What is Adaptive Manufacturing?

As supply chain automation and preventative maintenance needs grow to combat disruptions and costly downtime, there are solutions that many manufacturers are starting to look into. Adaptive manufacturing technologies allow manufacturers to be flexible by monitoring production remotely and automating systems to adjust based on real-time indicators. It is an innovative approach to quickly and efficiently modify production processes to keep up with ever-changing demand, allowing manufacturers both big and small to maintain the highest production capacity and efficiency. Put simply, adaptive manufacturing uses sensors, customized programming, control systems, etc., to create a proactive system that can react to order levels, supply chain disruptions, customer input, and more.

In traditional manufacturing, retooling or reprogramming machines to produce different products can take up a significant amount of time and resources, and potentially be hazardous for employees. With automated, adaptive manufacturing, the system can adjust its settings or tooling to switch from one product to another with little downtime.

Here is a basic understanding of how it works; it all starts with data collection from machines and sensors. Once the sensors collect the data, it’s time to move on to planning around factors such as material availability, production capabilities, and timelines. After manufacturers formulate a plan, the adaptive process will rely on a wide range of advanced machinery, robots, or automation systems. During the manufacturing process, sensors and monitoring systems will continue to collect real-time data manufacturers can analyze to ensure quality control and adjust as needed. Now manufacturing workers can adjust the processes, machine settings, and production priorities based on real-time information to produce unique or customized pieces to meet each customer’s preference. After all of this comes continuous improvement from performance data analysis.

Benefits of Adaptive Manufacturing in Your Process

Adaptive manufacturing allows companies to be more responsive to market demands, but is this something needed in your manufacturing process? Let’s explore the benefits of adaptive manufacturing.

Preventative Maintenance

Instead of waiting for a machine to break down, adaptive manufacturing notifies users when parts are beginning to wear out and can tell them where to find the replacement. If a machine has been running too long and becomes overheated, adaptive manufacturing technologies will notify machine operators before it’s too late.

Integration that breaks down silos

Are all your systems communicating? Does every worker have access to the same information? Too often, organizations are not communicating across the company which leads to disruptions in information that can cause back-ups and mistakes. Track products as they pass through certain gates or on delivery routes and use cloud-based monitoring systems to store information with visibility throughout the entire pipeline. With this, you can coordinate schedules and production easily.

Immediate response from suppliers

It’s possible for you to let suppliers know immediately when an order comes through so they can match their production to yours. If you connect to a supplier portal, an adaptive manufacturing system automatically calculates materials needed based on the orders coming in, so suppliers know exactly what you know, at the same time. This process improves production, expedites shipping, and allows you to meet customer demands more easily.

Incorporating customers into your process

Just like supplier portals, customer portals let you work directly with your customer. Through them, customers can place orders, respond to survey questions, or discuss pricing directly with their correspondent. Once a customer places an order an adaptive system will process, set up, order parts, schedule, and plan shipping routes proactively, providing quick turnaround times that keep everyone satisfied.

Drives significant progress

With your ERP software and adaptive technology connected, access to data is limitless. View your entire shop floor, from production to shipping, and notice trends earlier to make intelligent decisions on scheduling, capacity, hiring, and more. This modern factory is only scratching the surface of the future of technology and understanding it now will only help build your business in the future.

For most manufacturers working with repeated steps that they feel are inconsistent, an adaptive automated solution can make a huge difference. These solutions help improve the quality and consistency of processes and products.

Frequently Asked Questions

Can small to medium-sized manufacturing companies implement adaptive manufacturing without disrupting current operations?

Absolutely! We believe in the crawl-walk-run philosophy: focus on the area that you are most concerned and invested in, then grow from there once you see the return on investment. In practice, rather than overhauling the entire production process, start small with a pilot project in inventory management, for example. Once you feel comfortable with the automation capabilities and see the impact, the adoption can be gradual in the other areas of the business with training and skill development along the way. Collaborate with technology providers, test, and evaluate what works for your company. In no time, your entire production will be flexible, responsive, and optimized.

How long does it typically take to see the benefits of adaptive manufacturing?

There are many factors to consider, and results may vary, but seeing the small benefits of adaptive manufacturing can be relatively quick. To see the full range of benefits, however, it may take several months to a year. This is a long-term transformation that requires organizational readiness, learning curves, and resource allocations with continuous evaluation and refinement.

How does adaptive manufacturing improve product quality?

Automation plays a crucial role in adaptive manufacturing. Automated processes ensure products are manufactured according to predefined specifications that result in improved quality. Adaptive manufacturing techniques like additive manufacturing allow manufacturers to create quick prototypes, test them, and make necessary design changes before actual production. This coupled with real-time monitoring and data-driven decisions leads to a nearly perfect production process.

Technology is the future of the industry and with more demand comes the need for quicker, error-free supply. Technology is not meant to take the jobs of hardworking people, only enhance and perfect them. If you’re interested in beginning your company’s digital transformation, try connecting your data to a cloud-based ERP. Take advantage of faster pivots to new products, increased visibility and control over costs, and superior product quality. All with M1 ERP software.

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