Smart factory transformations in manufacturing

Throughout 2023, smart manufacturing technologies, such as digital twins, 3D modelling, and IoT, were used to strengthen the metaverse. In 2024, Deloitte anticipates that these technologies will be used to ‘scale manufacturing improvements across disparate processes and people’, as well as in their decarbonisation journeys. While the sector hopes that 2024 will be a much…

Throughout 2023, smart manufacturing technologies, such as digital twins, 3D modelling, and IoT, were used to strengthen the metaverse.

In 2024, Deloitte anticipates that these technologies will be used to ‘scale manufacturing improvements across disparate processes and people’, as well as in their decarbonisation journeys.

While the sector hopes that 2024 will be a much easier year than the last few, gritty realism leaves the industry planning for the worst. Continued supply chain unpredictability, geopolitical uncertainty and rising costs will mean that smart factory technologies such as AI, 5G, IoT, data analytics and cloud computing will be utilised to help provide real-time insights and end-to-end visibility.

Smart factory transformations in 2024 across manufacturing

Tim Gaus, Principal at Deloitte Consulting LLP, feels that Deloitte’s 2024 Manufacturing Outlook puts smart factory transformations at the centre of what will define the industry over the next year.

“Manufacturing leaders continue making strides in their smart manufacturing transformations. In 2024, we foresee the boom of generative AI, the scaling of smart manufacturing technologies that were experimented with over the past few years – the metaverse, machine learning, vision analytics and others. They will have a core focus on creating a data model that enables scalability as the biggest trends towards making manufacturing processes more efficient and integrated. Through these technology and process enhancements, manufacturers can anticipate a new scale of innovation in 2024, as the industry moves from being simply resilient to being truly agile.”

Digital twins in smart manufacturing

Digital twins have gained attention in manufacturing since advancements in computing, modelling & IoT have made digital twin technology accessible The term “digital twin” has gained significant attention among manufacturers and industrial companies in recent years, but its meaning can vary. Organisations from Ford to Airbus have adopted digital twins to strengthen their operations and…

Digital twins have gained attention in manufacturing since advancements in computing, modelling & IoT have made digital twin technology accessible

The term “digital twin” has gained significant attention among manufacturers and industrial companies in recent years, but its meaning can vary.

Organisations from Ford to Airbus have adopted digital twins to strengthen their operations and business value for customers. Michael Grieves of the Digital Twin Institute and NASA’s John Vickers are credited with popularising the core ideas and coining the term “digital twin” in 2010. This technology encompasses more than just virtual models and has become feasible due to advancements in computing, modelling techniques, and IoT connectivity since 2020.

How Digital Twins are making manufacturing smarter

Digital twins are used in smart manufacturing to provide real-time monitoring, optimisation, and simulation of manufacturing processes, for example:

Process monitoring

Digital twins create virtual representations of manufacturing equipment and processes, allowing real-time monitoring of their performance, which can help to identify any problems.

Predictive maintenance

The same method allows manufacturers to predict maintenance needs and prevent unplanned downtime.

Supply Chain optimisation

What kind of manufacturer, in 2023, would not want to utilise all supply chain visibility gear available?

Digital twins can be applied across a manufacturer’s whole supply chain, to track products and materials. This offers better coordination and improved logistics.

Digital twins in the Metaverse

The metaverse, a virtual collective space where individuals can interact with each other and digital objects in a shared virtual reality environment (for example, through the use of AR technology).

The metaverse is a place for virtual interaction, while a digital twin is a virtual representation of a physical thing. They both involve virtual representations, but serve different purposes – usually.

Digital twins can play a role in the metaverse by providing virtual representations of physical objects or systems within the virtual environment:

Virtual product representation

Digital twins can serve as virtual replicas of physical products, allowing users in the metaverse to explore and interact with them in a realistic manner, which enables customisation.

Simulation

Digital twins within the metaverse can be used for training purposes. In industries like manufacturing or aviation, users can engage with digital twins to practise maintenance procedures and emergency response protocols.

Analytics

Digital twins integrated into the metaverse can offer real-time data on the performance of physical objects, which can be used for making informed decisions within the virtual environment.

How remote assistance technology can transform manufacturing

Manufacturing Digital speaks with Niclas Elvgren, Head of Imint’s Professional Solutions Business Unit on the role of remote assistance in manufacturing In this interview with Manufacturing Digital, Niclas Elvgren, Head of the Professional Solutions Business Unit at Swedish software company Imint, speaks about his career journey, the company’s offerings and the role of remote assistance devices in…

Manufacturing Digital speaks with Niclas Elvgren, Head of Imint’s Professional Solutions Business Unit on the role of remote assistance in manufacturing

In this interview with Manufacturing Digital, Niclas Elvgren, Head of the Professional Solutions Business Unit at Swedish software company Imint, speaks about his career journey, the company’s offerings and the role of remote assistance devices in the manufacturing sector.

Please introduce yourself and your role.

“My name is Niclas Elvgren and I am the head of the professional solutions business unit at Imint, which includes our remote assistance technologies unit. I have been with the company for seven years, taking part in our journey of introducing new products, leading our entrance into the remote assistance category and expanding our offerings into new applications and markets.”

What led you to this industry?

