PPD113-B03-10-150000 The factory was retrofitted with advanced technology
In an increasingly digital world, manufacturers must be proactive in implementing Industry 4.0 technologies and solutions such as automation, simulation technologies, and Machine Intelligence (MI). A recent survey of 100 high-performing organizations by MIT’s Manufacturing and Operations Machine Intelligence (MIT MIMO) program and McKinsey & Company found that the organizations that have gained the most from digital technologies typically have strong governance and deployment capabilities, partnerships, employees who are trained in MI, and a wealth of data available. These companies are investing 60% more in machine learning than their competitors, and these investments can translate into optimized production lines, less waste, and better product lifecycle visibility. To get the most out of these Industry 4.0 deployments, companies will necessarily need to invest in technology and train their employees for development. While each company’s path forward is different, each can use technology to increase productivity, increase competitiveness, and gain resilience.
Industry 4.0 technologies provide manufacturers with a competitive advantage, allowing them to determine the most effective solutions based on their business. For example, manufacturers of products such as automobiles and medical devices, which are complex, costly and have long life cycles, may choose to invest in highly specialized automation solutions to optimize production lines; Manufacturers with a high proportion of consumer products may benefit from “plain old automation” or automated processes for performing common steps such as fastening sPPD113-B03-10-150000 crews, applying labels, and packaging products.
In addition, manufacturers can gain the advantage of better insight into production line and supply chain planning by investing in IT infrastructure that enables data collection and sharing throughout the product lifecycle. From planning and production to warehousing, delivery and aftermarket, every part of the product lifecycle is connected through a data architecture that allows factories to better respond to possible future disruptive events, with the flexibility and confidence to act to recover from setbacks. The initiative will also help companies identify growth opportunities and new ways to become more competitive and “sticky” to consumers.
A recent Harvard Business Review article supports this view: “Analytics can help members in the supply chain identify common components across product lines and design optimal buffers.” A digital twin, a digital model of the supply chain, can alert downstream factories of upstream disruptions faster, allowing them to take advantage of buffer zones faster.”
Look for ways to streamline processes and production lines
In the future, factories should attach great importance to process skills and a culture of continuous imPPD113-B03-10-150000 provement. Mastering Industry 4.0 technologies is only the first step, and manufacturers should apply Six Sigma management and lean manufacturing principles in accordance with the execution strategy to achieve efficient operations. Flextronics plants foster a culture of continuous improvement by applying these principles. In 2022, Flextronics’ plants in Tecev, Poland, and Tanjong Pelepas, Malaysia, were both awarded the Lean Innovation Manufacturing Excellence Award by the Manufacturing Excellence Association.
If a manufacturer neglects process skills and improvement practices, it can end up paying a high price. When technology deployment is rushed or sloppy, manufacturers’ machines and software platforms may not be fully utilized, and the quality of the product will not be guaranteed. If a manufacturer manually automates the inspection process without clear conformity criteria, it is likely that the manufacturer will end up with too many nonconforming products and higher unit costs, or with low-quality products that damage brand reputation and customer loyalty.
