The pace of technological change in the manufacturing sector has meant that processes on the factory floor are looking very different to how they did even 10 years ago. The evolution of Industry 4.0, otherwise known as the Fourth Industrial Revolution, is now in full swing, as more manufacturers look to harness opportunities such as digital twin solutions.
Additionally, emerging technologies such as artificial intelligence (AI), robotics and automation are beginning to take centre stage, while sustainability is now a much more significant driving force behind manufacturing processes.
These developments are placing 2D solutions, such as Excel spreadsheets, under the spotlight, which have been traditionally used to inform manufacturing processes. These applications are now failing to provide the insight needed for organisations to plan ahead and identify and reduce mistakes.
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Research undertaken by Visual Components of UK decision makers in the manufacturing industry discovered that the average cost of general mistakes and/or associated downtime totalled almost £98,000, while 30% of errors made in implementing robotics or automation were due to focussing on the wrong area or process.
It’s little surprise therefore that the combination of these factors are pushing 3D simulation software’s capabilities into the mainstream.
AI and Industry 4.0
Further findings in the research by Visual Components discovered that 24% of respondents identified artificial intelligence (AI) as the most important to build or redesign the factories of the future, which has numerous applications in areas such as robotics and automation. As Industry 4.0 advances, manual processes are typically making way for more efficient automated technologies.
However, without an effective way of testing certain pathways or movements, manufacturers are unable to identify areas of inefficiency and where costs are being wasted. It could be a process as simple as a robot with insufficient reach to complete a basic task due to an inaccurate design. Robust 3D simulation software allows for manufacturers to test robotic movements and how these machines interact with humans or even other equipment.
Adopting a trial-and-error approach in the safety of a simulated environment is proving critically important as AI, robotics and automated technologies increase in use. 3D simulation software makes the construction of a digital twin possible, which is a dynamic, virtual software-generated representation of corresponding physical assets and processes. In this environment, processes can be refined via an infinite number of mistakes, aiding continuous improvement.
Supporting sustainability
Rapid advances in the world of technology are not the only trends that are re-shaping 3D simulation software’s role in the manufacturing sector. With more than 130 countries globally now committing to reducing carbon emissions to net zero by the middle of the 21st century, organisations are under increasing pressure to play their part in the battle against climate change.
Applying 3D simulation software to sustainable practices allows manufacturers to make improvements in several key areas. By being able to test smaller changes on the shop floor at an early stage, unprecedented efficiency gains in production processes and outputs allow for more sustainable strategies moving forward.
With Visual Components’ research revealing that only an average of 31% of materials in the manufacturing process are currently sustainable, leaner manufacturing methods can be deployed, such as the ability for raw materials to be re-used rather than be disposed of.
Energy can be saved via the ability for floor space to be used in the most efficient way, which can be fully tested within the software. Sustainable practices can also be devised in the wider supply chain by applying simulation software to these operations and then applying the same principles to the real environment.
Another application in the sustainable space for 3D simulation software is the ability for proposed factory layouts to be presented virtually to colleagues or clients as opposed to in-person, playing a crucial role in reduction of car or air travel and its associated carbon emissions. Professionals also then benefit from the fact that workflows are a more persuasive tool than charts or spreadsheets.
The must-have tool
3D platforms were previously shackled by being expensive solutions that only specialists within a business could use. Now, easily accessible, plug-and-play component-based simulation software enables any professional within a small or medium sized enterprise to create a simulated layout. Small edits can be made without having to start the project over again from scratch.
Additionally, 3D simulation platforms are now even more of a necessity due to their ability for layouts to be devised within weeks or even days compared to the previously typical month-long timeframe to reach the end goal.
3D simulation software is now a business necessity due to its driving role within Industry 4.0, emerging supporting technologies and the drive towards sustainability. Alongside this, accessibility to the right software has significantly eased, particularly due to the ease-of-use of modern solutions and a new generation of skilled workers who have already used the software at university level before joining the industry. Adopting this software is a natural progression and one that manufacturers must take to empower their operations and maintain competitive advantage.
