5 Remarkable Applications of AI in Manufacturing Industry

The manufacturing industry is one of the enduring pillars of global economies, and its products form the very backbone of the modern world. From the cars we drive to the smartphones we rely on, virtually every aspect of our daily lives is intertwined with the outputs of this sector. However, the journey from raw materials to finished goods is not without its share of complexities and challenges.

The manufacturing industry confronts a multitude of issues that necessitate innovative solutions. These include maintaining consistent product quality, optimizing operational efficiency, managing rising production costs, ensuring stringent safety compliance, and meeting the increasingly urgent call for sustainability practices. It is within this intricate landscape that Artificial Intelligence (AI) has emerged as a transformative force, offering ingenious solutions to tackle these challenges head-on. With the world moving towards technology based solution, it is time to revolutionise the industry by using AI in manufacturing industry

In this blog, we aim at exploring five remarkable applications of AI powered safety monitoring in manufacturing industry, examining not only how these technologies are revolutionizing the industry but also shining a spotlight on their impact.

Before diving into the applications of AI, it's vital to grasp the complex hurdles that manufacturers face on a daily basis:

• Quality Control: It is paramount for the manufactures to ensure that high-quality products are been delivered constantly. Even the slightest variations in production processes can lead to defects, rejections, and increased operational costs. Thus, quality control stands as the topmost challenge being faced by the manufacturers.

• Operational Efficiency: Staying competitive in a global market demands optimization of manufacturing processes, reduction of downtime, and minimization of energy consumption. Thus, achieving operational efficiency is another hurdle for the manufacturers.

• Cost Management: The spectre of rising production costs, including those related to labour and raw materials, looms large, threatening profit margins and economic viability.

• Safety Compliance: The manufacturing sector faces a wide range of safety risks ranging from falls and fire and explosions to machine-related injuries and forklift/ power jack/ lift truck/ reach truck collision.

• Productivity Issues: Lower rates of productivity has been a growing challenge for manufacturing industries worldwide. There are several causes at the backdrop of this dropped productivity like equipment failure, defects in product, theft & security challenges, poor inventory management and so on. Mitigating these inherent issues is crucial to increase productivity in the manufacturing plants.

In the ever-evolving landscape of manufacturing, where precision, efficiency, and quality are paramount, Artificial Intelligence (AI) has emerged as the ultimate ally. From the shop floors of large industrial plants to the assembly lines of smaller manufacturers, the use of AI powered video analytics is orchestrating a technological revolution.

In this regard, viAct is emerging as a standout player, pioneering in providing tailored AI solutions for the manufacturing sector. viAct harnesses the power of AI & video analytics to address critical aspects of manufacturing, including safety, security, and operational efficiency. Its innovative AI-powered video surveillance system (VSS) is designed to elevate the industry's standards by identifying safety hazards, monitoring equipment health, and detecting anomalies.

In this section, we'll take a closer look at five remarkable applications of AI in manufacturing industry that are reshaping the manufacturing industry. These cutting-edge AI solutions are not just addressing common industry challenges but also ushering in a new era of smart manufacturing, where data-driven insights and automation hold the key to unparalleled efficiency and competitiveness.

• Quality Control and Defect Detection:

AI powered video analytics through computer vision systems can inspect products with remarkable precision. These systems employ an array of cameras and sensors to capture and meticulously analyze product images in real-time, swiftly identifying defects or anomalies. This transformative technology is a linchpin in ensuring that only products of the highest quality find their way to market, thereby significantly reducing waste and elevating customer satisfaction.

In this context, viAct has harnessed the power of AI video analytics for product quality management in manufacturing plants. With specific scenario-based detections, viAct use of AI in manufacturing industry streamlines and tracks inventory in real-time, all while minimizing manual efforts and potential errors. Furthermore, viAct's AI monitoring solutions exhibit exceptional prowess in detecting non-conformities in finished products, identifying damaged items, spotting anomalies, and providing early detection of defects in products. This extensive repertoire extends to product counting along assembly lines and comprehensive product packaging inspections, collectively bolstering product quality management within the manufacturing industry.

• Inventory Management:

Efficient inventory management is essential for maintaining smooth operations and cost control in manufacturing. AI in manufacturing productivity can optimize inventory levels by predicting demand, monitoring usage patterns, and automatically placing orders when stock is low. This not only reduces carrying costs but also ensures that production lines never run out of essential materials.

