MAY - JUNE, 20188 MANUFACTURING TECHNOLOGY INSIGHTSBy Francois Barbier, President, Global Operations and Components, FlexWelcome to Industry 4.0, a term coined in 2011 by Henning Kagermann, the head of the German Academy of Science and Engineering. This new fourth wave is powered by advancements that include smart manufacturing, robotics, artificial intelligence, and the Internet of Things (IoT). It propels industry leaders to work more efficiently while giving product designers more control.At the same time, this shift will drive the need for smart automation further, says François Barbier, president of Global Operations and Components at Flex, a global design, engineering, and manufacturing leader. Flex knows firsthand how companies are adopting IoT solutions. All over the world, from automobiles to consumer goods to chemicals, integrating the IoT into manufacturing is not only under way but already proving to be cost-effective. While the current supply chain system consists of several steps--marketing, product development, manufacturing, and distribution--that occur independent of one another, smart manufacturing could streamline the time, effort, and communication between each step, creating faster and more reliable service.For many companies, operating in this new paradigm will require support. "The way we are designing products today and the way we are getting information from our customers have changed dramatically. The data that informs how we design our products can be much more or much less prescriptive depending on the customer," says Barbier. He explains that Flex still has traditional customers who are very prescriptive--Flex offers these companies the service of making those products and materials, and delivers those products to customers. "But now we have a new set of customers coming to us with a sketch of a product idea. They're asking Flex to design it. For us, this is driving a need for new ways of working, new processes in the manufacturing space."So what skills must manufacturing leaders possess to find success in Industry 4.0?1. Seeing Around Corners--in 360°New tools allow companies to create and test situations in the virtual world. Given that ability to transform design and production, virtual reality is being adopted by more companies. Simulating the product-creation phase helps cut down on manufacturing time, and that means companies are able to get a more realistic version of what they want. Flex is utilizing augmented reality solutions for technical remote assistance, which allows users in distant locations to connect with each other through a live view. 2. Viewing the Fourth Wave--in 3DAlso making a mark in the manufacturing world is 3-D printing, which allows for the seamless creation of tangible products using a single machine. Barbier says that this is "a fundamental change, because if you're adding material, that gives you a lot more possibilities for how you design the part." Three dimensional printing can also reduce waste by recycling plastic and cut down on the wait time for replacement parts and transportation. In addition to these consolidation and scrap benefits, additive manufacturing also offers many other benefits, including precision material placement, significant time and cost savings, and the ability to decentralize the manufacturing of basic parts by providing services closer to end markets. These benefits allow for a vertically integrated supply chain in Flex's operations.3. Advanced Manufacturing--on AutopilotAutomation is another vital aspect of the industry's future. According to Barbier, a significant portion of Flex's manufacturing processes are already fully automated. New robots that are more agile, skilled, cheap and safe could decrease labor costs. The Wall Street Journal reported, "The latest [robot] models entering factories and being developed in labs can work alongside humans without endangering them and help assemble all sorts of objects, as large as aircraft engines and as small and delicate as Five Trends for Manufacturing's Fourth Wave: Essentials for Global Operations LeadersIN MY OPINION
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