manner.

7. E-Tail Supply Chain Model

AI-based automation at varied points, warehouses, procurement facilities, is helping the logistics in the manufacturing sector for efficient and productive ­­­­­­­­­­­­­ end-to-end processes and deliveries. This has created a new model, the e-tail supply chain model that connects, integrates inventory, and varied other logistics stakeholders ensuring improved supply-chain management overall.

8. Visual Inspection Tool

AI-enabled automated visual inspection tool is another landmark AI innovation in the manufacturing sector. Businesses are leveraging this AI capability to a great extent as it can detect flaws that are too small which humans cannot see with the naked eye. Products with microscopic flaws can be detected by AI-enabled cameras that are highly powered and sensitive than human eyes. The overall system can recognize even the smallest defects, flaws in products, mark them and send timely alerts to the concerned department.

9. AI-ML Inventory Management Solutions

Manufacturing businesses take into cognizance this aspect of AI intervention in the sector. Inefficient inventory management leads to greater overhead costs that are detrimental to any business involved. AI-ML-powered inventory management digital solutions help to manage the entire process effectively increasing productivity and efficiency. Manufacturers can manage inventories seamlessly based on demand and supply meters.

10. AI-Enabled Robots

 AI-enabled robots are replacing humans for risky transactions and lifting heavy equipment required frequently. Thus, AI is more than just a digital method to optimize automated processes. Remotely controlled  AI-enabled robots can do varied tasks that are beyond human capacity.   It enhances the traceability, flexibility aspects enabling successful operations in the ecosystem.

Wrapping Note

Want to know what is the future of AI in the manufacturing industry? As per Fortune Business Insights, AI (Artificial Intelligence) in the manufacturing market is geared for a massive USD 9.89 Billion by the year 2027! This is self-explanatory of the beneficial use cases of AI and how the technology is transforming the industry with magnificent innovations and inventions bringing positive outcomes!

We know during the entire manufacturing process, you deal with several challenges, right from raw materials to the process of production, from testing to marketing, and then for delivery. AI can help you in eliminating mundane tasks and bring productivity in multiple areas – Connect to our experts to know more.

Let me have an honest confession first!

When I think of manufacturing, the very first image that occurs to my mind is a factory stacked with heavy machinery, some old-fashioned, obsolete models of machines quite rusted, continuously operating, and operating, just to produce some finished goods. Well, goods mean, something like a car, car of Mr.Bean? Or, if I fan my wild imagination a bit more, then I see a black & white picture of Laurel & Hardy mending machines in a garage. Sounds weird?  Indeed ‘Yes’! Because my intelligence fails before Artificial Intelligence. When AI arrives, the world halts, Industries automate, and disruptions act as blitzkrieg. That’s the modern story about the manufacturing industry where digital technologies like AI and Video Surveillance tools are highly disrupting the ecosystem, bringing in a greater ROI in businesses across the globe.

In this blog, I am trying to explain why video surveillance has a growing importance in the manufacturing industry, and its top 10 applications therein!

Video Surveillance Benefits

A typical manufacturing organization needs video surveillance tools and solutions for maintaining and taking care of multiple areas, for instance, CCTV cameras around car parking, at entrances, at exit points, office areas, delivery points, dispatch, as well as the manufacturing & assembly areas. Being a complex business due to inherent operational features, the very industry involves a greater number of areas involving high potential security risks, and health, and calls for urgent safety guidelines to strictly adhere to!

In broader terms, video surveillance to manufacturing has the following significant benefits:

• Business security aspects like machinery, and product
• Site visitors’ safety as well as safety for employees
• Monitoring varied  manufacturing processes
• Optimizing  business processes

Top 10 Applications

1. Reinforce Security

The major objective of video surveillance tools, equipment, and solutions is to reinforce end-to-end security. For a manufacturing business, plant, machinery, raw materials, finished goods or products, all have equal importance. Effective & efficient perimeter protection, sending alarms, alerts to security personnel regarding breaches, any suspicious behavior, and intruders, are all made possible via an integrated video surveillance system. It is required to protect the first line of site- security. Thus, a facility equipped with prominent security cameras conveys a powerful, deterrent message to one and all.  

2. Safety Attention

Video surveillance system minimizes any sort of mishappening at manufacturing facilities. The nature of the manufacturing environment attracts frequent injuries, accidents taking place. In industrial sites, factories, manufacturing facilities, the gravity of accidents may prove fatal and serious. However, video surveillance cameras can be effectively used to reinforce safety at all these places, at the workplace, too. Yes, at workplaces this surveillance tool actively reduces the chance of abrupt casualties owing to safety measures adequately taken. Otherwise, work-related illness or injuries carry a massive cost. Video surveillance helps to reduce varied accident costs, as video surveillance cameras help during post-incident investigations identifying the exact persons accountable for it. This saves further lives and incidents because investigations let them know the causes and they can take actions to deter such repetitions of incidents in the future. They deploy visible signage, new machinery, and protective barriers for that safety vigilance. Thus, manufacturing facilities use surveillance cameras to monitor constantly all dangerous machinery, high-risk areas, high- traffic areas which are vulnerable to accidents.

