12 ways advanced materials impact world-class manufacturing 4.0

Advanced materials in World Class Manufacturing 4.0

In the ever-evolving landscape of manufacturing, the integration of Advanced Materials (AM) has emerged as a pivotal force, revolutionizing World-Class Manufacturing (WCM) 4.0. AM encompasses novel materials and modifications to existing ones, enhancing critical properties for specific applications. From composites to polymers, ceramics to inter-metallics, and coatings, advanced materials have become the cornerstone for improving the performance metrics of WCM structural elements. Let's delve into the 12 ways through which AM is reshaping the manufacturing paradigm.

#1: 6S - Elevating Workplace Efficiency and Safety

Six Sigma (6S) stands as a proactive methodology, and AM is seamlessly woven into its fabric. Advanced cleaning agents, surface coatings, and Personal Protective Equipment (PPE) are the vanguard. These materials not only bolster cleaning efficiency but also create a sterile and hygienic environment. Advanced coatings serve as shields against dirt and pests, while PPE offers enhanced protection for eyes, face, hands, body, respiratory, and hearing.

#2: Focused Improvement - A Research Hub for AM

The Focused Improvement pillar acts as the R&D nucleus of WCM. It prioritizes losses, scrutinizes data from other structural elements, and unveils the need for advanced physical properties. AM, with its innovative synthesis techniques, addresses these needs, propelling the industry forward.

#3: Autonomous Maintenance - Innovations in Daily Tasks

Daily equipment maintenance, under the Autonomous Maintenance pillar, witnesses the benefits of AM. Hydrophobic coatings prevent corrosion, advanced oils extend servicing periods, and gels enhance bonds between fastening members, preventing unlocking.

#4: Planned Maintenance - Prolonging Product Life

Planned Maintenance, performed on a scheduled basis, finds a valuable ally in AM. The durability and reliability of maintenance consumables, such as bearings, are enhanced, leading to extended product life and reduced maintenance frequencies.

#5: Visual Management - Transparency with Advanced Glass

A visually managed workplace is empowered by AM, particularly through advanced glass. Its integration into components allows for internal equipment inspection, making the workplace self-ordering, self-explaining, self-regulating, and self-improving.

#6: Equipment and Product Management - Extending Life Cycles and Enhancing Quality

In the realms of equipment and product management, AM plays a pivotal role. It extends equipment life cycles and enhances performance. Additive manufacturing of consumable parts reduces spare inventory, leading to superior product quality.

#7: Quality Maintenance - Precision through Miniaturization

The Quality Maintenance pillar, aiming for a zero-defect environment, leverages AM for precision. Miniaturization of sensors improves testing times, and AM enables the sensing of advanced quality metrics not achievable with traditional materials.

#8: Energy and Water Management - Sustainable Practices with AM

The Energy and Water Management pillar adopts AM for sustainability. New materials facilitate clean energy production, storage, and conservation. Lightweight and efficient components reduce energy consumption, while advanced properties open new avenues in water treatment.

#9: Small Group Activities - Collaborative Innovation

The application of advanced materials necessitates collaboration between research, engineering, and production teams. This collaborative approach tackles manufacturing challenges comprehensively, from conception to application, improving overall conditions.

#10: People Development - Fostering Awareness and Expertise

The People Development pillar is instrumental in spreading awareness and knowledge about advanced materials. It ensures a clear vision, essential roles, and effective involvement of individuals within WCM group activities, emphasizing the importance of managerial factors in applying advanced materials.

#11: Safety, Health, and Environment - Mitigating Risks with Rigor

The SHE pillar addresses risks associated with advanced materials through a rigorous risk assessment, mitigation, and elimination framework. Proactively considering opportunities and risks, it sustains a comprehensive approach to safety, health, and environmental concerns.

#12: Cost Management, OEE, and OLE - Maximizing Efficiency and Compliance

AM's inherent characteristics - lighter, stronger, durable, corrosion, and erosion-resistant - translate into longer life cycles and substantial cost savings. AM compensates for operational challenges, improving overall equipment and labor effectiveness. Importantly, it aids manufacturing organizations in complying with regulations without compromising performance.

In the era of World-Class Manufacturing 4.0, the influence of Advanced Materials is not just a trend but a transformative force shaping the future of manufacturing excellence. As we continue to unlock the potential of these materials, the industry stands at the cusp of a new era, where innovation, efficiency, and sustainability converge for a manufacturing renaissance.