Five ways machine learning will transform manufacturing in 2021

SOLUTIONS

MACHINE LEARNING

By Ingo Mierswa

Five ways machine learning will transform manufacturing in 2021

Emerging developments that will become reality with machine learning part of everyday operations

Technology advances, such as complex robotic systems and artificial intelligence (AI), transformed manufacturing over the past decade and driven what’s commonly called the Industry 4.0 Revolution. COVID19 has further accelerated this transformation for many manufacturers as more plant operations need to be run effectively, and in many cases, be monitored and managed remotely. Machine learning (ML) — a branch of artificial intelligence centered around creating computer programs that learn from experience and improve their decision-making ability over time — is increasingly important in many industries, and manufacturing is no exception.

Cheaper sensors and data storage, as well as the maturation of big data technology, has allowed manufacturers to capture vast amounts of data, and ML allows enterprises to derive actionable intelligence from said data, enabling smarter equipment, improved quality and increased productivity. As enterprises continue to use machine learning (ML) as part of their everyday operations, here are five ways manufacturing is expected to develop in the year ahead.

1. Widespread predictive maintenance

Typically, factories have relied on regular maintenance schedules dictated by usage or time to determine when a machine needs to be serviced — or have even waited until equipment breaks down to conduct maintenance. Leveraging AI, manufacturers are developing predictive maintenance models trained on historical data about what led up to past equipment problems to predict when machines need maintenance. They can then fire an alert and the equipment can be repaired.

Because equipment is only shut down for repair when it’s actually needed, instead of according to a schedule, these models can save both time and money. Furthermore, as fast innovation cycles are shortening product lifecycles across most product categories, and dramatic shifts in customer expectations are shortening delivery lead times, manufacturers must be faster and more flexible with machine repairs and retooling.

While predictive maintenance isn’t new to 2021, expect to see a dramatic increase in its widespread adoption this year, with enterprises using data from connected devices such as sensors embedded into equipment to remove the guesswork from maintenance decisions.

2. Improving energy efficiency

Most factories today operate on a 24/7 schedule to maintain optimal efficiency, requiring large amounts of energy to keep things moving. By taking energy prices, equipment maintenance, labor costs and inventory into account, ML algorithms can schedule the perfect time to perform energy-intensive activities. As a result, enterprises can maximize cost savings by running the right processes at the right time.

This company has already seen this practice in play with a number of manufacturers, including a major global petrochemical manufacturer who came to RapidMiner looking to reduce its power consumption. The company was consuming $20 million a year in energy but wanted to cut costs and be more environmentally friendly. By deploying AI models that were easily adjustable in real time and worked on sensor data, RapidMiner was able to reduce its power consumption by 5%.

3. Guaranteeing product quality

Regardless of how optimized a manufacturing process is, every factory experiences product defects. Although there are various options for trying to correct them, flaws are still commonplace and treated as a cost of doing business. With ML, manufacturers can significantly reduce the possibility of error while optimizing quality control efforts.

Instead of relying on humans to visually inspect each product on an assembly line, image recognition and

other types of ML models can be trained to analyze images and detect anomalies early in a product’s creation. As a result, factories can ensure they’re creating high-quality products while reducing waste.

4. Creating a safer workplace

Anyone who has worked in a factory has experienced thorough, annual health and safety trainings and knows the importance placed on proper use of safety gear. While these tools are critical for workplace safety, new technologies, like AI, can help further avoid risk, because accidents happen even when proper protocol is being followed.

Data analysis from ML can augment video surveillance systems to recognize potentially unsafe practices, including being used to identify overworked or tired employees before they operate heavy machinery. ML also can be used with sensor data to reveal important insights about safety-system performance. By relying on AI to sift through the thousands of data points generated every second by the Industrial Internet of Things (IIoT) and other connected devices, employers can get automatic alerts about potential dangers and thus create a safer workplace.

