Digital Manufacturing: Types, Benefits, & Examples

Here’s something REALLY important that every industry leader should know about digital manufacturing. As we progress through the fourth industrial revolution, which is leading to the advent of new techniques and methods of doing things. Digital manufacturing, along with other systems, is an integral part of this revolution.

A recent World Economic Forum report by Weforum indicates that digital manufacturing technologies could add up to $3.7 trillion to the global economy by 2025. The integration of advanced technologies like Industrial IoT, AI, VR, AR, automation, cloud computing, and ML are transforming production and manufacturing processes.

Digital manufacturing is not just a buzzword—it’s a game changer that’s transforming the industry landscape. Let’s delve deeper into what is digital manufacturing and how it’s transforming the production landscape, one technological breakthrough at a time.

What is Digital Manufacturing?

Digital manufacturing is an advanced approach that uses computer systems or modern technologies to enhance machines, processes, and productivity. In a digital manufacturing unit, you will find connected technologies meant to simplify the process and boost work flexibility.

It all starts with using connected technologies to create a virtual model before building a product physically. Engineers test and refine the design using Industry 4.0 manufacturing principles before committing resources to production.

This approach also allows for the creation of personalized products on demand without needing significant minimum order quantities. Products are only manufactured when ordered, eliminating the need to stock finished goods.

The Components of Digital Manufacturing

Transforming a traditional manufacturing plant into a digitally mature one requires the merger of three things: Strategy, Digital Tools, and People.

1. Strategy

Start by evaluating your existing manufacturing unit infrastructure to identify the areas of improvement. While almost all the areas might need some work, identify the high-priority ones to begin strategy making. With this, define the goals you wish to achieve from the digital transformation of the manufacturing unit.

My suggestion is to have an eye for greater adaptability, resilience, and increased efficiency. With these goals in mind, you can build a proactive strategy while making the right technical decisions.

2. Digital Tools

Invest in the right tools for all processes related to product manufacturing. Whether it’s about CAD software or PLM systems to create digital product modes, choose tools that facilitate simulation, product testing, and on-the-spot optimization

Furthermore, integrate smart factory technologies like IIoT, etc., to collect and process data. Cloud computing can store the entire database in the cloud and make it accessible from anywhere, anytime.

3. Invest in Your People

Upskill and equip your workforce with the necessary skills to work with digital technologies. Build training programs to help them learn data analysis, automation, and using digital tools. Upskilling them will create a culture of innovation and change while fostering innovation through continuous learning and feedback.

Types of Digital Manufacturing

Digital manufacturing represents the utilization of connected technologies and approaches to build products. There are 5 Major types of Digital Manufacturing:

#1. Smart Factory

Smart factories use sensors, radars, etc., to extract data in real time and use software programs to turn raw data into insights. Technologies like Cloud Computing, IIoT, ML, and AI are utilized to analyze data on machine performance, production capacity, environmental impact, etc. This setup keeps factories digitally connected. They can quickly adapt to new trends or demands.

Here’s how these technologies work hand-to-hand:

Cloud computing is essential. It offers flexible online storage and data processing. It allows easy collaboration without lag. Information sharing becomes simple, and helpful software is accessible directly from the cloud.

AI dives deep into data. It helps companies plan their next moves. AI excels at scheduling production, predicting maintenance needs, and aiding smart decision-making. This keeps operations running smoothly.

Machine learning is crucial. Computers spot patterns or issues on the production line. This reduces waste and ensures top-notch product quality. It also monitors machine health to prevent serious problems.

#2. Digital Twin

Digital twins are software models of physical assets and processes. They simulate asset behavior under various conditions. This aids better decision-making. A key benefit of digital twins is progressive learning. They capture and store tacit knowledge. Information is structured in an understandable way for engineers and operators.

One major advantage of digital twins is that manufacturers can use this technology without replacing existing systems. This leads to faster value at a lower cost. The existing MOM architecture remains the foundation of operations.

 Implementing a digital twin alongside the current MOM setup allows manufacturers to maximize the value of previous technology investments. It avoids the need for a complete overhaul. Digital twins capture data from all existing systems and contextualize it quickly and effectively.

#3. 3D Printing

3D printing is a digital manufacturing type that uses a computer-controlled printer to create three-dimensional objects from a digital model. Also known as additive manufacturing, it builds objects by adding materials layer by layer.

The 3D printing industry is where many technologies driving the 4th industrial revolution intersect. Sensors digitized the physical world. Now, 3D printing enables physical output from digital information, allowing rapid prototyping and tooling like never before.

