As we embrace Industry 4.0 and shift towards a new dawn of machining innovations, robotics and AI are firmly and steadily paving the way for the future of machining.
The exciting fast development and penetration of Artificial Intelligence in all spheres of life and all industries is bringing forward fundamental changes to businesses and work trends.
While users and companies worldwide enjoy the fascinating benefits of using Generative AI, Chat GPT and other AI-based innovative developments in daily life and the way of doing business, the penetration of AI and robotics has also affected and altered more specific industries and sub-sectors globally. AI and robotics are seen to deeply disturb specialized industry sectors, bringing beneficial pioneering modernizations in machining, industrial manufacturing and machine shops.
A new game changer: Machining with AI and robotics
The exceptional rate of advancement of Artificial Intelligence and robotics in machining is powered by the fast development of fundamental emerging technologies. The combination of these technologies allows the present unparalleled and exciting industry advancements to take place and gain full spread and reach. The future of AI and robotics is particularly promising in machining in the manufacturing industry, including precision and smart manufacturing, as well as in other specialized and challenging industries. AI and robotics have the potential to unleash never-before-seen beneficial alterations in the way society and work are organized and managed. In manufacturing, machining with AI and robotics is seen to be a true game changer for the industrial technological evolution, as it fuels optimized accuracy, higher productivity and enhanced efficacy in production processes and operations.
The blooming digitalization of the manufacturing sector has skyrocketed the application of robotics, Artificial Intelligence, IoT, Cloud Computing and Machine Learning in the process of modernization of factories and production lines. The revolutionization of industrial manufacturing is radically transforming work, production facilities and industrial equipment. The wide and rapid adoption of these emerging technologies is seen to enhance, improve and optimize manufacturing processes and production quality, as well as workers’ safety, well-being and overall satisfaction at the workplace. These latest technological developments are means to improve human-machine interaction and collaboration. Thus, technology can be used to advance work quality and performance of both humans and machines, creating fruitful ground for successful modern industrial work organization and collaboration between humans and machines.
Manufacturing industries are heavily investing in the deployment and utilization of industrial robots, CNC (Computer Numerical Control) machining and the wide application of Artificial Intelligence for automation of complex processes. The integration of AI and robotics into machining is powering a transformative shift, revolutionizing and paving the future of the industry.
With the constant evolution and advancement of technology, given the rapid rate of innovation and new developments, the future of AI and robotics in machining is expected to be more than promising. The possible advancements in machining in the world of manufacturing include functionalities for greater control and customization, capabilities of further automations, aimed at reduction of the need of manual intervention and human involvement, and fully automated smart factories and production lines. Artificial Intelligence will surely penetrate in more and more aspects of manufacturing and will be further integrated in machining and modern production lines.
AI’s role in machining
An integral part of leveraging the latest innovations in manufacturing includes ushering AI in CNC machining advancements. Artificial Intelligence is being increasingly incorporated in machining to boost profitability, performance and efficiency. For manufacturing businesses, it is vital to stay up-to-date with the industry trends and to keep up with the deployment and application of machining innovations. AI is able to unleash the power of CNC machining, aiming at greater precision and optimized productivity. The integration of AI and other Emerging Technologies, such as IoT, Machine Learning, Cloud Computing, XR, and many others, in machining enables process optimization and downtime reduction, based on real-time data, data analytics, insights and predictive analytics.
The incorporation of AI in CNC machines is a true game changer for the manufacturing industry. When AI is deployed in machining, operations are raised to a new level where CNC machines are able to predict and respond to commands. AI’s role in machining is unparalleled, as it is a fundamental technology which brings true innovation in automation and manufacturing. When applied to machining, Artificial Intelligence is fueling impressive potential for groundbreaking new developments and innovations in industrial automation, predictive analytics and Machine Learning. While human input is still needed in machining processes and operations, AI gains a vital role, as it provides real-time data and analytics. When these large amounts of data are further processed and analyzed with AI, new insights on machine performance and function are provided. Once these insights are analyzed by Machine Learning algorithms, the responsible teams are provided with valuable insights on performance improvement. As CNC machines are operated by advanced software, it is possible to upgrade the existing software with software with AI capabilities. For manufacturers this means that no heavy investments are needed to take advantage of the supreme benefits of leveraging AI in machining.
The role of AI in machining is crucial, given the numerous benefits of the integration of AI in CNC machines.
One of the most significant benefits is the enhanced precision and accuracy in manufacturing. With AI, machines are able to learn, detect abnormalities in production processes and operations, provide real-time data on potential failures and deviations and even self-regulate to maintain optimal accuracy and faulty-free performance while in production. This leads to greater control on the quality of the manufacturing procedures and the produced materials.
