DigiKey says manufacturing is entering a new era with the automated factory

The manufacturing landscape is undergoing a profound transformation, driven primarily by the rapid adoption of industrial automation. Several factors are accelerating the adoption of automation in manufacturing, including:

Increased efficiency and productivity: Automation can significantly reduce labor costs, improve production speed and minimize downtime.
Improved quality and consistency: Automated systems can deliver consistent product quality, reducing defects and rework.
Enhanced flexibility: Modern automation technologies enable manufacturers to quickly adapt to changing market demands and product variations.
Data-driven decision-making: Automation generates vast amounts of data that can be analyzed to optimize processes, improve efficiency and identify potential issues.
Labor shortages: In many regions, the availability of skilled labor is limited, making automation a viable solution.

At DigiKey, we have been keeping a close eye on the impact various technologies have had or will have on the future of manufacturing. Following is our take on how robotics, artificial intelligence, the Internet of Things and augmented reality are ushering in a new era of manufacturing.

Robotics

Collaborative robots (cobots), autonomous mobile robots (AMRs) and automated guided vehicles (AGVs) will all continue to grow in popularity. AMRs provide the ability to work around tight spaces where toxic chemicals and heavy machinery can be a danger to humans. Using sensors, machine vision and artificial intelligence, AMRs are capable of accurately navigating surroundings independent of human control. AGVs are a great solution for material handling in warehouses and distribution facilities. They move on pre-programmed paths through software programming and the use of sensors such as LiDAR. AGVs are designed to handle tasks such as moving pallets or removing trash.

Cobots are designed to work in the presence of human counterparts using an array of sensors to detect the presence of people or obstacles. They handle menial and even dangerous tasks to free up people to work on more complicated tasks.

AI and digital twins

AI has taken the entire world by storm and is being used to optimize production processes, predict equipment failures and enhance quality control. We are also seeing AI being used to program PLCs and robotics.

Over the past couple of years, digital twin technology has become increasingly popular across industry. Digital twins give manufacturers the ability to accurately view their entire floor in a simulated environment to see how changes in programming could affect real-world production. AI (artificial intelligence) can enhance the accuracy and realism of digital twins by using computer vision, machine learning and deep learning to analyze data from sensors, cameras and other sources.

AI can also generate realistic 3D models of physical objects and environments using generative adversarial networks (GANs) and other techniques to run simulations and scenarios to optimize performance, efficiency and sustainability. AI can also help digital twins learn from their own experiences, adapt to changing conditions, and provide insights and recommendations based on the data and outcomes of the simulations.

Internet of Things (IoT)

Connected devices and sensors enable real-time monitoring of production processes, facilitating predictive maintenance and improving overall efficiency.

While predictive maintenance has been around for a long time, there has recently been an enormous increase in the need to collect data from every aspect of the industrial manufacturing process. Every step in a manufactured product’s journey is analyzed. Sensors monitor vibrations, temperatures, noise, humidity and more to decrease waste and loss by ensuring that a line is working at peak efficiency.

Condition monitoring systems report when a bearing or a motor is reaching the end of its life cycle. Gone are the days of sending a technician onto the floor to perform routine scheduled maintenance on a motor just because the calendar says to do so. With the ability to monitor every aspect of a motor’s performance, we can now know exactly when it will fail and when we should place an order to replace it. This means fewer line-down situations or reductions in line production, minimizing loss to plant throughput.

Augmented reality

One of the fastest-growing technologies in industry is augmented reality (AR), which can provide workers with real-time information and instructions to improve productivity and reduce errors. Last year, I watched an electrician use AR to diagnose a problem in a cabinet and make the repair. The AR provided the electrician with a step-by-step process and enabled them to get the cabinet back up and running in a very short amount of time.

Immersive technology like virtual reality (VR) can be used to train employees in factory operations and maintenance skills. This helps to reduce time-to-competency and transfer a high level of skill, factory knowledge and situational awareness on demand.

Applying emerging technologies

In DigiKey’s Factory Tomorrow video series, we partnered with world-class manufacturers such as Siemens and Banner Engineering to explore the products and technologies that are shaping the factory floor today.

We visited Siemens at Lift Technologies in Detroit, where we saw firsthand applications of digital twin technology being applied to streamline the manufacturing process. With real-time simulation and analysis, we could see how the digital transformation of the manufacturing process enables manufacturers to increase production while reducing error and waste.

A visit to Banner Engineering’s headquarters in Minneapolis allowed us to see and share insights on the advancement of IIoT (Industrial Internet of Things) and the role it is playing in communication on the factory floor. We saw how the enablement of machine-to-machine communication improves overall efficiency and increases the longevity of mechanical assets, protecting manufacturers’ investments.

Eric J. Halvorson is senior marketing technology manager, automation and control at DigiKey.