The manufacturing landscape has undergone a transformative shift over the past two decades, evolving from manual labour-intensive processes to highly automated and intelligent operations. Let us explore the progression of manufacturing from traditional methods to the advent of smart manufacturing, projecting forward to a vision of the industry in 2030.

Historical perspective 

In the late ’90s, as a Graduate Engineer Trainee at a paper manufacturing plant, I observed a heavy reliance on manual operations. The plant teemed with workers; automation was minimal and used sporadically due to the prohibitive cost of sensors and basic control systems composed of relays, switch gears, and mechanical gauges. This era, while still nascent in automation, saw the emergence of ERP systems like SAP, albeit constrained by significant capital and operational expenditures.

During this period, equipment control was largely managed by AC motors and variable frequency drives, with SCADA/DCS systems playing a crucial role within a predominantly PC-controlled environment. Challenges in supply chain management often led to overstocking or stock-outs, causing production delays. Decentralised operations necessitated extensive manpower, escalating infrastructural and operational costs, and manufacturing plants typically struggled to achieve an Overall Equipment Effectiveness (OEE) of over 60 per cent.

The Rise of Smart Manufacturing 

The turn of the century heralded the beginning of what we now term smart manufacturing. This phase was marked by the rapid embrace of automation, robotics, and enhanced connectivity. Technologies such as Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), and robotics transformed traditional manufacturing workflows, supported by advancements in communication technologies like Ethernet and Wi-Fi that enabled real-time data transfer and decision-making. Sensors, IoT platforms, and AI-based predictive systems have become fundamental in enhancing manufacturing efficiency.

Technological revolution and enhanced efficiency 

Advancements in technology have drastically reduced the need for manual intervention in manufacturing processes. Condition monitoring systems and sophisticated algorithms now enhance asset uptime and optimise OEE. Today, operational data from the shop floor is transmitted in real-time, allowing for immediate responses and adjustments to production metrics. The introduction of automated material handling systems and improved logistics planning has transformed the supply chain and material management, enhancing operational excellence.

Operational excellence and safety improvements 

Modern manufacturing operations emphasise stringent safety and compliance measures, with sensor-equipped personal protective equipment and digital incident logging systems ensuring adherence to safety standards. The integration of real-time data analytics platforms has streamlined data management, enabling manufacturers to quickly address quality issues, minimise downtime, and improve product quality.

Unlocking the potential of smart manufacturing: A vision for 2030 

Looking ahead to 2030, manufacturing is poised for further groundbreaking advancements, driven by technologies in automation, artificial intelligence (AI), and the Internet of Things (IoT). IoT serves as the backbone of data produced and is expected to witness remarkable growth driven by the need for increased automation and connectivity within factory settings, highlighting the critical role of technological integration in modern manufacturing practices.

The concept of discrete manufacturing will evolve significantly, incorporating software-defined products and traceable, interconnected platforms. Paperless operations, wireless factory networks, and cloud-based enterprise platforms are expected to dominate, reducing the environmental impact and fostering a more dynamic production environment.

Sustainable manufacturing and future 

Sustainability is set to become a cornerstone of manufacturing, with an increasing reliance on renewable energy sources like solar and wind power factories and integrated sustainability features in tools ranging from Mechanical Computer-Aided Design (MCAD) to ERP and IoT platforms. The traditional roles of managers and supervisors are likely to be replaced by AI-powered manufacturing co-pilots, reducing managerial overhead and enhancing efficiency.

Digital twins and cybersecurity 

The adoption of digital twins will enable manufacturers to simulate and optimise production processes more effectively, while augmented and virtual reality technologies will enhance training and maintenance protocols. As manufacturing becomes increasingly interconnected, robust cybersecurity measures will be essential to protect sensitive data and maintain trust across the supply chain.

Market potential 

The Asia Pacific region claims the largest share (37 per cent) of the global smart manufacturing market, propelled by the dynamic ecosystem across Japan, India, and Australia. Small and Medium-sized Enterprises (SMEs) are anticipated to be the primary adopters of smart manufacturing solutions. The escalating adoption of disruptive technologies such as Industry 4.0, artificial intelligence, augmented reality, and IoT, underlines the region’s stride towards cloud adoption, thus boosting demand for cloud-based smart manufacturing solutions across these countries.

The global smart manufacturing market is projected to experience robust growth, anticipated to reach US$ 985.5 billion by 2032 at a compound annual growth rate of 16 per cent. This expansion is fueled by emerging technologies such as artificial intelligence, cloud computing, Big Data, and machine learning, which are pivotal in propelling the smart manufacturing market forward. 

As the industry evolves, it will offer vast opportunities for service providers and manufacturers alike to capitalise on the enhanced capabilities of smart technologies, promising a future of heightened agility, efficiency, and sustainability in manufacturing. 

Orignal source: https://www.tatatechnologies.com/media-center/the-future-of-smart-manufacturing/

Gowthaman Swarnam, Global Practice Head – Digital at Tata Technologies.