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Microfactories – the future of manufacturing?
Microfactories – the future of manufacturing?

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Manufacturing is continuing to evolve and adapt to new changes and become smart and one of the most exciting concepts to emerge is microfactories. Long gone are the days of a traditional factory building, with huge facilities, long production lines, and workers working. Technologies like AI, automation etc. are continuously improving operational efficiencies and productivity. Micro-factories or micromanufacturing are expected to help manufacturers improve margins and increase customer responsiveness at low costs.

 

What are microfactories?

Microfactories are small-to-medium scale manufacturing set-up, which is highly automated, and technologically advanced, and has a wide range of process capabilities. In essence, it is a manufacturing facility whose output can be scaled up by replicating such setups in large numbers. Microfactories require less energy, less material, and a small labour force, due to the high-tech automated processes. They are a smaller set-up and does not require any special build-outs or retrofitting, and hence more sustainable.  They are highly flexible, working on scaled-down machine tools to produce low-volume, highly customizable products. This flexibility allows companies to focus on providing a variety of services and solutions for a smaller network of customers. The micro-factories are based on a cellular configuration, where pieces can move from one station to another in any order, and not necessarily in a linear fashion, and can even return to the same station more than once in a manufacturing process.

Traditionally, manufacturing set-ups first produce a product and then push them for sales. However, the micromanufacturing model requires a product to be ordered first and then it is produced and hence a customized solution and product can be shared with the customer.

Tech components in Microfactories

1. Use of robotics- Microfactories often rely on robotics needed to move parts or modules of the production process from one station to the other.

2. Automation – Microfactories use greater levels of automation than traditional factories, which is suited to a more concentrated, highly skilled workforce.

3. Artificial intelligence (AI)- AI helps in faster design innovation and customising products and solutions according to customers’ needs while keeping the production’s needs in mind.

4. Faster and smarter feedback – Use of IIOT, IOT, Industry 4.0 leads to using data effectively to get smarter feedback to make the production more streamlined.

 

Advantages of Microfactories

Microfactory 1

 

1. Smaller footprint - Microfactories can be installed almost anywhere, including in existing warehouses or vacant facilities, without the need for major retrofitting.

2. Closer proximity - They can be designed to operate in proximity to the customer base.

3. They reduce supply chain disruptions, improve operating margins for manufacturers and allow customers to order nearly any quantity and larger facilities experience issues adapting and keeping up with demand.

4. Less overheads as the scale and size of the production facility and workforce is smaller.

5. Customized, bespoke solutions and products with design flexibility can be made available to the customer in any quantity. There is no minimum order size.

6. Efficiency improvements – With the use of latest technology getting incorporated into microfactories, companies realise greater efficiencies in production.

7. Increased innovation – Due to their lean nature, companies can innovate, build, test rapidly without significant costs for the companies or the customers.

8. Microfactories are more sustainable than traditional manufacturing setups.

9. Connected with customers – Due to their size and by offering personalised offerings, microfactories can closely work in incorporating the customer feedback and offer value addition.

While the microfactories tend to be appealing for some factions, it is not to say that the era of a traditional manufacturing set up or a gigafactory is over. Microfactories as a solution may not be suitable for every company. It may not be cost effective for high volume manufacturing setups. There is a limitation to the design and material options due to the very nature of microfactories. There might be difficulty in managing the large number of microfactories. Hence the solution has to be tailored specific to the organisation’s structure and manufacturing setup whether through a microfactory or a gigafactory.

 

 

Sources - 

1. https://www.autodesk.com/design-make/articles/microfactory

2. https://www.advancedtech.com/blog/what-is-a-microfactory/

3. https://www.futurebridge.com/blog/microfactories-the-next-big-thing-in-manufacturing/

4. https://www.weforum.org/agenda/2024/03/microfactories-why-smaller-highly-automated-factories-are-the-future-of-manufacturing/


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Vandhna Babu
Principal Analyst - Research

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