The building hype in recent years around Industry 4.0 in the manufacturing industry has led many manufacturers to question what impact this will have on the human workforce. Industry 4.0 is completely transforming traditional manufacturing processes once and for all, with many processes becoming completely digitised and automated.
Many of those employed within the manufacturing industry have found themselves questioning their role in this transition, which has led to some levels of uncertainty amongst manufacturers. Instead, we must approach Industry 4.0 and the subsequent rise in robotics as a means for us to improve our efficiencies, productivity and overall product quality which will insure and protect the longevity of a business. Manufacturers are currently experiencing this inevitable transition into the world of robotics, however, the role of the human workforce will still firmly remain in these new manufacturing processes.
Factories fit for the 21st century
Smart factories are incorporating robotics at every stage of the manufacturing process, from raw material handling to packing the completed product. Recent advances in manufacturing technology have enabled robotic equipment to be customised to perform more complex tasks safely and efficiently. Robots can and will be employed to monitor stock, assess processes and machine status and enhance efficiency and reliability, removing human error from specific tasks and ultimately reducing machine downtime.
By making this transition toward smart factories manufacturers will reap the benefits for many years to come. The benefits extend beyond the day to day functions of the factory itself into capabilities such as forward planning and supply chain management. Using robotics, all of these separate processes can be connected through the cloud and the Internet of Things (IoT) so that processes such as measurement, control and communication can be automatically aligned.
Consistency is key
The manufacturing industry is built upon consistency, it is essential that manufacturers are producing reliable identical parts time and time again. The slightest variation can result in costly product defects which will have a knock-off effect throughout the entire supply chain, delaying further processes and orders. Robots equipped with vision technology are capable of moving quickly to rectify even the slightest change in temperature and weight. This technology makes it possible to make adjustments that would be undetectable by the eye to ensure products are consistently made to the highest quality.
Collecting insights and learning from them
Not only will incorporating robotics change and improve the manufacturing processes themselves but, as a by-product of digitising these capabilities, manufacturers can capture previously unattainable performance data and analytics. Data collection is a key benefit of this Industry 4.0 transition. With new systems in place, an entire factory can report on and provide data around performance, inventory and efficiency. On top of this, manufacturers can receive real-time projections and identify any issues in their processes. Ultimately, the data collected by these devices can enhance and improve manufacturing processes, as well as increasing visibility and availability of information amongst employees.
A hybrid workforce
While Industry 4.0 is rapidly transforming our manufacturing processes, it’s important for manufacturers to embrace these changes and not feel threatened by the impact this could have on the roles of their employees. Instead, we should view this as a collaboration, the bringing together of human expertise and technological efficiencies to create a hybrid workforce.
Robotics can protect workers from repetitive and dangerous tasks in manufacturing which enables the human element of the workforce to focus on prototyping, quality control, machine maintenance and programme management. While robots will respond efficiently and effectively to prescribed events, the technologically typically cannot handle unexpected situations. This element of unpredictability means there will always be a role for humans to work alongside robots and this transition also provides employers with an opportunity to upskill their workforce. For employees to be on-board with this change, employers must empower their employees as ‘change champions’ and look to bring them along on the Industry 4.0 journey.
Ultimately, manufacturers wanting to compete on a global scale must align with the principles of Industry 4.0 through digitisation, automation and data collection. It is a long-term investment that will pay dividends as manufacturers will benefit not only from an increase in productivity but also the reduction in machine downtime. This seamless collaboration will inevitably create a hybrid workforce, enabling manufacturers to continue to evolve and adapt to meet the ever-changing demands of their customers.
Article by Scott Fawcett, Managing Director, Essentra Components