Four ways AI is helping to improve operational efficiency in manufacturing
Optimizing efficiency is an essential element of manufacturing. To deliver quality products swiftly and cost-effectively, operations must be streamlined at all stages of the design, creation and distribution phases. One of the most transformative ways to supercharge operational efficiency is with Artificial Intelligence (AI), which is proving itself to be a game-changer for those working in the manufacturing sector.
In this short guide, we explore four ways that AI technologies are revolutionizing this industry.
Predictive maintenance
Traditionally, maintenance is done reactively – waiting for an error code or malfunction before realizing you need to update or fix a machine. But AI algorithms can switch your maintenance schedule from reactive to proactive. A report from PwC found that not only does predictive maintenance cut costs by 11%, but it also improves uptime by 51%.
By analyzing data from machinery sensors, AI can predict when a machine is likely to fail and schedule in the necessary maintenance – before a breakdown occurs. This minimizes unexpected downtime, extends the lifespan of your equipment, and ultimately results in a more efficient production line.
Quality control automation
AI-driven quality control systems can detect defects in real-time, ensuring that only products meeting high standards leave the factory floor. With less chance of human error or oversight and the ability to process huge amounts of data quickly, this reduces waste and recalls while maintaining a consistently high quality in your products.
Vision systems that are powered by AI can spot minuscule defects that human inspectors might miss, plus they can run constantly without becoming fatigued or complacent.
Production planning
To run as efficiently as possible, manufacturers need to manage multiple obstacles and unexpected issues that crop up on a daily basis. AI can be used within production planning to streamline workflows by analyzing production data, identifying bottlenecks and suggesting optimizations.
While this requires some initial investment and set up time to train the AI model with the data it needs to make reliable suggestions, it can eventually reduce lead times and throughput times by as much as 62%. This enables you to meet deadlines more reliably and adapt quickly to any changes in demand while cementing a trustworthy reputation for your business.
Customer service
Every business needs to have a robust customer service platform that can respond to queries promptly and competently – and the manufacturing sector is no exception. AI can support this goal by providing instant support and personalized experiences, either with chatbots or virtual assistants, that can handle customer inquiries round the clock.
Fuelled with detailed information on your specific products and clients, AI can analyze historical customer data to anticipate needs and suggest tailored recommendations – or escalate to a human when necessary. A UK study found 78% of customers still prefer talking to a human about an inquiry, so while AI can provide valuable support, customer service experts still retain significant value to any business.
Finding a balance between human support and AI use has the potential to not only enhance customer satisfaction, but also to hugely cut down on operational costs and overheads in this area of your business.
Make the most of AI
By integrating these AI applications, manufacturers can enhance efficiency, reduce costs, and maintain a competitive edge in the market. AI is a powerful tool that can be used to accelerate production with the utmost precision and quality, when implemented correctly. If you’re looking to invest in AI-powered technology for your business, be sure to research thoroughly and take the time to train your employees on how to make the most of its capabilities.