HSE Europe

We have been witnessing manufacturers seeking and adopting recent technologies, looking for more efficient processes in a search for increased efficiency, productivity, and profitability. Terms like Artificial Intelligence (AI), Machine Learning (ML), and Data Science became almost consensus for manufacturing organizations as a natural and obvious way forward. The benefit of recent technologies are so evident in a way that we can identify a general “race” on several industries on how to get differentiated first from competitors. There is a common understanding that companies with manufacturing processes, which do not adapt and make use of technologies, will be left behind.

These new technologies are becoming more and more known and pursued. AI, for example, can be used to analyze large amounts of data and effectively make decisions in manufacturing. We can predict, for instance, when equipment maintenance is required. This helps manufacturers to prevent breakdowns and downtime, leading to increased efficiency and reduced costs. Similarly, Machine Learning technology enables machines to learn from data without being explicitly programmed, identifying patterns that can be used to optimize the production line. As an example, the systems can identify a strong correlation between any process parameter and the conformity of specific characteristics of a product– and then the process can be corrected or adjusted autonomously.

The benefits of adopting these new technologies have brought results to early adopters and the use is spreading among manufacturing facilities everywhere. However, it is very important that organizations understand how and which of these technologies can be integrated into their operations. While automation can bring many benefits, it is important for companies not to overlook the importance of know-how and employee expertise. It is the expertise that is developed over time through hands-on experience, training, and education. In many industries, know-how is a critical factor in the success of a business. It must be adapted.

The advancement and popularization of these technologies brings with it, the need to adapt to the environment, in which machines begin to share with people not only the execution of tasks but also the design and control of processes.

“For the successful implementation of Industry 4.0 technology, it is necessary to have well-defined processes and an organizational culture that is open to change and the adoption of new technologies”

Along with the decision to invest in and adopt some of these new technologies, companies also need to take some precautions. From the perspective of Quality Management, we can mention some important aspects which are necessary to be covered and guaranteed before manufacturers invest in the technologies:

1. Knowledge Of Processes And Systems: Digitalization can amplify the negative effects of a poorly controlled or inefficient process. We may face the risk of increase in the speed and volume of data, making it more difficult to manage and analyze, if the underlying process is not well-designed. A proper understanding and control of existing processes and systems is a pre-requisite to take real advantage of new technologies.

2. Digitalization Strategy: It is important to identify which processes to focus on and which technologies will be adopted. Here, a possible herd effect should be avoided, in which companies invest in technology for technology’s sake. Instead, the decision of what and where to invest should come from the business need or the situation of the production unit. It is also important to start in small steps, so that there is greater control and understanding of how best to use technology and learn from interaction and gradually extend to other processes where there is benefit. For the successful implementation of Industry 4.0 technology, it is necessary to have well-defined processes and an organizational culture that is open to change and the adoption of new technologies.

3. Adequate Change Management: The transition to smart factories needs to be managed extremely well, as it will probably impact many stakeholders, not only internal but also external. Suppliers, customers, and service providers can be impacted and this needs to be anticipated and addressed in journey planning. Business leaders need to be aware of the importance of a proper transition and take actions to mitigate risks of failure in the journey.

4. Upscaling And Adapting Employee Skills: With repetitive activities being delegated to increasingly autonomous and robotized systems, a change in the way people will intervene in the process is needed. In short, the industrial units will need to adapt the way their employees work. For this to happen, it is important that people become more knowledgeable in automation, robotics, and data science. This will likely result in smaller and more specialized teams. One of the main challenges is the need for skilled workers, which requires a significant investment in training and development.

It is important that, at a time when many organizations are investing significant amounts in digitalizing their factories, the entire process is carried out strategically, with the clearest possible vision of the advantages and benefits each technology can offer. And this will vary depending on the needs of each one, considering external factors as well as internal factors. The ideal transition process does not exist, it should be developed internally, considering all factors and circumstances.