Additionally, when powered with AI, productivity and efficacy of CNC machines is boosted. The real-time data collected from the machines is analyzed by the AI and when needed, AI can recommend particular enhancements and changes to the machine operators, in order to maintain high-quality production, as well as to boost and improve effectiveness and the real-time output of the machines.
Further, when Machine Learning is also utilized along with AI in CNC machines, the performance of the machines is raised to a new level. Machine Learning enables machines to learn on-the-go in real-time production environment and to respond to custom commands. This is particularly valuable for non-interrupted production cycle, as machine operators are provided with useful insights on the performance of machines while they are in production. Such insights are then administered by the operators, in order to perform changes and enhancements to machines, if needed, aiming to improve CNC machine performance over time. This is particularly valuable for manufacturing businesses to undertake a strategy of data-driven decision making. Embracing such business tactics makes it possible to improve sustainability, risk management and business resilience.
Moreover, AI in machining fuels a cost-saving preventive maintenance approach. AI is capable of predicting when machines will need servicing and maintenance, which enables manufacturers to embrace a powerful cost reduction strategy of preventive maintenance. Such strategy allows necessary maintenance procedures to take place out of the regular servicing schedule, which saves production costs and prevents downtime of machines in production.
Another great benefit of leveraging AI in machining is its ability to restructure and modernize operations. AI is capable of a radical transformation of the work with CNC machines in manufacturing. Artificial Intelligence enables many other innovative technologies to be incorporated in the machines, which unlocks a wide range of new opportunities of machine operation and handling. Machines can be controlled with AI, using custom commands and patterns.
Besides, AI is a powerful ally in the process of robotic automation. RPA is already being widely adopted in many industrial environments. With AI, robots are able to learn, adapt and improve while in production, which provides greater control on risk management. When AI is combined with robotics in manufacturing, robots learn to handle exceptions, errors and unforeseen scenarios, while handling a growing and varying, based on production needs, set of tasks.
Without any doubt, one of the revolutionary benefits of AI in machining is its role in the fundamental transformation of the process of manufacturing custom elements, parts and modules. Artificial Intelligence enables machines to produce excellent quality components with minimal deviations and failures and with enhanced accuracy and equality in the produced materials.
How robotics is changing the machine shop
Some examples of the mass adoption of robotics in manufacturing are: smart factory robotics, robots for industrial site safety, robots for process automation, robots for monitoring and control, robots for logistics, robots for material handling, robots for processing operations, assembly robots, inspection and quality control robots.
The unprecedented boom of revolutionary developments and innovations in all industry sectors is essentially unleashed thanks to the rise and firm growth and wide application of Artificial Intelligence. The manufacturing industry is being affected by rapid transformations and improvements and this is especially evident in machining in manufacturing. The future of machining is strongly centered around robotics and AI. Robots and AI are paving the way for the future of machining. One aspect of this swift shift is evident in the way robotics are used in machine shops.
The recent industry disruptions have imminent effects — there is an evident rise in the demand for larger assortment of products and functionalities. Manufacturers of machinery and machine shops are being overwhelmed by the growing demand for custom modules, parts and elements. At the same time, manufacturers are required to be versatile, efficient, adaptable and swift. The characteristics of such ecosystem are the root cause of the need of faster and more efficient industrial manufacturing adaptability and ability to satisfy evolving needs. This is where robotics is seen to usher machine shops using CNC machines.
In the current landscape, industrial robots are required to execute a diverse range of tasks and activities with minimal setup and re-tooling time and efforts. This means that there is a robust need of extremely flexible and multi-purpose robots in machine shops. Additionally, in some sub-sectors of the manufacturing industry, product alterations might be needed daily. To answer these demands and needs, modern manufacturers are deploying automation into machine shops and their manufacturing processes. The demand for robots in machine shops and machinery manufacturing is steadily growing, given that they have become easier to program and operate, and their cost has become more reasonable and affordable.
The types of robots used in machine shops vary based on factors, such as the required set of tasks, level of complexity, size of necessary parts, workspace characteristics, etc. In machine shops, robots are responsible for different activities involved in machine tending, for example inspection and control, parts handling, changing tools, crafting materials, transporting parts and many more. The most commonly used types of robots in machine shops are:
- Cobots (Collaborative robots)
- SCARA robots (Selective Compliance Assembly Robot Arm)
- Cartesian robots
- Articulated robots
Each of these types of robots are responsible for a particular part of the process of manufacturing of machinery and for the operations in machine shops.