One Fortune 500 mining and chemical production firm was able to use machine learning to identify an unforeseen variable in its production process that commonly led to huge Environmental Health and Safety (EHS) risk factors. Using an ML model, built by process engineers, operators were able to keep the plant from going offline, avoid mountains of administrative paperwork and reduce its overall EHS risk by about 90%. The company estimates it avoided more than six incidents per year using ML.

5. Forecasting and responding to real-time consumer demands

Forecasting consumer demands can be a daunting task and is challenging to do perfectly. Thankfully, AI programs can be used to forecast demand with an unmatched level of sophistication and accuracy. Drawing from new and historical data, ML models can help businesses understand which factors drive demand and how enterprises can adapt to variables on the spot.

On the flip side, demand sensing lets businesses track fluctuations in demand, as well as consumer purchase behavior, in real time. By analyzing data from warehouses and point-of-sale systems, ML can identify significant changes in sales to ensure that supply is not outstripped by demand.

The advantages of ML systems for these processes, instead of relying on strict rules, have been highlighted by the COVID-19 pandemic. At the outset of the pandemic, as lockdowns began, consumption of, and thus demand for, products changed radically, leading to things like food and toilet paper shortages. Regularly scheduled deliveries based on what was typically needed weren’t able to keep up with changing behavior.

Wrapping up

Although we’re in the midst of the Industry 4.0 revolution, the manufacturing industry is only beginning to fully embrace digital transformation. Prior to 2020, quality, process optimization and operational expense reduction were key business drivers of this transformation. But now, amid a global pandemic, safety, remote worker enablement and information transparency are being added to that list. Advanced technologies based on AI and ML will continue to drive innovation and change how manufacturers think about problems and how to solve them, paving the way for a safer, more efficient and more profitable future. PE

Leveraging artificial intelligence (AI), manufacturers are developing predictive maintenance models trained on historical data about what led up to past equipment problems to predict when machines need maintenance. Image courtesy: RapidMiner

Ingo Mierswa, PhD Is the founder and CTO of RapidMiner. He has been an industry-veteran data scientist since starting to develop RapidMiner at the Artificial Intelligence Division of the TU Dortmund University in Germany. He has authored numerous publications about predictive analytics and big data. As founder and CTO of RapidMiner, he is responsible for strategic innovation and technologies. RapidMiner has grown around 300% per year over the last seven years.

input #12 at www.plantengineering.com/information

The voice of the engineering community speaks loud and clear in the following pages featuring the corporate profiles of these companies participating in the 2021 Executive Voice program presented by Plant Engineering magazine:

ABB Motor and Mechanical

AutomationDirect

BinMaster

Camfil Air Pollution Control Digi-Key

Flexicon Corporation

Flowserve Corporation SEW Eurodrive, Inc.

Sullair Corporation

Manufacturers face common employment challenges across the US, including aging workforces, changing skill needs, limited interest in working in manufacturing, and a lack of real-world learning experiences for students.

A number of years ago, we identified advanced tools and processes for the future of our industrial manufacturing. We also realized these resources require different skills and abilities than we have today. At a minimum, we knew we would need to invest in reskilling and retraining our current employees to prepare.

However, in order for the right people to be in place five and ten years from now, we looked to our communities. We established a strategic initiative within our business to create a pipeline of technically skilled young talent in the communities in which we operate. While each community is different based on its size, employers, educational institutions, and economic development goals, in every location we are finding commonality and models that are becoming effective.

We believe we must work together to change the perception of manufacturing. Many think of manufacturing as dark, dirty and unsafe. So, we bring students, parents and educators behind our walls where they see bright lights, clean floors and safe conditions. They see automation mixed with manual processes and robots working with humans.

An initiative of this size can’t be done alone. Across the country, we are partnering with local education systems to rethink the way we approach recruitment and career and technical education of young talent. We work side-by-side with K-12 systems and 2 and 4-year universities and colleges.