“When I started at Imint seven years ago, we were targeting the top smartphone vendors of the world. After establishing strong relationships with most of the big Android-based brands, we started broadening our perspective. It was then natural to expand our focus to the remote assistance market, since it was rapidly growing and we saw great potential in leveraging our expertise and fine-tuning our products to fit this segment. My background running our customer service team and managing all presales at the time gave me the experience needed to help Vidhance evolve and address new areas of video usage.”

What is Imint?

“Founded in 2007, Imint is a listed Swedish software company with world-leading expertise in real-time video stabilisation and enhancement based on motion sensor data analysis. Imint’s Vidhance suite of video enhancement solutions is the culmination of 15 years of R&D and has to date been integrated into more than 850 million camera devices, across consumer and industrial markets.”

What is Vidhance for Remote Assistance?

“Vidhance for Remote Assistance is a new suite of tools designed to transform the quality of video content captured by remote assistance devices used in the manufacturing industry. It consists of the Vidhance Premium Video Stabilization feature and Vidhance Click & Lock feature.

“The Vidhance Premium Video Stabilization feature efficiently eliminates shakiness by keeping the frame stable and the horizon level for video captured on handheld, head-mounted or body-worn cameras, while also correcting for lens distortions.

“In addition to stabilising and levelling the video stream, the Vidhance for Remote Assistance solution also provides remote viewers direct control over the video’s focus point through the all-new Vidhance Click & Lock feature. With a simple click, remote viewers can select an object on the live feed to lock onto it as the camera’s focus point, using automatic tracking and zooming to centre the object regardless of how it or the camera wearer moves.

“Vidhance for Remote Assistance is offered through a subscription model where solution providers that integrate the software suite can provide a free trial period for users, then offer a monthly or annual subscription for full-time adoption.”

How has COVID-19 impacted the manufacturing sector?

“Clearly, the pandemic fueled a major increase in the use of remote assistance technology, simply because it became a necessity in order to maintain operations when travelling was not possible. The ability to support manufacturing plants remotely significantly reduced the impact of COVID-19 in those environments. Had the pandemic come 10 years earlier, when remote assistance technology was not readily available, the situation could have been very different.

“The onset of the pandemic sped up the adoption and development of remote assistance solutions, but the trend has flattened out since. In order to continue the growth of remote assistance adoption, we must address one of its biggest challenges, which is to make it easier and more natural to use. This is a challenge we are certain the Vidhance for Remote Assistance suite will help solve.”

Why have remote assistance devices struggled to gain widespread adoption in manufacturing?

“Remote assistance is still in the early phase of its evolution within the complex manufacturing ecosystem. To successfully deploy a remote assistance solution,  manufacturers need a camera device, a video communication platform and video monitoring software, often provided by different suppliers. All three have an impact on the video quality, and the inherent challenge of maintaining stable video feeds from cameras constantly in motion is rarely addressed. In fast-paced manufacturing scenarios, particularly ones involving equipment troubleshooting and complex repairs, on-site workers are constantly making head movements unconsciously.

“This isn’t a problem for on-site workers – as their eyes can quickly adjust to see exactly what they want to see. That said, the video quality for remote manufacturing experts viewing the feeds has, to date, been far from a real life experience. Feeds from body-worn cameras can appear shaky or dark to remote viewers, greatly reducing their effectiveness and even causing viewers to experience motion sickness.

“Some organisations and remote assistance solutions have attempted to integrate stabilised hand-held smartphone or tablet cameras as the primary video input device, but they have a major inherent flaw – they require the on-site user to hold the device the entire time, leaving them with only one free hand.

“While video stabilisation is a common feature in smartphones, it can’t safely be mounted for hands-free use in challenging environments, and it’s typically limited to the device maker’s camera app, making it unavailable for third-party apps used to stream live video for remote assistance like Teams and Zoom.

“Head-worn cameras and smart glass device manufacturers are now beginning to implement video stabilisation that is always active – even in live video scenarios. The tuning differs from that of smartphones, as the primary goal is not artistic video creation, but rather ensuring a clear and steady video stream for remote experts.”

How can imminent technology breakthroughs change that?

“Breakthroughs like Vidhance for Remote Assistance eliminate shaky video in real time, thus offering the remote viewer improved working conditions and better chances to provide accurate support.

“The software achieves this feat by leveraging data from the camera’s motion sensors to calculate the optimal stabilisation frame-by-frame – a robust and efficient method that has been battle-proven in millions of smartphones powered by Imint to date.

“In addition, the Vidhance Click & Lock feature gives the remote viewer control of the video and the ability to zoom, focus and lock the video on an object of interest with a simple click.”

Does the future of manufacturing rely on remote assistance?

“As manufacturing continues to evolve, remote assistance will serve as an invaluable link connecting on-site workers with off-site experts as it enables instant communication in demanding and high-stress manufacturing environments. We believe that remote assistance devices are indispensable for real-time collaboration among field workers and experts in the manufacturing industry and anticipate that deployment of these technologies will be widespread in the coming years.”

Why is now the time for manufacturers to invest in these devices?

“As we witness the growing adoption of remote assistance devices in manufacturing and other industries, fostering a collaborative ecosystem becomes increasingly important. By providing access to advanced technologies and embracing flexible subscription models, manufacturers and developers can ensure that these devices stay current and remain equipped with the latest features, driving further improvements in manufacturing efficiency and safety.”