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Wednesday, December 11, 2024

Exploring AI Applications in Advanced Manufacturing: Case Studies and Insights

The Evolution of Artificial Intelligence: From Turing to Today

Artificial intelligence (AI) has a rich history that can be traced back to the pioneering work of Alan Turing, often referred to as the father of computer science. In 1950, Turing posed a fundamental question in his seminal paper, “Computing Machinery and Intelligence”: “Can machines think?” This inquiry laid the groundwork for decades of research and development in AI, which has evolved significantly over the years. Today, AI is not just a theoretical concept; it is a transformative force reshaping industries, particularly in the wake of challenges like the pandemic, chronic labor shortages, and supply chain disruptions.

The Current Landscape of AI Adoption

In a recent webinar hosted by Jim Beretta of Customer Attraction for the Association for Advancing Automation (A3), industry leaders discussed the current state of AI and its potential for revolutionizing manufacturing. Hugues Foltz, co-owner and executive vice president of Vooban, highlighted a common misconception: many people still view AI as a nascent technology. “One of our first tasks when meeting with a potential customer is to demonstrate how mature AI is,” Foltz explained. This skepticism often stems from a lack of understanding and trust in AI technologies.

Despite its maturity, North America is lagging behind other regions in AI adoption. The ongoing labor shortages have compelled many companies to innovate and seek solutions that can enhance productivity. Foltz emphasized the challenge of initiating AI projects, noting that manufacturers prefer tangible investments, such as robots or machines, over software solutions that are less visible. “Without AI and the Internet of Things (IoT), the robot or machine will not work as it should,” he stated, underscoring the need for a shift in mindset regarding software investments.

AI in Food Manufacturing: A Case Study

The food manufacturing sector presents unique challenges, including extreme working conditions and high employee turnover. Traditional ingredient delivery systems, such as augers and gravity dispensers, often struggle to adapt to changes in orientation or missing containers, leading to waste and inefficiencies. Rajat Bhageria, founder and CEO of Chef Robotics, shared how his company is addressing these issues through the use of collaborative robots equipped with AI and 3-D computer vision cameras. These systems can react dynamically to changes on the production line, ensuring that ingredients are delivered accurately and efficiently.

Bhageria explained, “The advantage of AI is the central ‘brain’ algorithm that leverages operational data to continuously improve over time.” This adaptability not only enhances productivity but also reduces waste, making food manufacturing processes more sustainable.

The Broader Implications of AI in Manufacturing

Sina Afrooze, founder and CEO of Apera.ai, emphasized that the digital transformation brought about by automation is not merely about purchasing robots and integrating AI. “It may require an evaluation of the entire manufacturing process to determine what can and cannot be solved with AI,” he noted. This holistic approach is essential for maximizing the benefits of AI technologies.

In traditional manufacturing environments, introducing new recipes or ingredients often necessitates significant investments in new tooling and downtime. However, AI-based collaborative robots can adapt to new requirements with minimal disruption, requiring only a software upgrade and a brief training period. This flexibility represents a paradigm shift in how manufacturers can approach automation.

Innovative Business Models and Data Management

Apera.ai has introduced a novel business model that offers robots as a service, allowing companies to subscribe to hardware and software solutions rather than making outright purchases. This model includes regular software updates and a focus on continuous improvement, which can lead to increased throughput and reduced waste. Afrooze highlighted the importance of data management in AI, noting that effective algorithms require access to quality data.

“Local, state, and federal governments provide access to free data on a wide variety of topics,” Foltz added, pointing out that demand forecasting and sales projections are among the first tasks that can be automated using AI. By leveraging this data, companies can train algorithms to optimize their operations along the entire supply chain.

The Power of AI in Complex Problem-Solving

One of the significant advantages of AI is its ability to process vast amounts of data quickly and accurately. While humans excel at managing a limited number of variables, AI can analyze millions of data points simultaneously, leading to more informed decision-making. Foltz shared an example of a solution developed by Vooban that schedules construction cranes based on various factors, significantly improving accuracy and profitability.

Apera.ai takes a different approach by using CAD data in simulations to create digital twins for customers. This method allows for precise training of AI systems before any physical implementation, reducing the risks associated with real-world variations.

The Future of AI: Generative AI and Beyond

The emergence of generative AI (Gen AI) is poised to revolutionize the automation landscape further. Gen AI can generate text, images, and other content based on the data it has been trained on, potentially streamlining the engineering processes involved in custom automation. Afrooze noted that AI could significantly enhance medical diagnostics by accessing comprehensive diagnostic information, eliminating human limitations such as fatigue and bias.

As AI technologies continue to evolve, Bhageria anticipates that AI-enabled flexible automation will fill gaps in staffing, allowing human workers to transition to higher-value roles. This shift could lead to the creation of entirely new industries, similar to how social media has opened up new opportunities.

The Global Shift Towards AI-Driven Decisions

The transition from data-driven to AI-driven decision-making is underway, with many companies recognizing the need to innovate. Foltz remarked that as AI demonstrates its capabilities and provides proof of concept, executives are becoming more comfortable making AI-based decisions across their organizations.

In a light-hearted conclusion to the webinar, the panelists likened the current state of AI adoption in manufacturing to a football (soccer) game. Foltz suggested that North America is “well past the half,” while Bhageria felt it was still early in the match regarding more advanced AI concepts like artificial general reasoning (AGR).

As AI continues to gain traction in advanced manufacturing, the next few years promise to be filled with innovation and transformation, paving the way for a future where AI plays an integral role in shaping industries.

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