Why Smart Manufacturing Must Start with Intelligent Planning?
Smart systems and applications are being rapidly deployed in organizations. Manufacturing is one area that is now being transformed with the integration of advanced technologies and systems. Terms like Industry 4.0 and Smart Manufacturing are becoming much more common. This is a data-driven manufacturing paradigm that embraces intelligent automation and systemic change. At its core, depends on fully integrated and collaborative systems that intelligently function based on real-time needs and requirements.
Obviously, planning is an essential component of any industrial process but in the manufacturing space, the planning challenge was always immense. There were so many variables and constraints to factor in. It was difficult to get accurate data from the various outposts of the manufacturing enterprise. Participation from the stakeholders was limited because of the difficulty of including them in an enterprise-wide planning exercise. The data, when available, was often stale and degraded. Net outcome was that often planning was done based on instincts, gut-feeling & arcane knowledge built with experience. The output was often unreliable and inconsistent.
The good news is, advancements in technology have now made intelligent and data-driven planning possible. Planning can become more participative, real-time, comprehensive, and data-driven.
But there are wider implications too that suggest smart manufacturing strategies must include, or indeed must start with, intelligent planning and analysis.
Risk Assessment and Determination
Like any technology-led disruption, smart manufacturing is exposed to some risks and issues. The inclusion of the Internet of Things (IoT) and other technologies in the manufacturing procedures can change workflows and processes, that if not managed can introduce defects that may cause significant variations. The use of faulty algorithms can also lead to errors. Information security and privacy attacks are also possible with the growing influence of cloud and other technologies in the manufacturing systems. The implementation of new tools and equipment as per smart manufacturing requirements may increase workplace risks and safety due to the lack of workers’ knowledge and experience.
Intelligent planning is necessary for smart manufacturing to have information on all these risk scenarios. With intelligent planning, the data around smart manufacturing systems can be gathered and analysed to discover the risk patterns. Risk mitigation and response strategies can be developed in advance to assure improved quality and performance of the smart manufacturing processes.
Cost Planning and Assessments
One of the most significant aspects of industrial operations is the cost and budget attached to every operational aspect. Smart manufacturing comes with varied costs that include the cost of tools and technology, implementation costs, analysis costs, and others.
Industries need to have an understanding of the cost estimations and map the same with the expected benefits. Intelligent planning can drive data-driven decisions in these aspects. Cost-benefit analysis can be appropriately performed with intelligent planning based on good data. Industries can explore different internal and external costs involved with smart manufacturing systems and can plan for funding and budget management procedures appropriately.
Supply Chain Management and Regulations
Supply chain operations are critical for any industrial unit. The transition of manufacturing procedures from traditional to smart systems can have massive implications on existing supply chains. It is essential that supply chain handling and management be modified based on effective planning.
Intelligent planning can come in handy in these procedures. The supply chain data can be fed in the intelligent planning tool to get detailed information on supply chain risks, workflows, costs, and changes. Regulatory changes and modifications can also be identified with intelligent planning to ensure manufacturing supply chains are properly managed.
Integrated Control and Planning
A lot will change with the launch and implementation of smart manufacturing. There will be operational changes, regulatory modifications, workflows changes, technical alterations, etc. It will become essential for all managers and administrators to be aware of all these changes and the associated impact.
With thorough knowledge and deep understanding of these aspects, these managers & administrators can plan to deliver performance even in the changed circumstances. The lack of change planning can have adverse implications. For example, training will become critical to ensure that the workers and staff members are able to effectively utilize the smart manufacturing systems. However, the lack of early information on workflow changes and associated planning can lead to ineffective and inadequate training processes. With intelligent planning, such loopholes can be avoided. Managers and administrators can get streamlined information on all the changes and their impact to come up with integrated control plans and strategies.
Scope Determination and Schedule Management
What will change and when will it do so? Scope and schedule are two important elements of the overall organization/project management. Smart manufacturing also requires effective management of these two aspects to deliver successful outcomes.
It is essential to have a clear understanding of the in-scope and out-of-scope elements for the smart manufacturing processes. Similarly, it is important to analyse the schedule that needs to be followed for each smart manufacturing process. Data from various internal and external sources can be collected to provide the patterns and trends on the process scope and the associated schedule. The company can then plan for the resources needed at each stage -what is needed and when is it needed?
Intelligent planning can be utilized to carry out elaborate analysis and chart the course forward on the Smart Manufacturing journey. The key message here is that such a profound change has a much better chance of settling in, gaining acceptance, and delivering value if the conditions are right. And planning analytics has a crucial role to play in providing those very conditions.