What happens when the worlds of IT and OT have to be more closely aligned than ever before? We talk to manufacturers on both sides of the equation about the skills needed for “smart factory” workers and the cultural barriers that have limited wide-scale adoption to date.
Industry marketers call the smart factory or smart manufacturing the “convergence” between information technology and operational technology. Analysts and consultants forecast manufacturing’s future, and it’s downright digital.
“Forty percent of the workforce is retiring or reaching retirement status in the next three to five years, which is huge,” says Dr. Irene Petrick, a senior director of industrial innovation in the internet of things group at Intel, in an interview with Better MRO. “Automation will be a necessity.”
Most companies today, despite investing in new technologies, are not yet near the promise of Industry 4.0 where there is a complete integration of an optimized supply chain married to the factory floor and on-time delivery, says Mike Yost, outreach advisor for The Clean Energy Smart Manufacturing Innovation Institute (CESMII), in an interview with Better MRO.
“The reality is that many companies are doing plenty of ‘smart’ today and have been,” says Yost. “It drives me nuts how fragmented we are in the industry in the language we use … There’s a danger in defining these terms and thinking they are a final destination … We’re now evolving in every dimension, but no one is doing all of it.”
Why? It’s really complicated.
“Bottom line: The caution among manufacturers in going digital isn’t about a lack of internal strategic alignment and short-term focus. The world of manufacturing is complex,” says Stephen Gold, president and CEO of Manufacturers Alliance for Productivity and Innovation (MAPI) in the 2018 article “Manufacturers are Behind in Industry 4.0—and for Good Reason.”
Is more precise and accurate predictive maintenance happening? Yes. Automated systems, such as autonomous guided vehicles and artificial intelligence, are making their way to the machine cell and warehouse floor.
Software is getting smarter on machines. Mazak, for example, now has a spindle health monitoring system option for its horizontal machining centers. Makino has shown off voice-command technology for machine operations developed by the startup iT SpeeX.
“There are countless pieces to this puzzle, and the technology piece is likely not the hardest to solve,” says Gold. “While manufacturing companies can differ dramatically … they all share certain characteristics, such as increasingly complex supply chains, using production assets for decades before replacement, and the very real need to avoid production downtime at all costs.”
Business leaders in manufacturing have been hearing about “having the right data at the right time” for 25 years or more, though, says Yost.
What’s the difference today? There are a lot more digital software and intelligence tools, probes and smart sensors in the toolkit that can be used to help manufacturers reach their competitive and efficiency goals than ever before. New materials have arrived—and new ways of manufacturing by 3D printing or “additive” techniques.
With that, there are new, hybrid skills needed that combine operational and machining technology expertise with digital and data skills.
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