Redefining Manufacturing with Human-Machine Synergy

Last week, I participated in a manufacturing event where we explored various topics. However, industrial automation, including Operational Technology (OT) and the role of AI/ML, emerged as the primary focus for most participants, such as CIOs, business strategists, and supply chain leaders.

The shift from Industry 4.0 to 5.0 marks a deeper collaboration between humans and machines, emphasizing personalization and sustainability while maintaining the vital role of human involvement. OT (Operational Technology) plays a critical role in this evolution, supporting diverse manufacturing sectors—such as automotive, chemical, and FMCG—by enhancing quality inspections, detecting defects, and improving overall efficiency to achieve zero-defect products.

A robust OT platform closes the loop in the AI workflow through several key components:

1. Data Acquisition – Utilising cameras and sensors for data collection.
2. AI Model Development – Encompasses three main steps: Annotation: Verifying and disputing data. Training and retraining models. Deployment of models. (These can be deployed on the edge or in the cloud, whether public or private, based on specific needs.)
3. Auditing – Regular assessments to ensure process accuracy.
4. Monitoring – Continuous verification and dispute resolution, creating an ongoing feedback loop.

Once models are trained and implemented, the entire process gradually becomes automated. This is achieved through continuous training and retraining tailored to the organization requirements. Such automation enables capabilities like AI-driven inspection of product configurations and cosmetic defects or the implementation of various levels of Quality Assurance (QA) automation. It can also extend to supply chain automation, further optimising manufacturing processes.

As I’ve emphasised in my earlier blogs, successful deployment of these technologies demands extensive team collaboration, patience, clear objectives for initial use cases, and, crucially, a strong OT platform with strong AIML capabilities.

Ultimately, the benefits of deploying OT in the manufacturing industry far outweigh the initial efforts and costs. These technologies not only promise significant growth for individual companies but also drive progress across the entire sector and, by extension, the economy as a whole.