Cognitive Manufacturing

The WCM 4.0 Cognitive Manufacturing Delta Model

There's a groundbreaking transformation happening that is redefining how we conceptualize and execute production processes. WCM 4.0, a convergence of world-class manufacturing (WCM) and the Fourth Industrial Revolution Technology, where cognitive technologies take center stage. This innovative fusion is propelling manufacturers toward extreme levels of productivity and customization while reducing operational costs and accelerating time-to-market. This article delves into the realm of cognitive manufacturing, its components, and the myriad benefits it offers to the world of manufacturing.

The Convergence of WCM and Cognitive Systems

WCM 4.0 represents the fusion of World-Class Manufacturing principles with cognitive systems, opening up new possibilities for achieving unprecedented levels of productivity and customization. This paradigm shift leverages cognitive technologies to enable data synthesis and analysis, creating a manufacturing environment that supports end-to-end visibility – from product development to the finished product. This, in turn, yields actionable insights across the entire value chain, resulting in reduced operational expenditures, improved equipment health, and accelerated time-to-market.

Empowering World-Class Manufacturers

Cognitive systems empower world-class manufacturers to pursue their primary objectives of zero waste, zero accidents, and zero downtimes. By automating routine tasks, cognitive manufacturing places humans at the center of an integrated manufacturing platform. The influx of data and analytics in cognitive systems has led to innovations in machines, processes, products, and operations.

Three Levels of Cognitive Architecture

Cognitive systems are characterized by three distinct levels of cognitive architecture:

1. Point of Contact Level: This level is characterized by local activities and connection to the physical environment through technologies like Programmable Logic Controllers (PLC), Supervisory Control and Data Acquisition (SCADA), Distributed Control Systems (DCS), and Open Process Control (OPC).

2. Edge Level: The edge level brings the computing framework close to the data source using the industrial internet of things and local computing. It translates first-level signals into data visible to the cognitive model.

3. Enterprise Level: At the enterprise level, various structural elements of WCM, such as 6S, Group activities, Visual management, Focused Improvement, Autonomous Maintenance, Planned Maintenance, and more are deployed. Some of these applications may require local installations on the shop floor.

Benefits of Cognitive Manufacturing

WCM 4.0's cognitive manufacturing approach offers a range of benefits, including:

• Improved Fundamental Objectives: Enhancements in production output, reliability, versatility, quality, safety, and yield, with reduced downtime and costs.

• Heightened Visibility: Improved visibility, performance, product life cycles, planning, and asset health.

• Precision and Optimization: Real-time, complex decision-making and autonomous learning, sensing, adaptation, and control.

• Quality and Efficiency: Creation of an intelligent production line environment, resulting in quality, reliability, flexibility, efficiency, and eco-friendly manufacturing.

• Reliability and Performance Management: Enhanced reliability and performance management, process and quality improvement, and resource and supply chain optimization.

Cognitive Manufacturing and Manufacturing Processes

Analytical Prowess

Cognitive manufacturing harnesses the immense power of data analysis. It excels at recognizing patterns within manufacturing data, revealing normal and abnormal equipment behaviors, and predicting potential equipment failures, product quality issues, and safety hazards.

Rapid Response and Efficiency

The true prowess of cognitive manufacturing is unveiled in its ability to respond swiftly to potential issues. This involves taking immediate action to prevent costly downtime, while also enhancing product quality, increasing throughput, and promoting cost-effective processes.

Quality Maintenance Pillar

One of the most significant impacts of cognitive manufacturing is the reduction in reliance on manual inspections. It enables faster and more accurate defect detection, all the while providing real-time alerts and facilitating decision-making. This transformation improves the quality maintenance pillar, making it more agile and precise.

Advanced Technologies

Cognitive manufacturing leverages advanced technologies such as computer vision and acoustic insights. These technologies play a pivotal role in early detection of equipment degradation and safety hazards. They also enable prescriptive analysis for the optimization of equipment and product management. All of these contributions lead to a substantial enhancement of Overall Equipment Effectiveness (OEE) and Overall Process Efficiency (OPE).

Empowering People through Cognitive Manufacturing

Overall Leadership Excellence (OLE)

Cognitive manufacturing is not just about machines; it's also about empowering people. It significantly enhances Overall Leadership Excellence (OLE) by providing humans with real-time information. Moreover, cognitive systems sometimes act as valuable human assistants, supporting operations across various WCM structural elements.

Collaborative Robots (Cobots)

Cognitive manufacturing has witnessed the ascent of collaborative robots, or "cobots." These intelligent machines are increasingly integrated into manufacturing environments, playing pivotal roles in areas such as warehousing, personnel training, hazardous work zones, and surveillance. Cobots excel in autonomously performing repetitive tasks, such as material movement, streamlining fulfillment and delivery processes.

Bridging the Gap

Cognitive manufacturing acts as a bridge between humans and machines, fostering collaboration and harmony. This technology empowers foundational WCM elements, including the 6S principles (Safety, Sort, Shine, Set-in-place, Standardize, and Systemize), group activities, and visual management. The result is a manufacturing environment where human workers and machines coexist seamlessly.

Equipment Optimization and Intelligent Machines

Integration of Cognitive Technologies

Cognitive sensors, transducers, and actuators are seamlessly integrated with manufacturing equipment, giving rise to a new generation of intelligent machines. These machines are equipped with cognitive models, enabling them to operate beyond traditional programmable logic controllers and distributed control systems.

Reactive, Proactive, and Social Machines

Cognitive technologies empower equipment to be reactive, capable of sensing and responding to their environment, proactive in anticipating future conditions and guiding their actions accordingly, and social in sharing information with other humans and machines. This paradigm shift in equipment functionality enhances production capability, flexibility, and customization, paving the way for a transition from traditional batch production to a customer-centric system.

Elevating Production Capability and Customization

Cognitive manufacturing in Equipment optimization enhances production capability, facilitating increased efficiency and adaptability. The system allows rapid adjustments, resulting in higher production output and maintains quality. Moreover, it offers greater flexibility and customization, tailoring products to customer needs, departing from traditional batch production in favor of a customer-centric approach.

The transformative potential of cognitive manufacturing within the WCM 4.0 framework is evident. It enhances manufacturing processes, empowers individuals, and optimizes equipment, leading to increased efficiency and competitiveness. As the manufacturing landscape continues to evolve, the adoption of cognitive manufacturing becomes not just a choice but a strategic necessity for staying ahead in an ever-competitive market.