3D printing has evolved beyond just prototyping and design. Industrial 3D printers now produce quality, functional final parts and offer new levels of productivity. This advancement has changed the game.

3D printing empowers smaller creators and individual consumers. Just as personal computers revolutionized information, 3D printing is transforming the creation of goods.

#4. CNC Machining

CNC machining is a digital manufacturing process using computer-controlled tools to shape workpieces. It creates parts and components for various industries such as automotive, aerospace, medical, and consumer products.

CNC machining offers significant accuracy. Unlike older NC machines, CNC machines produce precise and consistent parts. A computer program guides the cutting tools, ensuring each cut is exact. This precision makes it easy to create complex machinery and parts.

#5. Value Chain Management

This aspect of digital manufacturing looks at the comprehensive value chain from suppliers to distributors. Utilizing smart technologies and techniques, it streamlines communication and optimizes inventory management. Through this process, manufacturers detect production bottlenecks and how to decrease inventory mishaps.

These three components also represent the fusion of virtual and physical worlds to create what we call Cyber-Physical Systems (CPS). CPS allows manufacturers to oversee product status in real-time throughout the manufacturing process.

How Does a Digital Manufacturing Unit Work?

A digital manufacturing unit represents the fusion of smart virtual and physical systems, proffering a technology-first work approach. Let me explain how it works by taking an example of a shoe manufacturing factory.

An invisible virtual pathway connects everything in a smart shoe manufacturing factory, called a digital thread. Here’s how the virtual factory operates;

• Design and Development

Leveraging product lifecycle management (PLM) technologies, designers create 3D models of the shoe, which are then virtually tested for fit, form, and functionality.

Using this design, developers create physical prototypes and progress with choosing the right material. Here, different material types are analyzed according to the requirements to find one that satisfies all the parameters in weight, durability, and environmental impact.

Computer programs are then used to simulate the shoe’s performance for wear and tear while identifying potential weaknesses.

All of this happens before the shoe goes to the assembly. Imagine the cost savings you will get with this approach as no shoe is manufactured and yet you will get all the information required to make the necessary changes.

• Moving to the Smart Manufacturing Unit

Digital tools are employed to finalize the design and material specifications and plan the production process. Smart programs are utilized to optimize shoe-cutting patterns, ensuring efficient resource usage.

As the machines are connected through sensors, they exchange data, optimizing their performance and increasing production capacity. The IIoT network plays a significant role at the backend.

All the information collected and processed helps save resources, execute predictive maintenance, and perform real-time machine monitoring to minimize unplanned downtime and pre-plan maintenance.

• Integration with the Supply Chain

Inventory management systems and digital tools connect the factory floor to the warehouse and suppliers. Electronic data exchange (EDI) systems facilitate seamless communication and automate order processing. This means factories can plan their production, material requirements, and resources according to market dynamics in real time.

Benefits of Digital Manufacturing

Digital manufacturing has solved several problems for manufacturers while facilitating improvements in production processes, product quality, and product distribution. Here are a few advantages of digital manufacturing.

• Better Work Efficiency

Digital technologies used in manufacturing offer real-time data analytics and automation speeds up the manufacturing process. Machine processes are improved with continuous data collection, ensuring predictive maintenance and minimizing downtime.

Compared to this, a traditional manufacturing process relies on printed work instructions and manual data collection. This means limited visibility into the machines and slow turnaround times, leading to performance degradation and inefficiencies.

• Room for Innovation

A digital manufacturing unit works with computer-aided design tools and solutions that allow for rapid design iterations and virtual prototyping. As you can make changes in the product design, shape, and size without ever sending one to the actual production line, I think it becomes easier to innovate and try out new ideas.

On the contrary, in a traditional production process, innovation comes at a big cost and extended time required to make design changes, get approvals, etc.

• Quick Turnaround Times

A digital manufacturing process is more agile, credited to better communication and real-time access to data. This means decisions are made faster and with higher accuracy. Combine all these aspects, and you will get quicker turnaround times while gaining the ability to make customer-centric decisions.

Traditional processes meant for the same purpose are inflexible, which makes adapting to changing customer demands difficult.

• Real-time Manufacturing Visibility

It’s no surprise that the digital technologies we use today provide real-time data. Manufacturing units can use this data for proactive changes in work management. Moreover, you can foster a culture where issues are identified quickly, and problems are resolved before they can create a big impact.

