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How AI Can Transform Manufacturing

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Artificial Intelligence is a buzzword with Generative AI “generating” the most hype. Globally, businesses have already started adopting AI for various use cases, and the Australian Government recently launched a public consultation to seek advice on how to mitigate potential risks and ensure it is applied responsibly. One of these uses cases is advanced manufacturing, which is a broad term that encompasses technologies applied to any manufacturing facility, including application software and AI tools to augment and generate higher value manufacturing output. So how can AI drive advanced manufacturing and what can manufacturers proactively do in this regard? Let us find out from this blog.

Speed and Safety

Part of removing human error to make manufacturing safer and faster means reducing reliance on human observation. As machinery drivers and operators are among the top three occupation groups with the highest rate of work-related injuries in Australia at 6.5% in the 2021-2022 financial year, this makes a use case for AI analytics in augmenting workplace health and safety. A use case for workplace health and safety is driven by AI video surveillance in manufacturing. AI analytics can match workers’ physical position in relation to how they interact with machines, particularly heavy industrial machinery, facilitating a more comprehensive understanding of safety in workplace operations and injury.

Intelligent operations is a top manufacturing technology trend and AI software can also manage workflows more effectively by identifying and allocating tasks. This can be taken one step further, with large site and heavy industrial manufacturing operations using Industry 4.0 technologies like digital twins to optimise these workflows – by using a virtual model designed to accurately reflect the manufacturing process to model operations and planning at significant scale. These digital twins can show how people and equipment can be moved and managed more quickly and safely around a site in a controlled manner before applying it to the actual operations. These use cases for AI are less about employing “robots to take manufacturing jobs”, and more about creating a productive workforce and giving advanced manufacturers a competitive edge. The challenge for individuals and corporations is to understand and embrace how this technology can enhance current advanced manufacturing processes, rather than downplaying the potential.

Upskilling Workers and Emerging Tech

With capital decisions carrying longer term implications, it is important for manufacturing businesses to consider their investment in any technologies and operational uplift, whether that be AI or other emerging technologies, including the current and future needs of upskilling their workforce and plan at least 5 or ten-years’ ahead to avoid sunken costs and stranded assets. IT will also require upskilling of the workforce and considerations regarding ethics, privacy, and cybersecurity. Therefore, a comprehensive approach that combines AI implementation with human expertise is crucial for successful transformation in the manufacturing  and pipe fabrication sectors.

The Final Bow

It is still to be determined how a future where advanced manufacturing is largely driven by AI looks like, however, it is expected that AI will make production more agile, efficient, and safe for a workforce that will become more highly skilled as they grow familiar with and train in it. So, is the hype around AI’s potential in advanced manufacturing justified? We may find out very soon.

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2023 Trends in Australian Manufacturing

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As we say goodbye to 2023 and step into 2024, it is a good time to reflect on the year that went by and what it meant for the Australian manufacturing sector. It was a transformative year for the industrial landscape as it navigated through numerous challenges throughout the year. 2023 saw many ups and downs and witnessed evolving technologies, stronger sustainability imperatives, and a greater demand for resilience. Let us take a look at the top trends that shaped the Australian manufacturing industry this year and how the momentum can be carried forward into 2024.

Revolutionising Operations

2023 witnessed smart factories becoming the norm, not just in Australia but beyond, with the rise of real-time monitoring and agile operations on many shop floors. Industry 4.0 technologies and top manufacturing technology trends, like Internet of Things platforms, big data analytics and advanced algorithms, the digital twin, and 3D printing, continued redefining manufacturing processes throughout the year and show no signs of slowing down. Australian heavy steel fabrication companies are also recognising the importance of upskilling their workforce in digital transformation and automation.

Sustainability Takes Centre Stage

Manufacturers are increasingly embracing eco-friendly practices all over the globe. In doing so, they are not only reducing their environmental footprint but also future-proofing their pipe fabrication operations against continuously evolving regulations and consumer preferences. This year, many Australian companies turned to digital and electrified technologies, from artificial intelligence to electric vehicles, to promote sustainability and combat the climate crisis. A report released this year by Schneider Electric revealed that 82 per cent of businesses in the country believe that the advantages of adopting sustainable technology far outweigh the associated costs. In an era where environmental consciousness is crucial, sustainability is in the spotlight for many Australian companies as a key element in driving the industry towards a more eco-friendly and resilient future.