3. Preventing Crimes

Video Surveillance plays a key role in identifying culprits and facilitating adequate safety and other precautionary measures in manufacturing organizations. Although statistics do vary, it is seen that in many cases, video surveillance significantly leads to the reduction of crime rates and several non-authorized activities in workplaces. Security cameras ought to be positioned in the correct manner that will help to discourage theft, illegal and unauthorized activities. Moreover, as described before, in the case of criminal investigations by authorized personnel and security, it also assists in related law enforcement.

4. Monitoring on a Remote basis

With the COVID situation prevalent and the very pandemic has compelled people to stay at home, remote service across industries has seen a big surge. Consequently, even manufacturing facilities have started creative schedules as a response to the pandemic by adopting remote monitoring features. An AI-based integrated video surveillance system allows authorized personnel to access security footage over the internet, desktop, or mobile, from any location that seems fit from security aspects. The surveillance also enables manufacturing organizations to manage varied locations on a remote basis without people being present physically onsite. This feature augments security guards, helps in controlling crimes, and preventing any untoward incidents as cameras are mounted across the sites. Live video monitoring allows logging into any camera, or all of them if any alert or alarm sends respective signals. Reliability is a significant character of any AI-based video surveillance system across the manufacturing organization.

5. Production Monitoring & Optimizing Operations

In a manufacturing business, machinery failure casts a serious impact on output or flow of production. This leads to a reduced profit and customers’ dissatisfaction as well as anxieties created amongst the stakeholders. After all, machinery costs are a big amount (in millions) while profit is the ultimate business goal, too. Manufacturing facilities greatly rely on machines, production at a larger scale, and they don’t want to take the aforementioned risks now.SO, installing and mounting massive video surveillance equipment which is more empowered by digital technologies such as AI and Robotics, makes the business error-proof. With the help of additional technologies like thermal imaging, video surveillance can minutely highlight any potential machine failures, machines overheating for instance, and prior corrective and proactive actions can be taken to avoid those issues. Thus, monitoring of an overall production process makes this application of video surveillance a great help. Furthermore, video analytics help control the flow and movement of people across the manufacturing plant, and unauthorized people are barred from entering restricted areas. The analytical tools with immense digital capabilities in the decision-making process, facilitating changes and improvements efficiently and on the scale.

6. Safety Training

Video Surveillance tools like CCTV cameras provide video clips that can show in slow motion leading to see footage meticulously.  This sort of video footage can now assist with employee training and coaching for specific purposes, safety training, as well as remedial training. Even the management committee can retrieve significant insights via these video footage clips. This helps the latter to spot employees and workers who need customized training related to their work. AI-powered video surveillance solutions help with predicting this kind of training requirement required thus facilitating the decision-making process.

7. Compliance Adherence

Video surveillance application empowers manufacturing facilities with the visual data of all operations and processes happening within. This also ensures that employees are adhering to compliance, following company protocols and procedures, adhering to specific policies. Also, it enables management with timely actions in advance, addressing vulnerabilities and sorting out relevant issues by implementing the required changes.

8. Proper Documentation

An integrated Video Surveillance system gives support, 24 hrs. of continuous coverage of the manufacturing facility. It means anything that happens is captured on video, which amounts to documenting records of the entire manufacturing process. With proper documentation, the very facility or company remains prepared for any requirement in the future,e.g. legal matters, law enforcement, etc. Video surveillance application allows properly documenting unauthorized access, safety violations, or onsite mishaps.

9. Preventing Product Losses

HD and IP cameras help to access video footage over any sort of network, viz., mobile phones as well as tablets. Thus, if a manufacturing organization is storing certain spare parts, products, installing HD cameras helps strict vigilance in the area. This prevents the loss of expensive equipment, stocks, and protecting assets. This allows smoother operations in the manufacturing facilities and businesses to thrive.

10. Internet Security System

AI-powered video surveillance cameras capitalize on internet protocol (IP),  the massive power of internet networking, for sending, receiving sensitive data. This facilitates an easy installation and connection to the required system, and viewing of live camera feeds, just at any time, any location(remote basis) is possible using mobile apps for smartphones, and tablets.

End-Note

Installing advanced technology-based video surveillance tools and solutions within the premises of manufacturing companies has become the utmost priority now. Necessitated by the mandatory security concerns,  businesses are actively inquiring and hunting the best digitally powered, AI- video surveillance tools for high-scale adoption. However, which type of video surveillance application is appropriate for your business type, you need to take professional advice from an established mobile application development company only.

Not sure how video surveillance and digital can apply to your manufacturing business? Speak to our experts.