We’ve worked with our educators to create a specific curriculum, develop concurrent credit programs, and provide college internships. We’ve also started a youth apprenticeship program in a couple of our locations. When an 18-year old student graduates from high school with a valuable career plan and relevant skills and can go straight to work, she’s well prepared for the years ahead. With a tuition reimbursement program like we offer, we can help her get a college education when she’s ready for it, an opportunity most parents appreciate as well.

The future of manufacturing is here. So is the talent. We need to continue to work together to help families and educators understand that manufacturing can be a rewarding career choice. It’s critical that we align the students of today with the jobs of tomorrow. Not only do we need them, but our customers do, too.

Through high school apprenticeships, ABB is able to provide real-world learning which complements classroom training.

Jesse Henson

President of ABB’s US Motors and Generators division

We need to continue to work together to help families and educators understand that manufacturing can be a rewarding career choice.

baldor.abb.com 479.646.4711

AutomationDirect takes the best ideas from the consumer world to serve the industrial market. As a direct seller of industrial automation products for more than 25 years, AutomationDirect is a leader in the industry that offers many customer services not typical with traditional distributors. The company’s online store provides complete product information and pricing so customers can make informed decisions on their automation purchases quickly and independently.

AutomationDirect’s products are practical, easy to use and offer a low cost of ownership. The company offers quality products at prices up to 50 percent lower than those of more traditional distributors. Most product programming software is free, requiring no initial or upgrade costs and no software maintenance contracts. Product offerings include programmable logic controllers (PLCs), alternating-current (AC) drives/ motors, operator interface panels/human machine interface (HMI), power supplies, direct-current (DC) motors, sensors, pushbuttons, National Electrical Manufacturers Association (NEMA) enclosures, pneumatic supplies and more.

The automationdirect.com online store is one of the most exhaustive in the industry

order history and making payments. Customers can also obtain return authorizations online for quick and easy product returns or exchanges.

AutomationDirect’s phone technical support staff has garnered top honors in service from industry magazine readers 15 years in a row. And, with tens of thousands of active customers, the company’s online technical forum taps into that knowledge base by encouraging peers to help each other with applications and other questions. Other online help includes frequently asked questions, application examples and product selection guides.

They Guarantee It

AutomationDirect wants you to be pleased with every order. That is why they offer 30-day money-back guarantee on almost every product they sell (see Terms and Conditions for certain exclusions).

AutomationDirect’s corporate headquarters near Atlanta, Georgia

Award-Winning Services Satisfy Customers

AutomationDirect has always maintained a huge inventory, allowing them to ship orders fast with free two-day shipping available for any order over $49. Shipment confirmations, any back order status and estimated delivery information are communicated electronically to keep you informed.

Their online store is one of the most exhaustive in the industry – all technical documentation can be downloaded free of charge, as well as software and firmware updates. Hundreds of instructional videos, as well as numerous PLC training courses are available for free. Online access to your account allows viewing and changing account information, viewing

1-800-633-0405 www.automationdirect.com customersupport@automationdirect.com

Digi-Key Electronics, a global Internet-based distributor of electronic components, is an authorized distributor of more than 11.5 million components, including over 2.6 million in stock, from more than 1,500 trusted suppliers. The company’s reputation extends worldwide through the continuous choice of Digi-Key’s customers as the provider of the widest range of electronic components in the industry, ready for immediate delivery. With this wide range of products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike.

Digi-Key is the preferred supplier for Industrial Automation, Control and Safety products. They carry a broad line of products from advanced controls such as PLC, HMI and temperature controllers to accessories such as wire duct, safety switches and safety light curtains. With excellent technical resources and same-day shipping, Digi-Key will get you the parts you need when you need them.

Digi-Key is investing in the future with the construction of a 2.2 million square foot Product Distribution Center expansion that will allow the company to expand inventory even further to meet current and future demands of customers. It will also allow for searching out new and innovative technologies and products from new and existing electronic component suppliers, allowing Digi-Key to continue being a one-stop-shop for customers in all industries.