Reshoring and Onshoring

Supply chain disruptions and geopolitical uncertainties continue to plague the global industrial landscape, making it more crucial for Australia to revive manufacturing and claim its position by reshoring and onshoring operations. In 2022, the Australian government introduced a $15 billion landmark bill that would support, diversify, and transform Australia’s industry and economy and position the nation as a country that manufactures. The National Reconstruction Fund (NRF) was welcomed by business leaders across all industries in the country, with the local manufacturing sector in particular set to receive a major boost from the funding. This investment is expected to help cement Australia’s position as a world leader in innovation and manufacturing and help to unlock the potential of local Australian steel companies. The NRF board held its inaugural meeting in September, officially launching the corporation that will help enhance Australia’s local manufacturing prowess.

Upskilling

Upskilling has emerged as one of the most vital catalysts for growth and innovation. With the rise of Industry 4.0, the need for a new paradigm that prioritises upskilling and re-skilling workers has never been more important. This year, the federal government rolled out the Artificial Intelligence Adopt Program, a new initiative that would help Australian businesses integrate artificial intelligence safely into their workplaces. Through the program, the government aims to create a network of industry-specific centres that will highlight the innovative capabilities AI can bring (such as AI video surveillance in manufacturing) and provide specialist training to help develop skills to manage AI. It has been proven time and time again that upskilling efforts not only empower individual workers but also propel the entire industrial sector towards a future defined by innovation, sustainability, and resilience.

Final Thoughts

The Australian manufacturing industry has been fortified by many challenges and innovations in 2023. As we enter the year ahead, it is important to remember that change is the only thing that is constant and will always be present every step of the way. Thus, embracing the transformative forces that defined 2023 may hold the key to staying competitive in this industry!

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Benefits of AI Video Surveillance in Manufacturing

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There is an increased need for video surveillance in the manufacturing and metal fabrication industries. This is partly due to a change in the way people work as a result of the COVID-19 pandemic, but also because of an increased awareness among managers to optimize production and reduce costs. In this scenario, introducing Artificial Intelligence (AI) in video surveillance and Augmented Reality (AR) has the potential to transform operations and empower managers to manage work more effectively. At the same time, AI can help to streamline manufacturing processes and provide real-time monitoring and security. So, how can we unlock these business benefits of AI video surveillance? This blog will analyze this topic in greater detail.

Unlocking Efficiency

CCTV surveillance has long been an indispensable tool for security, but its capabilities have expanded far beyond monitoring entrances and exits. With the integration of AI, managers can identify and optimize operational processes across a variety of areas, including staff, logistics, manufacturing, and production. Through machine-learning, AI video surveillance systems have been trained to detect people and vehicles with incredible accuracy. Alerts of vehicle movements enhance monitoring of production & shipment progress.

Heatmaps detailing areas of use can change the layout of work floors, storefronts, or office spaces. People detection, counting and queue management capabilities are built into AI video surveillance systems, enabling rapid response to customer service, more efficient logistics, and improvement in communication between employees across different departments, buildings, and locations. Real-time monitoring of employee activities allows for immediate response and intervention when necessary. Intelligent video monitoring by managers is especially valuable in industries where coordination and synchronization among team members are crucial for success.

Prioritizing Workplace Safety

Workplace health and safety (WHS) is of paramount importance for any business. AI video surveillance acts as a vigilant partner in preventing WHS issues and accidents. By analyzing footage, AI algorithms can identify potential hazards and unsafe practices, such as possible accidents during manufacture of pressure vessels. This proactive approach not only protects employees from harm but also shields businesses from potential legal and financial liabilities. Moreover, AI-powered surveillance can detect signs of a negative work environment, harassment, and abusive behaviour. Identifying such issues early on enables management to intervene and create a healthier workplace culture. It is necessary to protect the staff and business by implementing video surveillance policies that work to safeguard the well-being of staff and management.

Remote Security and Access Control

One of the most remarkable features of AI video surveillance is its capability for face, number plate, and metadata (attributes of people and vehicles, e.g.: vehicle colour) recognition. The latest AI video surveillance products offer the means to create permissions or blocklists for access control, thus improving security by granting or denying entry based on recognized faces. The system captures detailed vehicle number plates for accurate evidence and streamlines management by allowing searches based on specific characteristics such as clothing or vehicle colour. Each tagged AI video event allows one to zero in and export key moments across multiple cameras when incidents occur without having to search through hours of footage. These technologies can rapidly transform the way managers, especially those working remotely or off-site, take control of assets and allocate effort.

Closing Statement

It can be observed that AI video surveillance has multiple applications such as remote-site management, monitoring material and machinery arrival, adhering to specifications and requirements (e.g., during manufacturing of water tanks), ensuring worker safety and, site security. Thus, AI video surveillance is no longer confined to the realm of security; it has evolved into a catalyst for efficiency, safety, and strategic decision-making. In time, AI will no longer be an option in video surveillance – it will become a necessity!

© K999 Engineering & Construction Co. Ltd. 2023