A great deal of chatter, promotion and hype in the business world and among consumers centers around how artificial intelligence (AI) impacts the world. Like it or not, AI applications like ChatGPT are quickly integrating into our everyday lives and are playing an essential role in modernizing industrial manufacturing and production. For instance, when used with augmented reality (AR) and virtual reality (VR), AI is a great tool for capturing historical knowledge and training people. It also helps companies simplify operations, optimize performance and build the resiliency, sustainability and agility required to stay competitive.
But what is AI? How advanced is it? And should we be worried?
Demystifying AI
The idea of AI is not new. Designers and cyber enthusiasts have been developing this technology for decades. AI is the art of building “intelligence” into machines to approximate or simulate human cognition and thought. Modern AI software together with advanced sensor technologies enable computers or machines to experience the environment, to read and learn and to recognize people, images and objects. Specialized algorithms are used to analyze data and make conclusions to help solve problems. Generative AI learns from information, creating new and responsive material that echoes the original information’s style, format and parameters.
An AI layer or subset is machine learning (ML) technology, which uses data to enable machines to identify patterns, understand statistical relationships and respond appropriately. Within ML is yet another layer called deep learning, which uses neural networks – or mathematical models – that attempt to echo human brain function. ML technology facilitates recognition capabilities and machine memory. No human interaction is required for these artificial neural nets to learn.
Combining AI’s real-time data with AR technology provides a powerful and dynamic user experience. AR is based on logic programming, virtually combining digital information with the physical world in real time. For example, people can virtually “try on” a pair of shoes online before they purchase them or see how a piece of furniture looks in a house. In manufacturing industries, AR technology plays an important role in areas such as quality inspection, workforce learning, machine maintenance, simulation and safety.
These emerging capabilities will drive a step-change in manufacturing methodology and in the evolving role of humans in industry. AI-driven robotics, for example, are already part of the industrial environment.
Robots, Cobots and Androids – Oh My!
Robots and cobots – collaborative robots that work closely with humans – are commonly used in manufacturing to automate repetitive or low value tasks and perform inherently hazardous functions to mitigate risk to humans.
Industrial robots tend to be larger, fixed in place and located behind safety barriers. They are typically programmed to perform specific tasks such as lifting, welding or assembly. By comparison, cobots are smaller and precision-engineered to work safely and efficiently in proximity with human operators. These machines use AI to function and can help increase efficiency and improve product quality. People working together with cobots are safer and more available for tasks that require human intelligence, judgment and experience.
Robotic humanoids, or androids, look and behave differently than robots or cobots. Androids are AI-enhanced robots designed to emulate human appearance and movement, including facial expression. They are built to interface with humans in a more natural, intuitive way using AI and advanced machine technology.
For a fascinating glimpse into three of the most advanced androids in the world today, meet Erica, Sophia and Ameca.
(Click the image of an android above to learn more about them.)
All display a synthetic humanoid appearance and emulate human facial expressions, movements and gestures. They use AI technology to interface directly with people, hold conversations and respond or react appropriately. Erica, Sophia and Ameca each exhibit a unique personality and were developed to highlight specific strengths and capabilities.
These androids seem like little more than amusing dolls or puppets, but as AI technology rapidly advances, humans will rely increasingly on AI-based machines for assistance at home and on the job. Today’s science fiction movies sometimes suggest androids will take over the world while humans struggle to stop or contain them. Sorry, Hollywood. Androids can only mimic humans – not be humans.
Solving Manufacturing Challenges
In manufacturing, AI can enhance performance in areas such as scheduling, quality control, safety, supply chain optimization, reliability and production. The cumulative potential impact on productivity and profitability is both exciting and staggering.
Consider, for example, how AI is applied to two of industry’s most pervasive production challenges – the workforce skills gap and energy management.
Easing the Workforce Skills Gap
Manufacturers have been dealing with the workforce shortage and its impact on profitability and growth for several years, but now it is possible to implement a new, higher level of autonomous operation that augments and empowers people. Automating everything possible in a facility, or hyperautomation, is sometimes referred to as lights out or dark manufacturing, suggesting a scenario where operations stay up and running without people directly intervening. Smart factories can self-optimize, learn and adapt to improve productivity.
With hyperautomation, machines are involved in all processes, performing low value or repetitive work such as material movement. People are then available and enabled to do the kind of strategic, knowledge-based work that requires experience, problem-solving skills and situational awareness. AI applications and powerful advanced analytics access operational and business data to provide the right information to workers. Actionable digital insights support operators, users and management in making more data-driven decisions and helping to boost performance and help businesses achieve key outcomes.
AI applications also deliver personalized training to people based on their skill sets and areas of expertise. A flexible, purposeful training program enhances worker safety and provides people with the tools and knowledge to advance their career journey.
Dynamic Energy Management
Manufacturers today are practicing sustainability in every area, working toward the goal of “net zero” impact on the environment. Achieving net zero involves decarbonization, carbon capture, energy efficiency and more. AI enables companies to scrutinize energy management in new ways, using the digital thread and sophisticated algorithms to reveal opportunities to save energy, optimize use of alternative energy sources and minimize waste.
A comprehensive energy management strategy is enabled through advanced controls technology combined with AI and ML to optimize energy use continually while monitoring sustainability key performance indications (KPIs). Overlaying production data with energy management information provides a deeper understanding of how manufacturing processes work, how process variables affect energy use, and which products might benefit from a redesign to reduce energy consumption and lower production costs.
Make the AI Move
Smart factories combine AI technologies and human intelligence. While AI makes its powerful mark on manufacturing, people will continue to apply human skills and digital operational insights to push performance to new levels.
For companies that are ready to incorporate AI into their operations, consider consulting with a qualified automation solutions provider who knows their industry and understands AI technology. As society increases reliance on AI technologies, manufacturers will integrate the powerful capabilities of AI to benefit their customers and reach new levels of productivity, sustainability and agility.
Looking for ways to become more agile and adapt quickly to rapidly changing markets and an increasing diverse range of customer demands? Read The Road to a Smart Factory: A Planned, Holistic Approach
ABOUT THE AUTHOR
Carol M. Schafer (carol.schafer@rockwellautomation.com) is Global Senior Marketing Manager, LifecycleIQ™ Services at Rockwell Automation. She has 30 years of experience in automation and controls marketing and industrial instrument and systems sales.
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