The company recently launched the Digi-Key Marketplace to give customers access to even more products and services in applications including bare PCB boards, industrial automation, test and measurement,

IoT solutions and virtually all things related to technology innovation; while providing these added solutions through a singular shopping experience.

They also offer a vast selection of online resources including a range of EDA and design tools, reference design library, on-demand multimedia library, a comprehensive article library, and community forums, among others. Digi-Key also offers numerous Supply Chain solutions such as a complete set of APIs, bonded inventory, and just-in-time shipping, as well as a newly updated BOM manager.

Digi-Key prides itself on the ability to provide the best possible service to customers. A customer can request electronic components or reach the talented team of technicians and application engineers 24 hours a day, seven days a week, 365 days a year by phone, fax, e-mail or through the website.

From prototype to production, Digi-Key has the resources and products to take your design to the next level! Find out more at www.digikey.com.

Dave Doherty

President and Chief Operating Officer

sales@digikey.com • 1-800-344-4539 www.digikey.com

Flexicon Corporation engineers and manufactures bulk handling equipment from stand-alone units to automated systems that are integrated with new or existing process equipment and storage vessels throughout the plant.

Virtually any bulk solid material or blend

Flexicon equipment can handle virtually any bulk material, from large pellets to sub-micron powders including friable materials, free- and non-free-flowing products, and materials that pack, cake, plug, smear, fluidize or separate. After more than 22,000 installations, Flexicon is knowledgeable about virtually all bulk materials and blends that customers are likely to encounter.

Lifetime Performance Guarantee

The Flexicon Lifetime Performance Guarantee assures customers of a successful result, regardless of whether they purchase one piece of equipment or an automated plant-wide system, providing added assurance that customers can trust their process, and their reputation, to Flexicon.

Designed and constructed to industry standards worldwide

All Flexicon equipment is available in carbon steel with a variety of durable industrial finishes, and stainless steel in industrial and food, dairy and pharmaceutical finishes, including designed and constructed for 3-A certification and USDA acceptance. Stand-alone equipment

The Flexicon line of stand-alone equipment includes: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers and Weigh Batching and Blending Systems. Numerous model configurations are offered within each equipment category, as basic, low cost units up to engineered, automated, high- capacity machines.

Large-scale bulk handling projects

Customers can alleviate the burden and risk of designing large-scale bulk handling systems, coordinating multiple suppliers, integrating components and trouble-shooting start-up, by relying on Flexicon’s Project Engineering Division for it all.

Flexicon can evaluate customer material(s), plant layout, through- put rates, cost, cycle times and other parameters, and engineer the optimum solution to individual bulk handling problems in the form of CAD drawings that integrate Flexicon and other equipment with new or existing equipment in the customer’s plant.

In addition, Flexicon can test customer materials on full-size test equipment, build the equipment, supervise installation, validate the project, and train customer personnel to operate it— anywhere in the world. David Gill

President

Manufacturing on four continents

Flexicon manufactures equipment in the US, UK, Australia and South Africa, maintains dedicated factory representation in Chile, France, Germany, Indonesia,Singapore, and Spain, and also markets equipment and systems through an extensive network of Applications Engineers worldwide.

The company holds 36 patents in 13 countries.

Flexicon Corporation +1 610 814 2400 • sales@flexicon.com www.flexicon.com

T.o help solve the biggest flow-control challenges, customers worldwide rely on the product lines, engineering, project management and service expertise of Flowserve. Our history began over 200 years ago, and today Flowserve employs more than 17,500 associates in 300-plus locations around the world, including over 180 quick response centers that provide aftermarket parts and services to customers.