In this regard, viAct has harnessed the power of video analytics to revolutionize inventory management. viAct’s use of AI powered monitoring system is well-trained and tested to execute specific scenario-based detections for real-time inventory management. Moreover, viAct's intelligent AI monitoring system can conduct stock counting, automate documentation with OCR scanning, provide round-the-clock access to inventory data, issue alert for understock situations, and manage available storage space seamlessly, thereby streamlining the complexities of inventory management.

• Predictive Maintenance:

AI-driven predictive maintenance is redefining how manufacturers approach equipment upkeep. By scrutinizing historical data and real-time sensor data from machinery, AI algorithms can predict when equipment is likely to fail. AI in manufacturing industry enables proactive maintenance, reducing unplanned downtime and curbing maintenance costs. Notably, Indian companies like Tata Steel have harnessed AI systems for predictive maintenance to enhance equipment reliability and operational efficiency.

In this context, viAct's cutting-edge use of AI in manufacturing maintenance through video analytics excels in Machinery Defect Detection, Machinery Operational Hours Monitoring, Fault Diagnosis in Machines, issuing Machine Non-functioning Alerts, and overseeing Lights-out Manufacturing. These functionalities collectively contribute to the early identification of any potential issues, allowing for timely interventions to prevent minor problems from escalating into major disruptions that could hamper productivity.

• Safety Monitoring:

Safety takes precedence in the realm of manufacturing, and AI assumes a critical role in bolstering safety protocols. The use of AI in manufacturing safety uses systems that possess the capability to continually monitor industrial environments, promptly detecting potential safety hazards or deviations from established safety procedures. Furthermore, these systems can issue immediate alerts, effectively averting accidents and safeguarding the well-being of employees, as well as upholding the integrity of the manufacturing workflow.

viAct's video surveillance system (VSS) excels in identifying safety-related risks such as non-compliance with worker PPE regulations, incidents involving fire and smoke, forklifts collisions, instances of slips, trips, and falls (STFs), unauthorized access, and such others. Additionally, through HAZOP (Hazard and Operability) analysis, viAct's safety inspection system for manufacturing industry identifies potential hazards and operational challenges, helping manufacturers proactively mitigate risks and improve safety standards.

• Housekeeping Management:

AI powered analytics can be employed to optimize housekeeping management within manufacturing facilities. Smart sensors and AI algorithms can track cleanliness levels, identify areas that require attention, and even automate cleaning processes. This not only ensures a safe and pleasant working environment but also improves overall operational efficiency.

viAct has developed and rigorously tested its AI-enabled solution to ensure smooth housekeeping management. Using video analytics, it can identify obstacles in pedestrian and vehicle pathways, detect leaks and spills, identify unattended objects, and even send out alerts for potential pest contaminations – all contributing to improved housekeeping facilities. Moreover, viAct's centralized management platform - viHUB records comprehensive housekeeping insights, including workplace cleaning records and the day-to-day activities of housekeepers. These insights are readily accessible to stakeholders, offering real-time insights and ensuring the effectiveness of housekeeping management.

Apart from these above-mentioned applications, there are yet other applications of AI in manufacturing industry that hold immense potential. Asset management, for instance, involves using AI to track and optimize the utilization of manufacturing equipment, helping companies extend the lifespan of their machinery and reduce operational costs. Fleet management in manufacturing units is another area where AI plays a crucial role, allowing for real-time monitoring of delivery vehicles and optimizing routes for efficiency. Furthermore, AI-driven supply chain optimization can streamline the entire process from raw material procurement to product distribution, ensuring that manufacturers meet customer demands while minimizing costs. These additional applications underscore the versatility and adaptability of AI in addressing the multifaceted challenges faced by the manufacturing industry today.

Thus as reflected from above, this sector is experiencing a profound transformation due to the extraordinary applications of AI in manufacturing industry. From predictive maintenance to quality control and supply chain optimization, this revolution is empowering manufacturers to confront common challenges, enhance operational efficiency, and adhere to stringent safety and sustainability standards. In India and across the globe, AI in manufacturing productivity is taking on a central role in the processes taking place in the manufacturing floor, promising a future marked by enhanced sustainability and heightened competitiveness. As we progress further into this AI-driven era, companies like viAct are leading the charge by crafting solutions through the use of AI -powered analytics to meet the unique demands of the manufacturing industry, propelling its growth and innovation forward.

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