Demystifying Smart Manufacturing: Overcoming Roadblocks

Embracing Industry 4.0 and modern continuous improvement practices is crucial for small and medium-sized manufacturers (SMMs) to thrive, but many are overwhelmed by the prospect of moving beyond the safe haven of existing practices and technologies. We recently explored this topic in a webinar I moderated titled "Starting out on Your Smart Manufacturing Journey" alongside participants Duane Hebert, Learning and Development Analyst at Tooling U-SME, and Patrick Gaughan, Managing Partner at Axiom Manufacturing Systems.

As experienced engineers and practitioners, Hebert and Gaughan were able to share relevant insights and useful anecdotes from their work supporting digital transformation around the country. Tooling U-SME’s Learning Services team, together with experienced partners like Axiom, are working with businesses to educate stakeholders and key personnel to pinpoint opportunities to modernize their operations with the right technology solutions and exposing new forms of data and business intelligence into actionable improvements. 

Potential Roadblocks and the Need for Evangelization 

Ultimately, operational improvements resulting from Smart Manufacturing transformation require a matrixed orchestration of people, processes, and those modern technologies poised to deliver on a connected, data-driven enterprise. Finding the right balance can be daunting, and SMBs across the U.S. have been slow in some instances to adopt Smart Manufacturing, citing a number of challenges including:

• Resistance to Change: Change initiatives can meet resistance if staff are not fully informed about the benefits and the "why" behind the shift. 
• Resource Constraints: Budget limitations and lack of specialized IT expertise can make technology adoption seem overwhelming. 
• Data Uncertainty: It can be challenging to determine where to start with data collection and how to ensure meaningful results. 

Building a company-wide culture of continuous improvement and innovation is essential to overcome these hurdles. Like most successful initiatives, it is critical to also foster consensus and stakeholders across the highest levels of an organization, allowing a mindset that embraces digital transformation and ultimately supports those stakeholders tasked with forging a journey forward. By identifying evangelists who are eager to participate, as well as interested team members who know the processes and do the jobs, organizations will be well equipped for success at all levels of the organization.

Knowing this, as the Tooling U-SME Learning Services group works with organizations, the team is sure to address workforce awareness, education, and upskilling, often through a combination of workshops, employee training, and relevant case studies tailored to the unique challenges facing each employer. In the process, collaborative teams work together on tasks such as value stream mapping and process analysis to identify areas for improvement, citing where the collection and dissemination of data can produce the preferred results. 

Creating a Data-Driven Culture 

Often, the mere prospect of Smart Manufacturing transformation triggers project paralysis, which understandably happens when employers are suddenly faced with unfamiliar decisions about which data to value and how best to collect it. Furthermore, many organizations lack the experience analyzing new forms of data and business intelligence, leaving even more questions about how to take meaningful actions based on the conclusions. Collecting data for data’s sake is meaningless, but our teams help organizations through the maze, ultimately helping contextualize collected data into intelligence. We assist with technology selection, implementation, and adoption and help organizations find scalable solutions suitable for their budgets.

When implemented successfully, Smart Manufacturing can help SMMs use data to realize improvements in:

• Efficiency and productivity: Streamlining processes and spotting bottlenecks. 
• Waste and errors: Reducing waste and costly mistakes with better insights. 
• Maintenance and scheduling: Making informed, data-driven decisions to reduce downtime. 
• Product quality: Performing continuous monitoring for higher quality standards. 

Continuous Improvement Is a Mindset 

Remember, implementing Smart Manufacturing isn't a one-time project. SMMs should start small and choose practical, affordable projects that provide real results. It is important to demonstrate improvement and build on successes, adding early value to build consensus and show progress in more of an agile state than a waterfall state. As projects mature, we: 

• Monitor and Evaluate: Tracking, measuring, and adapting to optimize results. 
• Standardize and Optimize: Developing and refining best practices for lasting success. 
• Emphasize Change Management: Supporting your workforce through transitions, ensuring a smooth integration of new practices. 

Your Partner in Smart Manufacturing 

We understand the complexities of transforming your manufacturing operations. That's why we offer tailored support from planning and assessment to implementation and continuous improvement. 

Together, we can build a smarter, more competitive future for the manufacturing industry.

Click here to view this webinar.

Our continuing blog series on Smart Manufacturing for Small and Medium-Sized Manufacturers will help you unlock the potential of Smart Manufacturing in your organization. Don’t miss an installment. Sign up now to discover practical tips, real-life examples, and more! Or fill out the form below to speak with an expert. We can help you get started on your Smart Manufacturing journey today.