Detailed information on the different types of robots used in manufacturing can be found in my article “The Future of Artificial Intelligence for Robotics”.
The key tasks that robotics are used for in manufacturing machine shops are tasks requiring high-volume, often hazardous work, and a great level of repeatability. Some examples of how robots are used in machine shops are:
- Moving elements and parts
- Packaging
- Assembly
- Machine tending
- Cleaning elements and parts
- Welding, painting, grinding, polishing and finishing parts
- Work with metal
- Tracking
- Quality control and quality checks
Additionally, robots in machine shops are able to perform more tasks, given their versatileness, which might require additional automation, programming and engineering.
Challenges of implementation
The steady rate of adoption of AI and robotics for automation in machine shops and manufacturing operations creates an environment of constant development, improvement and evolution of the modern Emerging Technologies. As penetrating innovations, such technological advancements inevitably present new challenges. Such challenges in the field of implementation of robotics and AI are:
- Higher initial investments
- Doubt in the value of implementing robotics and AI
- Uncertainty about the particular needs
- Safety concerns
- Ethical, legal and social concerns
- Interoperability, consistency, compatibility and integration issues with industrial robots and industrial automation
- Resistance from staff; fear of making humans redundant; not understanding the advantages of automation and how Robotics can be used to help employees and business operations
- Lack of knowledge and training; lack of skills for integration and management
- Employees not understanding how Robotics can be used to assist them in the best possible way
- Managerial lack of knowledge and experience; organizational difficulty to understand how to best incorporate Robotics, given the specific business requirements and the existing organization of processes and workflow
Facing certain challenges is expected when choosing to innovate and modernize, however, if these challenges are addressed cautiously and thoughtfully, with a clear strategy, the rewards for businesses are substantial.
Benefits of implementing AI and robotics in a machine shop
The demand for the implementation of AI and robotics in all industry segments is steadily growing, given that robots have become easier to program and operate, and their cost has become more reasonable and affordable. The robotics market is presently at a rapidly expanding rate and is forecasted to keep within this trend, given the intensified demand and growing investments in most industrial sectors. Numerous companies and corporations are relying on solid investments in automation, robotics, Artificial Intelligence and other Emerging Technologies. Autonomous systems are being widely adopted and integrated in many industries, with the strongest growth in manufacturing. Such automations allow enhanced quality of production, products and processes and increase and improve productivity and performance. Other advantages from the increasingly adopted industrial automation are significant cost savings, facilitated operational management and improved risk-mitigation.
Robotics and AI in machine shops are in high demand and their application and adoption is growing significantly. This trend will continue firmly, given the numerous advantages and benefits from adopting robotics, AI, and automation for manufacturing of machinery and in machine shops. Some of these benefits include improved workplace safety, better organization, streamlined operations and processes, increased productivity and efficiency, improved accuracy, precision and greater quality insurance, cost optimization, focus on employee wellbeing and facilitation of employees’ duties and daily work.
Other important benefits of implementing AI and robotics in a machine shop include:
- Cost savings and ROI
- Continuous production
- Versatility of robots and their ability to multitask
- Mobility and adaptability
- Utilization of data
- Configuration and programming options
- Custom machining
- Continuous integration with other digital technologies
- Precision engineering
- Driving and powering further innovation
More insights on the latest trends and innovations in manufacturing can be found in my article “Robotics Trends in Industry and Manufacturing”.
Conclusion
Businesses, which stay behind in the race for adoption of robotics, AI and automation in manufacturing are expected to face challenges, to be incapable of remaining competitive, to be unable to fulfill the requirements of the market and to meet the needs of the customers. Eventually, such businesses will be pushed out of the market by competitors, which have managed to keep up with the industrial modernization trend.
The future of machining is centered on the implementation of AI and robotics in machine shops. Manufacturers of machinery rely on the most innovative software solutions to unleash the full potential of automating machine shops with robotics and AI. DELMIA is a pioneering suite of machining software applications which has the power to unlock the full potential and automation capabilities of CNC machines. The single integrated CAM & CAD software environment facilitates programming, simulation, and optimization of machining processes. DELMIA Machining and Fabrication solution is the ultimate integrated platform for optimizing manufacturing processes, reducing costs in the long-term, minimizing delays and errors, improving programmer and machine productivity and optimizing resources, thus aiding in sustainability.
Businesses are choosing DELMIA Machining and Fabrication to gain unparalleled advantage in optimizing machining and additive manufacturing.
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