Manufacturing is one such vertical that has its roots deep into the Indian Industry. The biggest challenge manufacturing industries face is adopting new technology with the coming age. It is mostly noticed that the employees of such companies are highly accustomed to the traditional legacy processes and various systems in the warehouses and factories. We can see that almost all the Manufacturing operations management is turning digital and thus this creates a demand for mobile technology. It is of no surprise that the manufacturers prefer this, since 204 billion times apps have been downloaded by people worldwide alone in 2019 (Statista). The modern manufacturing domain is standing on the cusp of Industry 4.0, a new industrial revolution coming up this year. This approach would create a need for all the manufacturers to rethink about the ways in which their companies operate. Technologies like AI, Machine Learning, AR and IoT are changing how the traditional ways were used in manufacturing. These ways are helping the companies move forward by leveraging this whole lot of technology.

How is Mobile Technology helping the Manufacturing Industries?

1. Operational Efficiency

Operational efficiency is a key factor when it comes to the manufacturing process. Companies are prompted to evaluate how they are making use of these technologies and how it is affecting their companies. Industries want to opt beyond the current technologies that offer single use and hard-mounted devices. These devices do not allow flexibility and thus they want to opt for something that shares real time data and helps in fast decision making. These devices should be built in such a way that they handle any kind of rough handling, bumping and any kind of drops that is inevitable in this kind of environment. Thus, this helps in an improved method that is efficient and provides better output. 

2. Form Factor Flexibility

Mobile devices are beneficial for workers who work in the assembly lines and demanding devices which can integrate these solutions across the companies. Integration of these mobile devices can help in inventory management for fast data entry on the shipping docks and can also be used for showing the proof of delivery. The transformation of traditional methods to modern and fast methods requires optimal device deployment and a trusted partner that takes care of all the business needs for their work. Technology is capable of providing hardware and software solutions tailored specially for the manufacturing industry. 

3. Streamline Device Management

Reducing costs is an important task that any company has to manage. This can be reduced by reducing the number of devices that are being managed by the IT department of your company. For example, instead of managing each and every device individually, the whole lot can be managed by using Mobile Device Management(MDM) or Enterprise Mobility Management(EMM)  tools. These tools allow all the updates to be simplified and makes the process of troubleshooting, repair and management easy. This ensures that you spend less and the IT team is more focused on innovation than troubleshooting.

4. Enable Versatility and Maximise Security

Tasks can be equally divided among the team leaders who can work on individual areas of development. Each member can handle different tasks like managing operator breaks, taking charge of work orders, tracking these orders, etc. By using certain security measures, it can be ensured that any company data is not leaked out in any case. In manufacturing industries, financial data regarding accounts are always passed from person to person which increases the chances of leakage. These can be kept safe by using devices which enable encryption modes to store data. 

5. Access Powerful Computing on the Go

The people who work for a manufacturing industry can leverage the advantages that come with mobile devices. These devices have the ability to put all the tasks on a fast track and improve the efficiency in each step of manufacturing. If computing data is delivered on the go, along with data processing, the factories will no longer need to wait for the solutions for a long time. These solutions act as the anchors for smart factories in the future. The businesses that look forward to adopting these solutions are surely poised to gain some competitive advantage.

6. Logistics and Supply-chain Coordination

The best coordination supply chain and logistics can be expected from a company that adopts mobile solutions. This technology brings a balance in the timelines, delivery and profit margins of the company. A continuous tracking process with reporting to the supervisor in real time helps the manufacturers avoid any kind of negative cash flows. 

7. Predictive and Proactive Maintenance

It is important that automation tools and other components work optimally on the assembly line. This ensures cost reduction and helps in meeting target outcomes. Predictive maintenance can mark out the potential issues with a system with the help of a mobile tablet that is configured with the latest technology. Data collected by this device can be shared to the supervisors and managers on a dashboard or similar thing and thus help them make quick real time decisions to fix the problems. With a device in hand, the employees can report any kind of maintenance data which can be fixed in a short time and thus increase the productivity of the company. There are companies that work on an autonomous loop i.e., their data is in a loop which makes the systems intelligent over time. In case a machine fails, this data is recorded into a Machine Learning program and thus makes it better for future use. These machines can warn in the future if they see any similar kind of problem approaching. 

8. Resource and Inventory Management

Inputs that are gained by barcode scanning for location tracking of raw materials for a specific batch run can be a valuable aspect for Inventory Management. Employees working across various factories can supervise the movement of all the critical supplies and thus schedule production on time. Supply chain management applications have the capability to send out timely alerts of the status of various shipments to the worker’s devices once the products are scanned. To automatically trigger supply orders when products are running low, inventory management softwares can be used. 

Conclusion

Need of the hour is introducing mobile technology well into the manufacturing industry and making it flow with the ongoing digitization in the world. This not only does improve efficiency of such companies but also makes this industry more promising.