• Continuous Improvement

A digital manufacturing unit facilitates continuous improvement with access to real-time data. An in-depth analysis of the production process is always underway, which feeds the required data for identifying areas of improvement and implementing the required changes.

In all the points, you might have observed how a digital manufacturing unit represents a quantum leap ahead. By harnessing the right technologies, manufacturers work on a higher pedestal that gives them a better oversight of the production process.

Examples of Digital Manufacturing in the Real World

Here are 5 digital manufacturing examples of real-world companies from APAC that have adopted digital manufacturing to varying degrees of success, listed in no particular order:

 #Example1: AVEVA

AVEVA’s Vision AI Assistant 2021 is an image classification-based analytics tool designed for manufacturers. It utilizes video and images captured by standard cameras to transform them into actionable insights and timely alerts. This allows operators to concentrate on their tasks without the need to constantly monitor live camera feeds.

#Example2: SIEMENS

Siemens Digital Industries Software is leading the charge towards a digital enterprise, bridging engineering, manufacturing, and electronics design for the future. Through its Xcelerator portfolio, Siemens empowers companies of all sizes to harness digital twins for innovation.

#Example3: Volvo Group

Volvo Group, known for its trucks, buses, construction equipment, and power solutions for marine and industrial sectors, is undergoing a strategic IT architecture transformation. This initiative focuses on consolidating PLM (Product Lifecycle Management) and CAD (Computer-Aided Design) platforms to enhance the utilization of product data throughout its value chain. As part of this effort, Volvo Group will unify its Creo CAD platforms using PTC’s products, which will serve as the primary solutions for CAD and PLM across the Volvo Group, supporting comprehensive vehicle design processes.

#Example4: Emerson

Emerson is revamping its pneumatic valve systems to align with digital transformation trends. These enhanced valves boast improved precision control for pneumatic-driven applications thanks to integrated sensors, industrial networking interfaces, wireless technology, and advanced digital controls. This combination brings greater versatility, enhanced control, and reliable performance to a wide range of automation and manufacturing processes.

#Example5: Malaysia Airlines

Malaysia Airlines aimed for a greener future by selecting Fuel Insight and FlightPulse from GE Digital. These aviation software solutions became the foundation for a revamped fuel-efficiency program. By tracking fuel usage and emissions, the airline aimed to reduce its environmental impact and achieve its sustainability goals.

How Can Plutomen Help You in Digital Manufacturing?

Plutomen is a connected worker platform that helps manufacturers digitize their manufacturing processes. This shift from paper-based methods to digital procedures boosts efficiency, productivity, and quality in manufacturing operations. Here’s how Plutomen’s Connected Worker Platform can help manufacturing companies drive this digital transformation:

• Streamlining Information Access

Centralized Knowledge Repository: Digitized procedures and guides are stored in a central digital repository, ensuring workers have instant access to the latest information.

Searchable Database: Workers can quickly find specific documents or instructions, saving time spent searching for physical papers.

• Enhancing Training and Onboarding

Interactive Training Modules: New employees are onboarded using interactive digital frontline training that includes videos, simulations, and step-by-step guides.

Consistent Training: Standardized digital training ensures all employees receive the same level of instruction, leading to a uniform understanding of processes.

• Real-Time Problem Solving and Collaboration

Instant Communication Tools: Built-in messaging and video calls allow frontline workers to seek immediate help from experts or collaborate with team members to solve problems.

Shared Knowledge: Documented issues and solutions build a dynamic knowledge base for future reference.

• Improving Quality and Compliance

Digital Checklists and Audits: Digital checklists ensure all process steps are followed correctly, reducing errors.

Audit Trails: Automated logs of actions and changes help maintain compliance with industry standards.

• Facilitating Continuous Improvement

Data Collection and Analytics: Platforms collect data on various aspects of the manufacturing process, allowing detailed analysis of performance metrics.

Feedback Mechanisms: Workers can suggest improvements, which can be quickly implemented and tested.

• Increasing Operational Flexibility

Mobile Accessibility: Workers can access information and instructions via mobile devices, providing greater operational flexibility.

Remote Assistance: Experts can offer remote guidance, enabling quicker issue resolution without needing to be physically present.

Conclusion

As digital manufacturing continues to evolve, it’s clear that the benefits extend far beyond just improving operational efficiency. Finding this game-changing approach will open up faster innovations, better quality, and an agile and resilient workforce. Whether it’s operational streamlining, collaboration enhancement, or training, the adoption of emerging technologies in digital manufacturing will set your business up for success as the industry continues to evolve at breakneck speed.