Moving into 2024 with Tempered Optimism

Summary

Introduction

As we look back on 2023 in preparation for 2024, we can finally breathe a sigh of relief. 2022 and the first half of this year has been difficult for every point in the supply chain. We are now beginning to see an easing of normal stated factory lead times. Inventory across the channel is increasing and finally coming back into a state of normalcy. Over the past year and a half, it wasn’t uncommon to hear lead times on drives, PLCs, HMIs and other advanced products to be well over 52 weeks. As a result, we’re looking with a degree of optimism in 2024 for industrial automation across the industry. To that point, here are some trends I see continuing into 2024.

Smart manufacturing

Smart, sustainable manufacturing will continue to lead the conversation in industrial automation. When we look at the world’s total energy consumption, we see manufacturing representing a large percentage of our total energy resources. Manufacturers are in a difficult but unique position that comes with a huge opportunity. Consumers now more than ever demand high-quality, sustainable products manufactured through smart and sustainable practices. As manufacturers look to be more competitive in getting goods in the hands of these consumers, environmental stewardship is more important than ever before. To add to the complexity, manufacturers continue to face a labor shortage epidemic. In order to meet the demands of the consumer, manufacturers need to be more nimble, more efficient in their processes and constantly looking to improve. We see manufacturers doing this through the use of solar powered microgrids, carbon capture projects, asset monitoring, the use of AI and cloud computing and many other technologies to meet net-zero goals.

Asset monitoring

Asset monitoring is one of the easiest, most effective ways to introduce automation on the factory floor. Manufacturers today, whether they are just beginning their journey into automation or have a state of the art, fully automated factory, need to maintain their equipment. This is by no means a new problem. Manufacturers need to protect their assets and minimize downtime. In the past, this meant scheduled maintenance plans that meant taking production lines offline to maintain compressors, tooling machines, motors, etc. Today, we can do it all with the ease of a tablet. The integration of IIoT onto the factory floor has enabled manufacturers to communicate with their assets in real time. If a motor is vibrating out of spec, they can address it immediately reducing downtimes, costly repairs or replacements and still maintain production levels. This also helps in reducing energy consumption greatly. The introduction of 5G has made asset monitoring even more achievable. By adding a wireless component with reliable, high-speed, machine to machine communication, manufacturers can monitor every machine on the floor without the need to run more wire into sometimes very difficult to reach locations. The end result is the ability to take older factories and bring them into Industry 4.0.

Artificial Intelligence (AI)

The introduction of AI has really taken the entire world by storm. It’s all around us. It has now made its way into industrial automation. We are seeing it being utilized to program PLCs, robotics, make accurate forecasts on production scheduling and much more. Over the past couple of years, we have been seeing digital twin becoming more and more utilized across factory floors. Digital twin gives the manufacturer the ability to accurately view their entire floor in a simulated environment. This allows the manufacturer to see how changes in programming, would affect real world production. It also reduces design cycle time, testing and improves outcome. Adding AI can enhance the accuracy and realism of digital twins by using computer vision, machine learning and deep learning to analyze data from sensors, cameras and other sources. AI can also generate realistic 3D models of physical objects and environments using generative adversarial networks (GANs) and other techniques. It can enable digital twins to run simulations and scenarios to optimize performance, efficiency and sustainability. AI can also help digital twins to learn from their own experiences and adapt to changing conditions, along withproviding insights and recommendations based on the data and outcomes of the simulations.

Robotics

The next trend we will continue to see in 2024 and beyond are robotics. AMRs (autonomous mobile robots), cobots (collaborative robots) and AGVs (automated guided vehicles) will all continue to grow in popularity. AMRs provide the ability to work around tight spaces in manufacturing environments where toxic chemicals and heavy machinery are present. Utilizing sensors, AI and machine vision, AMRs are capable of navigating surroundings accurately and completely independent of human control. AGVs are a fantastic solution for material handling in warehouses and distribution facilities. They move on pre-programmed paths through software programming and the use of sensors such as LiDAR. AGVs are designed to handle tasks such as moving pallets or removing trash. Cobots have been around for some time now. These robots are designed to work in the presence of their human counterparts. They handle menial and even dangerous tasks to free up the human to work on more complicated tasks. Cobots are designed with an array of sensors to detect the presence of obstacles or workers. Utilizing laser scanners, the cobot will reduce speed by predetermined zones to ensure the worker’s safety.

Immersive technology

Another trend that is growing in popularity is immersive technology in industrial automation. The use of augmented reality (AR) to help workers throughout the manufacturing process and even in the MRO space. I personally attended an expo last year where I was able to witness how an electrician utilized AR to diagnose a problem in a cabinet and make the repair. The AR provided the electrician a step-by-step process and enabled them to get the cabinet back up and running in a very short amount of time. It was quite impressive. Immersive technology is also being used in other ways. Virtual reality (VR) can be utilized for training employees in factory operations and maintenance skills. This helps to reduce time to competency and transfer a high level of skill, factory knowledge and situational awareness.

Reshoring manufacturing

Manufacturers continue to look to be more competitive while controlling quality and creating more sustainable processes. As a result, there is a trend in manufacturing reshoring to North America and Europe. The threat of intellectual property theft, geopolitical threats and environmental destruction are also considerations for the move. To be competitive, manufacturers look to automation as a means to meet demand. The US recently passed the CHIPS Act. This is a long-term project to bring back semiconductor manufacturing and research to the US as means to protect national security and make the US more competitive in this space. However, semiconductors aren’t the only industry making the change. We see a shift in everything from pharmaceuticals to household appliances. This means more higher-quality jobs in higher-cost labor markets. To achieve a balance, automated processes are implemented to ensure production quotas are met while maintaining a higher-quality product.

Conclusion

2022 and 2023 have been difficult years. We see economic pressures such as high inflation, high energy prices and a tattered supply chain. Looking ahead into 2024, there appears to be a light at the end of the tunnel as we move toward normalcy once again. Industrial automation is a rapidly evolving field that leverages various technologies to improve the efficiency, productivity and quality of industrial processes. To recap, we will see continued efforts to move toward smart manufacturing, increased adoption of IoT enabled asset monitoring technologies, the use of AI in digital twin, robotics, immersive technologies and a concerted effort to reshore manufacturing. These trends indicate that industrial automation will continue to grow and innovate in 2024, driven by the convergence of IoT, edge computing, AI, ML and 5G. These technologies will enable industrial companies to achieve higher levels of performance, efficiency and competitiveness in the global market.

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