Smart Manufacturing with Industry 4.0

Author: Vishal Badshah, Vice President - Operations, Tata Motors Commercial Vehicles.

The automotive industry is on the brink of a revolutionary transformation with Industry 4.0. A staggering 43% of companies are harnessing the power of artificial intelligence (AI) and machine learning (ML), with 32% extensively integrating these technologies to drive unprecedented innovation and operational excellence. Manufacturing plants are evolving into smart factories, utilizing connected systems and data analytics to maximize efficiency, while showrooms are adopting advanced software to elevate sales and customer experiences. By leveraging cutting-edge technologies and high-quality software, companies are streamlining production, improving product quality, and promoting sustainability, heralding a new era of mobility.

IoT elevates production efficiency

The Internet of Things (IoT) is transforming production efficiency by automating data collection and analysis, enabling real-time reporting on inventory levels, and swiftly identifying defects or missing components. This proactive approach helps prevent costly production delays and boosts operational agility. Continuous monitoring and maintenance of machinery through IoT reduce unexpected downtimes, leading to significant productivity gains and cost savings.

With IoT driving efficiency, its integration with emerging propelling manufacturing into a new era. For instance, IoT combined with 5G allows for rapid data processing, while IoT-enabled augmented reality (AR) glasses provide real-time instructions, improving workforce training and reducing reliance on manuals. Additionally, integrating IoT with blockchain technology ensures secure data storage and privacy.

Advanced robotics and AI: Powering premium vehicles

Alongside IoT, advanced robotics and AI are set to significantly boost productivity, with robots expected to perform 75% of the work on production lines by 2025. Today, advanced robots are deployed across various manufacturing functions. For instance, collaborative robots, or cobots, excel in the careful handling of complex assemblies, while specialised robots in painting and welding ensure uniform coverage and robust, clean joints. Material handling robots are equipped to detect even the minutest defects, ensuring each component meets stringent quality standards.

AI enhances the capabilities of robotics by adding intelligence into their operations. This reduces the need for human intervention across the manufacturing process, from conceptualisation to finalisation. It enables programmable shading, innovation generation, design, prototyping, and workflow optimisation. AI also enhances quality control by identifying errors or faults in real-time and facilitating data collection through integrated software systems.

Delivering end to end seamless experience

Continuous traceability enables real-time inventory monitoring and swift defect resolution. It reduces costs through timely quality checks, minimises warranty claims, and ultimately saves time. The benefits of this technology extend beyond internal operations to impact customer experience. Customers can look forward to real-time updates on their vehicles, including the status of parts, assembly, and packaging. Such transparency fosters trust between companies and customers. Through unique identification codes, mobile apps, and barcodes, customers can track their orders and contact manufacturers about any discrepancies or delays.

Driving sustainability through data analytics

A key aspect of modern manufacturing is its commitment to sustainability, with data analytics playing a crucial role. By monitoring battery performance across diverse conditions, data analytics supports the development of sustainable, electric, and low-emission vehicles, ensuring optimal performance.

Integrating IoT with data analytics allows manufacturers to optimise resource management for energy, fuel, water, and compressed air. For instance, Energy Mix Optimisation Analytics helps companies plan operations to maximise renewable energy use by analysing past consumption and forecasting future needs. This reduces reliance on fossil fuels, cutting operational costs and lowering the carbon footprint. Advanced analytics also enable efficient load balancing, minimising waste and positioning the automotive industry as a leader in sustainability.

Revolutionising skill development with AR/VR

AR/VR integration in the automotive sector is projected to grow at a robust CAGR of 18.1% from 2023 to 2028. Leading manufacturers are leveraging AR/VR to empower assembly workers with real-time access to critical technical information, facilitating thorough inspections, and immersive training through audio-visual tutorials. This minimises human error, accelerates production, and enhances skill development.

Automotive companies are also using AR/VR to create immersive 3D showrooms where customers can explore and customise vehicles in real-time, tailoring features to their tastes. This innovative approach enhances the decision-making process, allowing potential buyers to engage with their ideal vehicle before making purchase, ensuring greater satisfaction and product reliability.

The way forward

Digital technologies are transforming operations and driving future innovations that enhance production efficiency and corporate growth. Embracing a culture of innovation and research leads to faster production cycles and improved supply chain efficiency. Companies adopting a forward-thinking approach and digital continuous interaction will unlock growth potential and lead the way towards a more efficient, sustainable, and customer-centric future.

Published: 22 October 2024 | manufacturingtodayindia.com

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