Industries served

• Oil & Gas • Chemicals • Power • Water • Pulp & Paper • Food & Beverage • Mining, Steel & Metals • and others

Through our unmatched combination of products, engineering and aftermarket services, we help our customers achieve tangible business results: lower operating costs, optimized performance, prolonged equipment life, mitigated risks and higher productivity. And, they can depend on our industry expertise to help address their most pressing challenges — reduce expenses, minimize risk, and maximize performance.

RedRaven™ is the next stage in the evolution of Flowserve.

Industrial operators worldwide have many choices when it comes to gathering critical asset data in multiple plant environments. As IoT technology becomes more prevalent, Flowserve has introduced a unique solution for the next generation of asset health monitoring.

Flowserve’s RedRaven uses state-of-the-art IoT technologies to be your eyes and ears, monitoring your core infrastructure, and predicting critical equipment issues before they happen. With decades of experience, data analytics and diagnostics in its DNA, RedRaven’s IoT technology enables you to act immediately, avoiding costly downtime. RedRaven protects your systems 24/7, saving you time and money. With RedRaven on your side, you have the power to see beyond.

Predict Act

Protect

Use detailed insights to predict why your critical assets will fail. Make informed decisions to prevent equipment failures and improve plant performance and reliability. Protect your operation against crippling equipment downtime and production losses.

“Together, we create extraordinary flow control solutions to make the world better for everyone.”

Aric Zurek

Vice President, Global IoT

Discover the exceptional Flowserve product lines

• Pumps • Seals • Valves • Actuation and Instrumentation • Energy Recovery Devices • Hydraulic Decoking Systems • Performance Monitoring

Something revolutionary has taken flight...

Flowserve is taking the industry to new heights with capabilities to collect and analyze rotating equipment performance data.

In 2021, we’ll be soaring even higher with a new suite of solutions that will transform the way you think about monitoring and predicting your assets’ performance to solve critical issues before they happen.

Visit www.flowserve.com/iot to learn more.

Contact us to learn more: 972-443-6500 www.flowserve.com

As a world leader in drive technology and a pioneer in drive-based automation, SEW-EURODRIVE has established a reputation for quickly solving the most difficult power transmission and motion control challenges. We introduced the gearmotor in 1931. Since then, we have been bringing the best in drive technology to our customers worldwide.

SEW-EURODRIVE offers much more than just components. We offer the expertise and electronics to drive them. Being a single source partner radically sets us apart from others. Our products are designed to work together. No finger-pointing!

Furthermore, we make it very easy for engineers to do their own automation using our exclusive solution modules. No experience or programming required – perfect for new engineers. Your team will appreciate our value when they are able to be home with their families at nights and weekends instead of troubleshooting an application.

If you are short-staffed or cannot keep up with new technology, let us know. We can provide a complete engineering package from start to finish, including project planning, software, components, commissioning, and worldwide support. Our team of automation experts understand the latest technology and can solve even the most complex motion control challenges.

Your team will appreciate our value when they are able to be home with their family at night and on weekends.

Innovation

In addition to engineering excellence, SEW-EURODRIVE is also known for innovative new products. MOVIGEAR® is an all-in-one mechatronic drive solution for horizontal material handling. It combines the gear unit, motor, and electronics in one highly efficient and hygienically designed unit. In fact, it recently reduced energy consumption by 40% at a major expansion of the LAX airport. MOVIGEAR also eliminates excess inventory since it allows the use of a single ratio to replace several different ratios.

PT Pilot simplifies the choices and identifies a custom solution for each application

Online Quotation

Our PT Pilot® online drive selection tool quickly selects the perfect drive for your specific needs. PT Pilot simplifies the choices and identifies a custom solution for each application within minutes.

This powerful and intuitive program includes all technical documentation and CAD files. Don’t know your HP? No problem! Our application calculator will figure it for you. Plus, you will get an immediate net price that we guarantee. Visit ptpilot.com

Flexibility

Our products are based on a unique system of modular components that can be assembled in literally millions of different configurations. So, every drive solution is custom built to our customer’s exact specifications. Our five regional assembly centers in the U.S. stock millions of dollars of our modular inventory for quick delivery of drive solutions and spare parts.

