How Real-Time Data and AI Are Driving Discrete Manufacturing Innovation

Introduction

In an age where real-time data and artificial intelligence (AI) are rapidly transforming various sectors, discrete manufacturing stands as one of the most significant beneficiaries. Tim Burke, CTO and co-founder of Arch Systems, recently shared insights into how his company is navigating challenges in this arena by leveraging data and AI to improve operations on the factory floor.

Challenges in Data Collection and Processing

Traditionally, the manufacturing sector has faced significant hurdles in gathering and processing data in real time. The decision-making processes on the factory floor often rely on immediate access to data, requiring insights within seconds as production cycles shift. One of the main challenges lies in integrating various domains, including software development, data analysis, and manufacturing expertise. Each of these domains possesses its own set of challenges and requires specialized knowledge.

The complexity of the manufacturing environment, paired with the amalgamation of new and legacy equipment, compounds this issue. While newer machines may have modern data collection capabilities, older equipment can lack the necessary technology, thus requiring innovative methods to digitize and gather relevant data.

Arch Systems: The Evolution from IoT to Manufacturing Insights

Arch Systems has evolved over its nine years from a hardware-focused IoT company to a comprehensive platform creating software solutions for manufacturing. The transition occurred as they identified key data-related challenges in factories and responded to customer needs. Their initial aim was to collect data from legacy equipment, subsequently moving on to software solutions that allow manufacturers to analyze this data effectively.

This evolution culminated in the combination of AI with data analytics, enabling the design of intelligent systems that guide decision-making on the shop floor, automate processes, and significantly enhance operational efficiency.

Industry Applications and Workforce Solutions

Arch Systems has found a home within discrete manufacturing, serving various industries—including electronics, plastics, automotive, and aerospace.

A common challenge faced by manufacturers is the aging workforce. Experienced professionals are retiring, leaving behind knowledge that is often not documented. Arch's solutions aim to capture this tacit knowledge, making it accessible to new employees through easy-to-use interfaces that record insights during problem-solving scenarios.

In many manufacturing scenarios, human insights and expertise play an irreplaceable role. Arch Systems focuses on digitizing knowledge, enabling improved onboarding and creating a co-pilot system that empowers newer workers.

The Power of AI in Manufacturing

AI plays a critical role in addressing two specific challenges: downtime labeling and predictive maintenance. For downtime labeling, Arch Systems utilizes AI to automate the tracking of downtime incidents, translating natural language descriptions into actionable insights. This streamlines the manual processes that have long plagued manufacturers, resulting in reduced downtime and improved data accuracy.

Regarding predictive maintenance, one of the hurdles in conventional systems is the high false positive rate of alerts. Arch's AI can pre-triage alerts before they reach human operators, thus enabling technicians to focus their attention where it matters most. By summarizing data relevant to possible equipment failures, the AI improves the efficiency of response efforts and ultimately protects against unnecessary alarm fatigue.

Aligning Operational Decisions with Strategic Goals

As data becomes more accessible and actionable, upper management in manufacturing firms is reevaluating key performance indicators (KPIs). Traditions of relying on opaque monthly reports are being replaced with real-time data that provides granular visibility into operations. This allows managers to make informed decisions about investments and strategize more effectively.

Arch Systems' approach to aligning KPIs with real-time operational data is paving the way for a more coherent and unified set of conversations about performance improvement and operational efficiency.

Future Directions for Arch Systems

Looking ahead, Arch Systems plans to continue expanding its focus on the shop floor while integrating advanced AI capabilities into their offering. Their goal is to utilize data analytics to arm manufacturers with the knowledge needed to make informed operational decisions, ensuring they navigate the complexity of modern manufacturing with agility.

As manufacturers prepare for a future where available expertise may dwindle, Arch Systems aims to equip them with the tools necessary for efficient, data-driven decision-making, ultimately preparing them to embrace ongoing changes in the workforce landscape.

Keywords

• Real-time data
• AI in manufacturing
• Discrete manufacturing
• Data analytics
• Workforce challenges
• Predictive maintenance
• Downtime labeling
• Operational efficiency
• Key performance indicators (KPIs)

FAQ

Q: What challenges does the manufacturing sector face in real-time data collection?
A: Manufacturers often struggle with integrating diverse technological systems, particularly when dealing with both older and newer machinery, making it difficult to collect and process data quickly.

Q: How is AI being utilized in discrete manufacturing?
A: AI is used to automate downtime labeling and predict equipment failures, allowing for timely decision-making and resource allocation.

Q: What is the significance of capturing tacit knowledge in manufacturing?
A: Capturing tacit knowledge from experienced workers helps in training newer employees and ensures operational expertise continues within the organization.

Q: How do Arch Systems' solutions benefit upper management?
A: Arch’s solutions provide real-time operational data that aligns with KPIs, facilitating informed decision-making about capital investments and strategies for efficiency improvement.

Q: What industries does Arch Systems serve?
A: Arch Systems serves various industries, including electronics, automotive, aerospace, and medical devices, focusing on areas that involve complex assembly processes.