The New York Times ran an article recently about the advancements of AI in the artistic corners of our lives. After having the technology read vast amounts, it was told to write a story, and apparently it wasn’t half bad. Imagine what the technology can do with even more practice. There is AI that produces stunning works of art, fit to be hung in museums. Do we need technology to produce these things for us? Perhaps not, as literature and art are meant to be filled with emotion. In general, though, what scientists are proving is that AI can do whatever it is we need it to do, and with AI in manufacturing, that means a lot.
Consider this: in the US over recent years, several incidents have cost companies in excess of $1 billion. One of the largest to date, faulty phones, may cost as much as $5 billion itself. Similarly, the European Commission estimated that in some industries, as much as 50% of production is done away with because of defects.
This is to say that manufacturing can be more finely tuned. Things like defect detection, predictive maintenance, liquid level analysis, and asset inspection are all being shaped by AI solutions based on computer vision and machine learning. All part of Industry 4.0, now quality control inspections can happen faster and more thoroughly.
Why? Because AI can spot defects and problems that are otherwise easy to miss with the naked eye.
Let’s talk about the ways AI in manufacturing can benefit your enterprise.
Defect Inspection
When Henry Ford used his traditional assembly line over a hundred years ago, a team of men acted as quality control. The human eye can miss so much that AI technology cannot.
Computer vision enhances detection inspection via automated optical inspection (AOI). Using multi-cameras, missing pieces, dents, cracks, scratches and overall damage are easily spotted, and depending on the camera’s capabilities, the images may span millions of data points.
AI uses techniques such as template matching, pattern matching, and statistical pattern matching in order to find defects in products. Inspections are fast and accurate. AI also has the ability to learn about various defects so that, over time, it can get even better at its job. The more data the system is exposed to, the easier it is for it to learn more about different defects.
Therefore, AI helps manufacturers gather necessary information about their products and how to improve assembly lines going forward, leading to a reduction of waste, not to mention saving time and money.
Quality Assurance
If your quality assurance was up to 100%, how much would your profits soar?
With AI in manufacturing solutions, challenges like font distortion or missing text are overcome without bringing production to a standstill. For instance, computer vision is playing a key part across manufacturing industries due to its role in production process automation. These industries include electronics, automotive, general-purpose manufacturing, and more.
For instance, the automotive industry sees benefits in using computer vision from paint surface inspection, foundry engine block inspection, and press shop inspection. Similarly, in the electronics industry, these AI tools can detect defective components or gluing as well as missing pieces, and in general purpose manufacturing, inspections for fabric or packaging become more accurate. The technology is able to identify anomalies like cracks, dents, and scratches in the product before it leaves the production line. And it can help you to figure out why it is happening, too.
Product Assembly
AI can also help in the assembly process. When the machines have to switch products numerous times a day, AI can help operators with Standard Operating Procedures (SOPs). This allows for more efficient processes. AI tools can even provide the team on the shop floor with instructions for completing each step correctly. Or if your shop floor is even further automated, computer vision can guide robotic arms to even greater levels of precision.
Between your ERP system and AI tools, managers can use predictive analytics to step in anytime a problem is intimated, fixing a small problem before it becomes a big problem. Ultimately, AI is able to lower the cost of production in the manufacturing industry through efficiency in the assembly processes.
PPE Detection
According to the National Safety Council, in the United States alone, an employee is injured on the job every seven seconds. This leads to 7 million work injuries per year and equates to approximately 99 million lost days of productivity.
AI can help that greatly reduce that number. In general, the problem lies in the fact that it’s nearly impossible for a company to monitor their workers all day long for the use of personal protective equipment (PPE).
AI sensors and cameras can detect the use of required PPE like safety glasses, gloves, hard hats, and more. These tools can recognize if a team member is wearing the required PPE or not. Other worn sensors can detect if an employee is in distress or in need of assistance, much like predictive analytics on your machines. This greatly reduces workplace accidents and promotes a better working culture.
The Future of AI in Manufacturing
This is just the tip of the iceberg of what AI can do to enhance your ERP system and catapult your enterprise into Industry 4.0. Stay ahead of the competition by leveraging AI to speed up processes, improve safety, strengthen customer satisfaction ratings, and assist manual workers so that their skills can be used better elsewhere. Ultimately, AI works to improve your bottom line.
Ready to embrace Industry 4.0 in your enterprise? The consultants at Godlan can help you assess where your company currently stands and work with you to make and exceed company goals. The future is now. Call 586.464.4400 or visit www.Godlan.com today.