SEW-EURODRIVE…Driving the World

864-439-7537 www.seweurodrive.com

Operations that struggle with the challenges of inventory management and timely replenishment of powders, solids, or liquids can monitor silo levels on their smartphone, tablet, or desktop with complete solutions from BinMaster. Since the early 1960s, BinMaster has designed robust continuous level sensors, point level indicators, material management, and inventory monitoring devices. Today, specialized software simplifies material management and keeps people safe from the risks of climbing bins, tanks, or silos. The Lincoln Nebraska, USA company manufactures sensors and wireless devices and develops software used for monitoring inventory levels in real-time. Complete solutions make it easy for plant managers, maintenance engineers, processing and purchasing personnel to address inventory management systems in one phone call.

Continuous level measurement options include SmartBob cable-based, guided wave radar, laser and 80 GHz non-contact radar— all compatible with Binventory™ software. The unique 3DLevelScanner—sold exclusively worldwide by BinMaster—measures and maps material for volume accuracy and is the only sensor to generate a 3D image of silo contents. Battery-powered, wireless laser level sensors compatible with BinView® or FeedView® web apps enable on-site or remote monitoring. Point level indicators provide automated level alerts using rotaries, diaphragm switches, capacitance probes, tilt switches, and vibrating rod level sensors. Dust detection devices alert to baghouse leaks and unsafe particulate levels. Flow detection sensors prevent cross contamination and assist with regulatory compliance for human and animal feeds. Robust, easy-to-install systems are developed for a single site or networked across a multi-national operation. Custom configurations for plastics, food processing, chemical, construction, mining, and agriculture address specific needs of each industry. The FeedView® web application monitors livestock feed inventory for swine and poultry operations. BinMaster is US manufacturer certified to ISO 9001 quality management systems – requirements.

“BinMaster’s mission is to provide complete inventory management solutions in one phone call.”

800-278-4241/402-434-9102 info@binmaster.com • www.binmaster.com

pe202101_execVhalf_binmaster.indd 1 input #20 at www.plantengineering.com/information

12/28/2020 1:20:06 PM

In his nearly 21 years with Sullair, a lot has changed for Brian Tylisz, Senior Vice President of Sales for the Americas. The company has changed, and so has his career—but there has likely never been a more exciting time than right now.

Tylisz leads sales of all Sullair portable and stationary products in the Americas. An engineer by trade, Tylisz transitioned into sales in 2014 after spending nearly 15 years in engineering roles up to and including director of engineering. In 2014, Sullair began to focus on oil free, and Tylisz’s background and expertise made him a natural fit to lead oil free sales. “Having a technical leader in the commercial business allows us to better support our customers and understand the applications, such as food and beverage, packaging, pharmaceuticals and semiconductors,” said Tylisz.

In 2017, Hitachi acquired Sullair, which further expanded the company’s reach into oil free technologies. “It’s an exciting time to be at Sullair and part of Hitachi. It has segued two long-standing leaders in the compressed air industry who have complementary strengths. We can now better provide our global customer base with the full spectrum of compressed air solutions — Sullair with 55 years in predominantly oil flooded solutions, and Hitachi with 110 years in predominantly oil free solutions.”

Tylisz is not only a leader within Sullair but also within the compressed air industry. He was recently appointed to the Compressed Air and Gas Institute (CAGI) board of directors. CAGI is the unified voice and unbiased authority of the compressed air industry. This helps Sullair stay engaged with the industry and have a voice at the table for issues impacting the compressed air industry.

With Tylisz leading sales at Sullair, customers will have a voice at the table, too, as he blends his technical background with his commercial leadership role to better understand end customers’ needs and applications.

North America Operations in Michigan City, IN Brian Tylisz

Senior Vice President of Sales for the Americas

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Yaskawa America, Inc C-3 22 www.yaskawa.com

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